55 1 26MB
Service manual Veflex VR, VR SF, VRE150, VRE125SF Applies from serial number: 6004330-
Order number: 244989-020 Issued: 2013-03-04 ITS
© BT Europe AB
en
Document revisions:
Publishing date
Order number
Amendments
2006-12-15
A common manual with a new part number, 5000 (parameter 35), 3100
2007-08-27
New models, Maintenance, 5000.1, 5000.2
2013-03-04
Chapter 19-Electrical system — 5000.2 - Completion of parameter 33 (Wire warning) when introducing software package 249267-004. Chapter 4-Tools - Added Service instrument (CASTOR USB) for programming - Updated P/N for CAN key - Added jacking blocks
This manual contains information on the following trucks:
T-Code
Model
Serial number
485§
VR SF
966384-
487
VR
966384-
485
VRE150
6004330-
486
VRE150CC
6004330-
487
VRE125SF
6004330-
488
VRE125SFCC
6004330-
© BT Europe AB
Service manual
Veflex VR, VR SF, VRE150, VRE125SF
Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
1- Technical data ..................................................................................... 2-1 2- Maintenance ........................................................................................ 3-1 2.1 Introduction and safety, maintenance ............................................ 3-1 2.2 Safety regulations during maintenance work ................................. 3-1 2.2.1 Tilting the cab up on a cold store truck ............................ 3-3 2.2.2 Tilting the cab down on a cold store truck ....................... 3-3 2.3 Cleaning and washing.................................................................... 3-4 2.3.1 External cleaning ............................................................. 3-4 2.3.2 Cleaning the motor compartment .................................... 3-4 2.3.3 Electrical components ..................................................... 3-5 2.4 Safe lifting ...................................................................................... 3-5 2.5 Maintenance chart ......................................................................... 3-6 2.6 Oil and grease specifications ....................................................... 3-22
© BT Europe AB
3- Tools ..................................................................................................... 3.1 Electrical contacts .......................................................................... 3.1.1 Super Seal connectors .................................................... 3.1.2 AMP connectors .............................................................. 3.2 Other tools .....................................................................................
4-1 4-1 4-1 4-2 4-3
4- Chassis – 0000 ..................................................................................... 4.1 General .......................................................................................... 4.2 List of tools ..................................................................................... 4.3 Transporting the truck .................................................................... 4.4 Assembling the mast...................................................................... 4.5 Installation in narrow aisles ............................................................ 4.5.1 General ............................................................................ 4.5.2 Track-guided truck ........................................................... 4.5.3 Wire guided truck ............................................................. 4.5.4 General adjustment .........................................................
5-1 5-1 5-1 5-2 5-3 5-7 5-7 5-7 5-7 5-7
5- Frame, mounted components — 0400 ............................................... 5.1 General tightening torque............................................................... 5.1.1 Galvanised, non oiled bolts ............................................. 5.1.2 Untreated, oiled bolts .......................................................
6-1 6-1 6-1 6-2
6- Driver Protection — 0840 .................................................................... 6.1 General .......................................................................................... 6.2 Tilt Stops ........................................................................................ 6.2.1 Inspection and Adjustment ..............................................
7-1 7-1 7-2 7-2
7- Electric Pump Motor — 1710 .............................................................. 7.1 General .......................................................................................... 7.2 Dismantling the Pump Motor.......................................................... 7.3 Removing and Replacing the Pump Motor..................................... 7.3.1 Dismantling ...................................................................... 7.3.2 Assembling ...................................................................... 7.4 Bearing Replacement .................................................................... 7.4.1 Dismantling ...................................................................... 7.4.2 Re-Assembly ................................................................... 7.5 Installation Instructions for External Temperature Sensor .............
8-1 8-1 8-1 8-2 8-2 8-3 8-4 8-4 8-5 8-6
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
1
T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
8- Electric Steering Motor — 1730 .......................................................... 8.1 General .......................................................................................... 8.2 Replacing the Steering Motor......................................................... 8.2.1 Dismantling ...................................................................... 8.2.2 Re-Assembly ................................................................... 8.3 Removing and Replacing the Carbon Brushes .............................. 9- Electric Drive Motor — 1760 ............................................................. 9.1 General ........................................................................................ 9.2 Dismantling the Drive Motor......................................................... 9.3 Dismantling and Assembling the Drive Motor .............................. 9.3.1 Dismantling the Drive Motor .......................................... 9.3.2 Assembling the Drive Motor .......................................... 9.4 Bearing Replacement .................................................................. 9.1.1 Assembling .................................................................... 9.2 Installation Instructions for External Temperature Sensor ...........
9-1 9-1 9-1 9-1 9-1 9-1
10-1 10-1 10-2 10-3 10-3 10-4 10-5 10-6 10-7
10- Mechanical Drive Gear Unit — 2550 .............................................. 11-1 10.1 General ........................................................................................ 11-1 10.2 Drive/Transmission Assembly's Main Components and Technical Data 11-2 10.2.1 Position of Components ................................................ 11-2 10.2.2 Technical data ............................................................... 11-4 10.2.3 Dismantling the Transmission ....................................... 11-4 10.3 Replacing the Drive Motor/Drive Transmission ............................ 11-5 10.3.1 Dismantling the Drive Motor .......................................... 11-5 10.3.2 Removal of the Drive Transmission ............................... 11-6 10.3.3 Assembling the Drive Transmission .............................. 11-7 10.3.4 Installing the Drive Motor ............................................... 11-8 10.4 Checking/Replacing the Oil.......................................................... 11-9 10.1.1 Changing the Oil ............................................................ 11-9 10.2 Repairs ...................................................................................... 11-10 10.1.1 Leakage from the Upper Cover ................................... 11-12 10.1.2 Leakage from the Lower Cover ................................... 11-12 10.1.3 Replacing Wheel Bolts ................................................ 11-13 11- Travel brake system — 3100 .......................................................... 12-1 11.1 Brake system ............................................................................... 12-1 11.1.1 General .......................................................................... 12-1 11.2 Description of function ................................................................. 12-2 11.2.1 Releasing the accelerator .............................................. 12-2 11.2.2 Changing travel direction ............................................... 12-2 11.2.3 Pressing the brake pedal (without support arm brake) .. 12-3 11.2.4 Pressing the brake pedal (with support arm brakes) ..... 12-4 11.2.5 Parking brake ................................................................ 12-5 11.2.6 Emergency braking ........................................................ 12-5 11.3 Electromechanical disc brake, drive motor .................................. 12-6 11.4 Disassembly ................................................................................ 12-7 11.5 Inspection .................................................................................... 12-7 11.6 Assembly ..................................................................................... 12-8 11.7 Maintenance ................................................................................ 12-9 11.7.1 Adjusting the play .......................................................... 12-9 11.7.2 Wear ............................................................................ 12-10 2
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
11.8
T-code 485, 487
11.7.3 Checking the braking force .......................................... Multiple disc brake, support arm ................................................ 11.8.1 Assembly ..................................................................... 11.8.2 Dismantling .................................................................. 11.8.3 Maintenance ................................................................
12-10 12-12 12-12 12-13 12-14
12- Drive wheel — 3530 ......................................................................... 12.1 General ........................................................................................ 12.2 Dismantling the drive wheel ......................................................... 12.3 Assembling the drive wheel .........................................................
13-1 13-1 13-1 13-1
13- Fork/support arm wheel – 3550 ...................................................... 13.1 General ........................................................................................ 13.2 Dismantling the wheel .................................................................. 13.3 Assembling the wheel .................................................................. 13.4 Dismantling/assembling the wheel bearings ................................
14-1 14-1 14-1 14-2 14-4
14- Electric steering wheel/lever — 4310 ............................................. 14.1 General ........................................................................................ 14.2 Replacement of the steering generator 15-1 14.2.1 Dismantling .................................................................... 14.2.2 Assembly .......................................................................
15-1 15-1
15-1 15-1
15- Steering angle sensor — 4350 ....................................................... 15.1 General ........................................................................................ 15.2 Procedure .................................................................................... 15.2.1 Adjustment of directional sensor ................................... 15.2.2 Adjustment of the steering angle sensor .......................
16-1 16-1 16-1 16-1 16-2
16- Automatic steering system — 4500 ............................................... 17-1 16.1 General ........................................................................................ 17-1 16.2 Generator..................................................................................... 17-2 16.2.1 Technical data ............................................................... 17-2 16.3 Wire guidance system overview................................................... 17-3 16.4 Wire guidance components.......................................................... 17-4 16.4.1 Antennae, W1, W2 ........................................................ 17-4 16.4.2 Control unit, A3 .............................................................. 17-6 16.4.3 Home position sensor, S85 ........................................... 17-8 16.4.4 Steering angle sensor, U15 ........................................... 17-9 16.4.5 Diverse ........................................................................ 17-10 16.5 Operating description................................................................. 17-10 16.5.1 Run mode .................................................................... 17-10 16.5.2 Service mode ............................................................... 17-12 16.5.3 Parameter 36 ............................................................... 17-13 16.5.4 Parameter 71 ............................................................... 17-16 16.5.5 Parameter 72 ............................................................... 17-16 16.5.6 Parameter 73 ............................................................... 17-16 16.5.7 Parameter 74 ............................................................... 17-17 16.5.8 Parameter 75 ............................................................... 17-17 16.6 Error Codes................................................................................ 17-18 16.6.1 Error codes detected by electronic card A5 ................. 17-18 16.6.2 Error code detected by electronic card A3, WG-control unit 17-21 © BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
3
T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
17- Electrical System — 5000.1 ............................................................ 18-1 17.1 General ........................................................................................ 18-1 17.2 Electronics Card, traction controller A1 and lift controller A2 ....... 18-4 17.2.1 General .......................................................................... 18-4 17.2.2 Terminal Connections and Pole Bolts ........................... 18-5 17.2.3 Technical Data ............................................................... 18-6 17.2.4 Installation of New Controller on Truck .......................... 18-6 17.2.5 Programming ................................................................. 18-6 17.3 Electronics Card, Fork Apparatus, A4 .......................................... 18-7 17.1.1 Terminal Connections .................................................... 18-8 17.1.2 Installation of New Card on Truck ............................... 18-10 17.1.3 Programming ............................................................... 18-10 17.2 Electronics Card, Main Card, A5 ................................................ 18-11 17.2.1 General ........................................................................ 18-11 17.2.2 Terminal Connections and Voltages on A5 ................. 18-12 17.2.3 Installation of New Card on Truck ............................... 18-17 17.2.4 Programming ............................................................... 18-17 17.3 Electrical System, Overview ...................................................... 18-18 17.4 Symbol List and Wiring Diagrams .............................................. 18-22 17.1.1 Wiring diagrams VR SF ............................................... 18-25 17.1.2 Wiring diagrams VR ..................................................... 18-49 17.1.3 Component List, standard truck ................................... 18-73 17.1.4 Component identification ............................................. 18-79 17.2 Functional Description ............................................................... 18-87 17.2.1 Key in Position 0 .......................................................... 18-88 17.2.2 Key in Position I, Driver Seated ................................... 18-88 17.2.3 Direction of Travel Selection ........................................ 18-89 17.2.4 Driving ......................................................................... 18-90 17.2.5 Travel speeds .............................................................. 18-91 17.2.6 Steering ....................................................................... 18-94 17.2.7 Braking ........................................................................ 18-96 17.2.8 Aisle-End Slowdown .................................................... 18-97 17.2.9 Fork Lifting ................................................................... 18-97 17.2.10 Height Indication .......................................................... 18-98 17.2.11 Lift height limit .............................................................. 18-98 17.2.12 Height Pre-Set ............................................................. 18-99 17.2.13 Fork Lowering ............................................................ 18-100 17.2.14 Lateral Movement/Traversing of Forks (VR SF) ........ 18-101 17.2.15 Lateral Movement/Traversing of Forks (VR) ............. 18-102 17.2.16 Rotating the Forks (VR) ............................................. 18-103 17.2.17 Simultaneous Traversing and Rotation Movement (VR) 18-104 17.2.18 Extra Hydraulic Functions (VR) ................................. 18-106 17.2.19 Weighing .................................................................... 18-107 17.2.20 Driver Identification .................................................... 18-107 17.3 Parameter ................................................................................ 18-108 17.1.1 Parameter 1 ............................................................... 18-113 17.1.2 Parameter 2 ............................................................... 18-113 17.1.3 Parameter 3 ............................................................... 18-113 17.1.4 Parameter 4 ............................................................... 18-113 17.1.5 Parameter 5 ............................................................... 18-114 17.1.6 Parameter 6 ............................................................... 18-114 17.1.7 Parameter 7 ............................................................... 18-114 17.1.8 Parameter 8 ............................................................... 18-114 17.1.9 Parameter 10 ............................................................. 18-114 4
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
17.2
17.3
© BT Europe AB
T-code 485, 487
17.1.10 Parameter 11 ............................................................. 17.1.11 Parameter 12 ............................................................. 17.1.12 Parameter 13 ............................................................. 17.1.13 Parameter 14 ............................................................. 17.1.14 Parameter 15 ............................................................. 17.1.15 Parameter 16 ............................................................. 17.1.16 Parameters 17 and 18 ............................................... 17.1.17 Parameter 19 ............................................................. 17.1.18 Parameter 20 ............................................................. 17.1.19 Parameter 21 ............................................................. 17.1.20 Parameter 22 ............................................................. 17.1.21 Parameter 23 ............................................................. 17.1.22 Parameter 24 ............................................................. 17.1.23 Parameter 25 ............................................................. 17.1.24 Parameter 26 ............................................................. 17.1.25 Parameter 27 ............................................................. 17.1.26 Parameter 28 ............................................................. 17.1.27 Parameter 29 ............................................................. 17.1.28 Parameter 35 ............................................................. 17.1.29 Parameter 36 ............................................................. 17.1.30 Parameter 37 ............................................................. 17.1.31 Parameter 38 ............................................................. 17.1.32 Parameter 39 ............................................................. 17.1.33 Parameters 40 to 42 .................................................. 17.1.34 Parameter 43 ............................................................. 17.1.35 Parameter 44 ............................................................. 17.1.36 Parameter 45 ............................................................. 17.1.37 Parameter 46 ............................................................. 17.1.38 Parameter 47 (VR) .................................................... 17.1.39 Parameter 48 (VR) .................................................... 17.1.40 Parameter 49 (VR SF) ............................................... 17.1.41 Parameter 50 ............................................................. 17.1.42 Parameter 51 (VR) .................................................... 17.1.43 Parameter 53 (VR) .................................................... 17.1.44 Parameter 54 ............................................................. 17.1.45 Parameter 55 ............................................................. 17.1.46 Parameter 56 (VR) .................................................... 17.1.47 Parameter 57 ............................................................. 17.1.48 Parameter 58 (VR) .................................................... 17.1.49 Parameter 59 (VR) .................................................... 17.1.50 Parameter 60 (VR) .................................................... 17.1.51 Parameter 61 (VR) .................................................... 17.1.52 Parameter 62 (VR) .................................................... 17.1.53 Parameter 63 (VR) .................................................... 17.1.54 Parameter 64 (VR) .................................................... 17.1.55 Parameter 65 (VR) .................................................... 17.1.56 Parameter 66 (VR) .................................................... 17.1.57 Parameter 67 ............................................................. Instrument Panel and Display .................................................. 17.2.1 Show .......................................................................... 17.2.2 Operating Time .......................................................... 17.2.3 Programming ............................................................. Codes ...................................................................................... 17.3.1 Warning Codes .......................................................... 17.3.2 Error mode ................................................................. 17.3.3 Safety Logic ...............................................................
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
18-114 18-114 18-115 18-115 18-115 18-115 18-115 18-115 18-116 18-116 18-117 18-117 18-117 18-117 18-117 18-117 18-118 18-118 18-118 18-118 18-118 18-119 18-120 18-120 18-120 18-121 18-121 18-121 18-121 18-121 18-121 18-122 18-122 18-122 18-122 18-122 18-123 18-123 18-123 18-123 18-123 18-123 18-124 18-124 18-124 18-124 18-124 18-124 18-125 18-125 18-126 18-126 18-128 18-128 18-128 18-130 5
T-code 485, 487
Valid from serial number 600433017.3.4 17.3.5 17.3.6 17.3.7
Date 2013-03-04
Order number 244989-040
Warning Codes without Registration ......................... Warning Codes with Registration .............................. Error Codes ............................................................... Error Codes with Registration ....................................
18-130 18-160 18-182 18-183
18- Electrical system – 5000.2 .............................................................. 19-1 18.1 General ........................................................................................ 19-1 18.2 Logic card, drive controller A1 and lift controller A2 ..................... 19-4 18.2.1 General .......................................................................... 19-4 18.2.2 Connection terminal and terminal pillars ....................... 19-5 18.2.3 Technical data ............................................................... 19-6 18.2.4 Installing a new logic card in the truck ........................... 19-6 18.2.5 Programming ................................................................. 19-6 18.3 Logic card, fork unit, A4 ............................................................... 19-7 18.3.1 General .......................................................................... 19-7 18.3.2 Connector plug .............................................................. 19-8 18.4 Logic card, main card, A5 .......................................................... 19-11 18.4.1 General ........................................................................ 19-11 18.4.2 Connection terminals and voltages on A5 ................... 19-12 18.5 Electric system, overview........................................................... 19-18 18.6 Symbol list and wiring diagrams................................................. 19-22 18.6.1 List of symbols ............................................................. 19-22 18.6.2 Electric wiring diagrams VRE125SF ............................ 19-25 18.6.3 Electric wiring diagrams VRE150 ................................ 19-50 18.6.4 Electric wiring diagrams, cold store cabins VRE150 ... 19-72 18.6.5 Component list, standard truck .................................... 19-75 18.6.6 Component location ..................................................... 19-82 18.7 Function description................................................................... 19-92 18.7.1 Truck not switched on .................................................. 19-93 18.7.2 Truck started up ........................................................... 19-93 18.7.3 Travel direction selection ............................................. 19-94 18.7.4 Driving ......................................................................... 19-95 18.7.5 Travel speeds .............................................................. 19-96 18.7.6 Steering ....................................................................... 19-99 18.7.7 Braking ...................................................................... 19-101 18.7.8 End of aisle retardation .............................................. 19-102 18.7.9 Fork lifting .................................................................. 19-102 18.7.10 Height indicator .......................................................... 19-103 18.7.11 Lift height limitation .................................................... 19-103 18.7.12 Height preselector ..................................................... 19-104 18.7.13 Fork lowering ............................................................. 19-105 18.7.14 Sideshift/traversing of forks (VRE125SF) .................. 19-106 18.7.15 Sideshift/traversing of forks (VRE150) ...................... 19-107 18.7.16 Fork rotation (VRE150) .............................................. 19-108 18.7.17 Simultaneous traversing and rotation movement (VRE150) 19-108 18.7.18 Extra hydraulic function (VRE150) ............................ 19-110 18.7.19 Weight calculation ..................................................... 19-111 18.8 Display and programming ........................................................ 19-112 18.8.1 Keypad ...................................................................... 19-112 18.9 Setting all parameters 19-114 18.9.1 Parameter 19 ............................................................. 19-124 18.9.2 Parameter 21 ............................................................. 19-126 18.9.3 Parameter 38 ............................................................. 19-128 6
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
18.10 Warning codes ......................................................................... 18.11 Error codes .............................................................................. 18.11.1 Error mode ................................................................. 18.11.2 Safety logics .............................................................. 18.11.3 Warning code without recording ................................ 18.11.4 Warning codes with registration ................................ 18.11.5 Error codes with registration ...................................... 18.12 Truck log system, code lock ..................................................... 18.12.1 General ...................................................................... 18.12.2 SD 16 ......................................................................... 18.12.3 Components .............................................................. 18.13 I/O module ...............................................................................
19-130 19-131 19-131 19-131 19-133 19-161 19-183 19-219 19-219 19-219 19-219 19-221
19- Hydraulic system — 6000 ............................................................... 20-1 19.1 General ........................................................................................ 20-1 19.2 Hydraulic schematics ................................................................... 20-2 19.2.1 Symbols ......................................................................... 20-2 19.2.2 Hydraulic schematics (VR SF) ....................................... 20-4 19.2.3 Component description (VR SF) .................................... 20-5 19.2.4 Hydraulic schematics (VR) ............................................ 20-6 19.2.5 Component description (VR) ......................................... 20-7 19.3 Hydraulic components, positioning .............................................. 20-8 19.3.1 Overview ........................................................................ 20-8 19.3.2 Hydraulic unit ............................................................... 20-11 19.3.3 Hydraulic components in the fork unit (VR SF) ........... 20-13 19.3.4 Hydraulic components in the fork unit (VR) ................. 20-15 19.3.5 Cab tilt function (cold store cab) .................................. 20-17
© BT Europe AB
20- Hydraulic pump — 6140 .................................................................. 20.1 General ........................................................................................ 20.2 Replacing the hydraulic pump...................................................... 20.2.1 Dismantling .................................................................... 20.2.2 Assembling ....................................................................
21-1 21-1 21-2 21-2 21-4
21- Hydraulic connections — 6230 ...................................................... 21.1 General ........................................................................................ 21.2 Tightening torque for hydraulic connections................................. 21.2.1 Conical connection with O-ring ...................................... 21.2.2 Tredo seal ...................................................................... 21.2.3 Pipe couplings ............................................................... 21.2.4 Connections screwed into aluminium ............................ 21.2.5 Connections screwed into steel ..................................... 21.3 Quick connection ......................................................................... 21.3.1 Assembling .................................................................... 21.3.2 Dismantling ....................................................................
22-1 22-1 22-1 22-1 22-2 22-2 22-2 22-3 22-6 22-6 22-7
22- Main lift chain system — 7120 ........................................................ 22.1 General ........................................................................................ 22.2 Checking the chain setting ........................................................... 22.3 Chain inspection .......................................................................... 22.3.1 Noise ............................................................................. 22.3.2 Surface rust ................................................................... 22.3.3 Rusty links ..................................................................... 22.3.4 Stiff links ........................................................................
23-1 23-1 23-1 23-1 23-1 23-1 23-1 23-2
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
7
T-code 485, 487
Valid from serial number 6004330-
22.4 22.5
Date 2013-03-04
Order number 244989-040
22.3.5 Bolt rotation ................................................................... 22.3.6 Loose bolts .................................................................... 22.3.7 Outline wear .................................................................. 22.3.8 Stretching ...................................................................... 22.3.9 Damage ......................................................................... 22.3.10 Damaged discs .............................................................. 22.3.11 Damaged bolts .............................................................. 22.3.12 Dirty chain ...................................................................... Cleaning....................................................................................... Lubrication ...................................................................................
23-2 23-2 23-3 23-4 23-4 23-5 23-5 23-5 23-5 23-6
23- Turret Head Fork Apparatus – 7700 (VR, VRE150) ....................... 24-1 23.1 General description...................................................................... 24-1 23.1.1 Main Components ......................................................... 24-2 23.1.2 Fork turning ................................................................... 24-4 23.1.3 Side-shift movement ...................................................... 24-5 23.2 Inspection and maintenance ........................................................ 24-5 23.2.1 External inspection ........................................................ 24-6 23.2.2 Inspection ...................................................................... 24-6 23.2.3 Maintenance .................................................................. 24-6 23.3 Adjustment of turret head fork apparatus ..................................... 24-7 23.3.1 Fork carriage, end position rotation ............................... 24-7 23.3.2 Setting tooth flank play .................................................. 24-7 23.3.3 Adjusting the apparatus' lateral play on the mast guide 24-10 23.3.4 Potentiometer for the turning movement ..................... 24-11 23.3.5 Inductive sensor for the home position, side-shift ....... 24-12 23.4 Replacing components .............................................................. 24-13 23.4.1 Turning chain ............................................................... 24-13 23.4.2 Turning bearing ........................................................... 24-14 24- Shuttle fork unit – 7800 (VR SF, VRE125SF) ................................ 24.1 Maintenance ................................................................................ 24.1.1 Maintenance schedule ................................................... 24.1.2 Lubrication ..................................................................... 24.1.3 Adjustment of chains ..................................................... 24.2 Replacement of shuttle fork unit...................................................
25-1 25-1 25-2 25-4 25-5 25-8
25- Charger BTCM — 8340 .................................................................... 26-1 25.1 General ........................................................................................ 26-1 25.2 Installation.................................................................................... 26-1 25.3 Function and use ......................................................................... 26-2 25.3.1 Charging process .......................................................... 26-2 25.3.2 Shut-off conditions ......................................................... 26-2 25.3.3 Delayed start and charging ............................................ 26-3 25.3.4 Extra charging ............................................................... 26-3 25.3.5 Equalisation charge ....................................................... 26-3 25.3.6 Current and voltage characteristics ............................... 26-3 25.3.7 Safety shut-off ............................................................... 26-3 25.4 Display and keyboard .................................................................. 26-4 25.2 Service and maintenance .......................................................... 26-11 25.1.1 Resetting the statistics, code 31 .................................. 26-11 25.1.2 Calibrating measurement values ................................. 26-11 25.1.3 Modifying the charging characteristics ........................ 26-12 8
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
25.2 25.2
25.2
T-code 485, 487
25.1.4 Printing to a printer ...................................................... Trouble shooting ........................................................................ 25.1.1 Error messages, analysis and actions ......................... Service actions........................................................................... 25.1.1 Switching to timer charging ......................................... 25.1.2 Replacing the display card .......................................... 25.1.3 Replacing the computer board .................................... 25.1.4 Replacing the motherboard ......................................... 25.1.5 Replacing the diodes ................................................... Preventive maintenance ............................................................
26-13 26-14 26-14 26-16 26-16 26-16 26-17 26-17 26-17 26-17
26- Position sensors — 9390 ................................................................ 27-1 26.1 Height Indication and Height Pre-Set ........................................... 27-1 26.1.1 General .......................................................................... 27-1 26.2 Components for Height Indication/Height Pre-Set ....................... 27-2 26.3 Height Indication .......................................................................... 27-3 26.4 Height Indication .......................................................................... 27-4 26.5 Display A8.................................................................................... 27-5 26.6 Height Pre-Set ............................................................................. 27-5 26.7 Function ....................................................................................... 27-6 26.8 Display A7.................................................................................... 27-7 26.8.1 Description of the display symbols ................................ 27-8 26.9 Assembly of height preset............................................................ 27-9 26.10 Programming ............................................................................... 27-9 26.10.1 Programming a level ...................................................... 27-9 26.10.2 Erasing programmed levels ......................................... 27-10 26.11 Automatic operations ................................................................. 27-10 26.11.1 Collect load .................................................................. 27-10 26.11.2 Leaving a load ............................................................. 27-11 26.11.3 Control ......................................................................... 27-11 26.12 Parameters ................................................................................ 27-12 26.12.1 P1 ................................................................................ 27-12 26.12.2 P2 ................................................................................ 27-12 26.12.3 P3 ................................................................................ 27-13 26.12.4 P4 ................................................................................ 27-13 26.12.5 P5 ................................................................................ 27-13 26.12.6 P7 ................................................................................ 27-14 26.12.7 P8 ................................................................................ 27-14 26.12.8 P9 ................................................................................ 27-14 26.13 Programming parameters .......................................................... 27-15 26.14 Error codes ................................................................................ 27-17
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
9
T-code 485, 487
10
Valid from serial number 6004330-
Service Manual
Date 2013-03-04
Order number 244989-040
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Technical data Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
1- Technical data Model
VR SF VR SF C
VR VR C
Type
TSP 112/4-165-t
TSP 112/4-165-t
Power, kW
7,5
7,5
Intermittence, %
60
60
Insulation class
B
B
Type
2-step angle gear
2-step angle gear
Gear rotation
20,89:1
20,89:1
Oil volume, litres
3,3
3,3
Oil type
Hypoid oil
Hypoid oil
At normal temperature
SAE 80W90
SAE 80W90
< -15° C:
SAE 75W
SAE 75W
Diameter 350x130
Diameter 350x130
Drive motor
Transmission/gear
Wheels Drive wheel Wheel pressure without load
2020a
Wheel pressure with rated load
1420b
Wheel bolts’ tightening torque, Nm Support arm wheels
130
130
Diameter 230x85 alt. 230x110
Diameter 230x85 alt. 230x110
Axle pressure with rated load, kg
© BT Europe AB
Service Manual
5800c
Veflex VR, VR SF, VRE150, VRE125SF
1- 1
Technical data T-code 485, 487
Valid from serial number 6004330-
Model
Date 2013-03-04
Order number 244989-040
VR SF VR SF C
VR VR C
Pump motor, Type
TSP 112/4-195-T
TSP 112/4-195-T
Power, kW
14
14
Intermittence, %
15
15
Insulation class
B
B
Hydraulic system
Pressure with rated load, litres/min.
35
Tank volume, litres
38
38
ISO-L-HM32
ISO-L-HM32
Oil type: At normal temperature - 15°C
< - 15°C
BT 26777 (Spray) ISO-L-HM32 Hypoid oil SAE 80W/90 BT 73040 or BT 165148 (Klüber Hotemp 2000) BT 29916 (Texaco Molytex EP2) Topas NB 52 Grafloscon A-G1 (Klüber)
BT 26777 (Spray) ISO-L-HV32 Hypoid oil SAE 75W BT 163588 (Klüber 4LC-68)
Bearings and bushings Hydraulic system Gears
BT 177094 (Shell Aeroshell Grease 17) Topas NB 52 Grafloscon A-G1 (Klüber)
Gear racks and support roller contact surfaces
Service Manual
Chains
Steering motor gear Gear rim
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Tools Electrical contacts Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
3- Tools 3.1 Electrical contacts 3.1.1 Super Seal connectors 1 3
3 2
Figure
© BT Europe AB
Service Manual
Number
Use
159232
Crimping of pins/sleeves
159229
Removal of lock (1)
159230
Insertion of secondary lock, 2 pin (2)
159231
Insertion of secondary lock, 4 pin (2)
159228
Removal of pins/sleeves (3)
Veflex VR, VR SF, VRE150, VRE125SF
3- 1
Tools Electrical contacts T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
3.1.2 AMP connectors
Figure
2
3- 2
Number
Use
31-151080
Removal of pins/sleeves
1=163787 2=163788
Crimping of sleeves
1=163789 2=163790 3=163791
Crimping of pins 1: For 0.2–0.5 mm2 2: For 0.5-1.0 mm2 3: For 1.5-2.5 mm2
1
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Tools Other tools Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
3.2 Other tools Figure
1
Number
Use
7516708
Service instrument (CAN)
1=163793 2=163792
Service instrument for program modifications
1=7521083 2=163973
Service instrument (CASTOR USB) for programming
08-15444
Drive motor/Pump motor
2
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
3- 3
Tools Other tools T-code 485, 487
Valid from serial number 6004330-
Figure
-1 -2
Date 2013-03-04
Order number 244989-040
Number
Use
10-15639
Socket for drive gear nuts
08-13022
Drive gear puller
31-150030
Cab tilt tool
Complete set = V1015191 1=V10-15191-1 2=V10-15191-2 3=V10-15191-3 4=V10-15191-4
Oil cleaning 1=Filter for cleaning 2=Filter for removal of water 3=Pipe 4=Pipe
08-13585
Wheel shaft tool
-3 -4
3- 4
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Tools Other tools Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
Figure
© BT Europe AB
Service Manual
T-code 485, 487
Number
Use
V11-1133/1
Lifting yoke for mast.
651154
Jacking blocks
Veflex VR, VR SF, VRE150, VRE125SF
3- 5
Tools Other tools T-code 485, 487
3- 6
Valid from serial number 6004330-
Service Manual
Date 2013-03-04
Order number 244989-040
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Chassis – 0000 General Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
4- Chassis – 0000 4.1 General This is an instruction for the assembly, installation and functionality check of the truck. The document also contains a list of tools and instructions how to transport the truck without the battery installed.
4.2 List of tools • Overhead crane or lift crane with a capacity of at least 2500 kg. • Lift yoke V11-1133/1 • 1/2" ratchet handle • 24 mm socket • 30 mm socket • 1/2" torque wrench 0 -270 Nm. • 3/4" torque wrench 0 -500 Nm. • 27 mm combination spanner • 30 mm combination spanner • 36 mm combination spanner • Cloth • Absorbent • Cable ties
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
4- 1
Chassis – 0000 Transporting the truck T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
4.3 Transporting the truck Transport the truck and mast to an assembly area equipped with an overhead crane or lift crane.
The 48V battery voltage must connected to the truck in order to transport the truck to the chosen assembly area. - Opt.1 Fit the truck's battery - Opt. 2 Connect a 48V battery to the truck's battery cables.
4- 2
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Chassis – 0000 Assembling the mast Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
4.4 Assembling the mast • Cut off the steel band holding the mast. • Lift off the forks. • Loosen the four M16 bolts and remove the upper part of the stud bracket (see diagram). • Grease the mast's axle studs. • Use the Mast assembly kit that contains the following: - 2 bolts and 2 washers to secure the mast on the chassis. - 0 - 6 shims to align the backward mast angle, which should be 90° +10’ -0’. - 1 two-part hose clip for the feeder hose on the mast. • Move the hydraulic hoses and cables on the chassis to one side. • Lift up the mast using an overhead crane and the lift yoke.
• Guide the mast slowly to the chassis. • Guide in the mast fully and lower it so it rests on the pins (3). • Position the upper section of the stud holder and secure the four bolts (1) loosely. • Screw in the bolts (2) holding the mast in the bottom of the mast mounting, but still allowing the shims some space. © BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
4- 3
Chassis – 0000 Assembling the mast T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
• Position the shims (3) and move the overhead crane in the direction of the forks so that they fasten with the mast.
• Tighten the bolts (1 and 2) with the following torque:
Bolt
Tightening torque
Stud bracket bolt (1)
222 Nm
Bottom bolt (2)
385 Nm
• Assemble the mast struts in the brackets on the chassis. NOTE The struts should not be tightened too tight. At the correctly adjusted length it should still be possible to turn the struts by hand.
• Lift up the mast's inner guide using the overhead crane. NOTE! Make sure that the chain or hoses/cables are not crushed.
• Secure the mast's inner guide with a brace. • Remove the plugs on the feeder hose (3) and on the manifold block (4). • Fit the feeder hose (3) on the manifold block (4).
4- 4
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Chassis – 0000 Assembling the mast Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
• Connect the connectors X16, X17 and X60 from the mast cable. • Secure the cables and hoses using ties so that they do not hang or lie loose and can be damaged. • Remove the plugs from the hoses to the fork unit. • Fit the pressure hose (5) and the return hose (6) to the fork unit on the side of the mast. Pull the hoses straight up from the clamp on the mast mounting. NOTE! The pressure hose is the one to the right and the return hose the one to the left, as seen from in front of the truck.
• Secure the hoses by the mast's reinforcement bar (7) using ties. • Connect 48 V DC to the truck and lift the forks approx. 1000 mm. • Fit the forks on the fork yoke. • Lower the forks and check the height above floor, according to Ccode 7120. • Adjust if necessary. • Fill the hydraulic system with oil • Test the lifting and lowering functions as well as all fork unit's functions. • Check that oil does not leak from the hydraulic hoses. • Dry or wipe off any oil spillage on the truck. • Lift in and secure any supplied counterweights. Tighten the four bolts to the torque set out in the instructions C-code 0400 © BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
4- 5
Chassis – 0000 Assembling the mast T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
• Dismantle the lifting eyes if these are regarded as unnecessary.
4- 6
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Chassis – 0000 Installation in narrow aisles Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
4.5 Installation in narrow aisles 4.5.1 General • Drive the truck into a narrow aisle and verify that the truck's aisle sensor works, photocell or magnetic switch. • If the truck is equipped with aisle-end slowdown, check that this works correctly. • Handle “largest loads” in narrow aisles. Check that there is sufficient play between the load on the forks and goods in the rack during the entire lifting range.
4.5.2 Track-guided truck • Fit the side steering wheel • Test the truck in a narrow aisle, check the play between the truck and the rail. Should be 5-10 mm. • Shim the side steering wheel equally on both sides so that correct play is obtained if necessary. • Check that the steering wheel centres when the truck is driven in a narrow aisle.
4.5.3 Wire guided truck • Check the loop's frequency and current data. • Check the truck's wire guidance setting, instruction C-code 4500 parameter 71. • Test the truck on the loop with and without a load. • Observe how the truck performs on the loop. • Adjustment the wire guidance, “Learn”, according to the instruction C-code 4500.
4.5.4 General adjustment • Adjust the truck's parameters according to the customer's wishes and installation demands, instruction C-code 5000.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
4- 7
Chassis – 0000 Installation in narrow aisles T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
This page is intentionally left blank
4- 8
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Frame, mounted components — 0400 General tightening torque Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
5- Frame, mounted components — 0400 5.1 General tightening torque Millimetre threads. The following applies under ideal conditions, e.g. steel against steel.
5.1.1 Galvanised, non oiled bolts Thread
A
M3
M4
M5
M6
M8
M10
Tightening torque Mv in Nm for
8.8
1.15
2.8
5.5
9.5
23.0
45
Tightening torque Mv in Nm for
12.9
2.0
4.7
9.3
16.3
38.5
75.8
Thread
A
M12
M14
M16
M20
M24
Tightening torque Mv in Nm for
8.8
77.7
123
189
369.6
638.5
Tightening torque Mv in Nm for
12.9
130.5
208
319.7
623
1075
A = Strength grade
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
5- 1
Frame, mounted components — 0400 General tightening torque T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
5.1.2 Untreated, oiled bolts Thread
A
M3
M4
M5
M6
M8
M10
Tightening torque Mv in Nm for
8.8
1.2
2.9
5.7
9.8
24.0
47
Tightening torque Mv in Nm for
12.9
2.1
4.9
9.7
17.0
40.0
79.0
Thread
A
M12
M14
M16
M20
M24
Tightening torque Mv in Nm for
8.8
81
128
197
385
665
Tightening torque Mv in Nm for
12.9
136
217
333
649
1120
A = Strength grade NOTE! Experience has shown that if you adjust the torque wrench to the values for untreated bolts, you will get the correct torque value for galvanised bolts. Do not tighten more than the values set out in the table otherwise the bolts can be destroyed.
5- 2
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Driver Protection — 0840 General Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
6- Driver Protection — 0840 6.1 General Tilt stops are mounted standard issue on all trucks. Tilt stops may not be removed permanently from the truck, because the truck's capacity sign is thus no longer valid. It is however permissible to temporarily remove tilt stops during transport of the truck, for instance between different warehouses, but the truck may not then be used to transport cargo. WARNING Reduced stability. Trucks without tilt stops can tip over, if used to transport cargo. Ensure that tilt stops are re-mounted with proper distance to the floor if they have been temporarily removed.
The tilt stops are located on the rear corners of each support arm and consist of lugs, shims, bolts and washers. .
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
6- 1
Driver Protection — 0840 Tilt Stops T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
6.2 Tilt Stops 6.2.1 Inspection and Adjustment To ensure safe operation of the struck, it is important to check the space between the tilt stops and the floor regularly. • Park the truck on a flat surface. • Measure the distance between the support heel and the floor (max. 15 mm). .
• If the tilt stop scrapes the floor or if the distance is too great, the lugs must be adjusted. • Lift the rear edge of the support arms with a pneumatic jack such that you can insert a wooden block or the like. Push the block under the support arm to prevent the truck from rocking. • Remove the bolts and washers. • Re-shim the heel such that the distance between it and the floor is as close as possible to 15 mm. The distance may not exceed 15 mm. Each shim is 4 mm. • Mount the remaining shims between the support lug and the bolt's washer.
• Replace the bolts and washers. • With a torque wrench, tighten bolts to 77.7 Nm.
6- 2
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electric Pump Motor — 1710 General Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
7- Electric Pump Motor — 1710 7.1 General The pump motor is a three-phase AC motor. In the motor, there is a thermoelement measuring the motor temperature, as well as a bearing with an integrated measuring unit for measuring rotational speed and direction. The pump motor model designation is P112—195. This service manual includes instructions for replacing bearings, axle gaskets and the temperature sensor.
7.2 Dismantling the Pump Motor
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
7- 1
Electric Pump Motor — 1710 Removing and Replacing the Pump Motor T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
7.3 Removing and Replacing the Pump Motor 7.3.1 Dismantling • Disconnect the battery leads. • Drop the forks to the lowest position to reduce pressure in the hoses and pump. • Pump the oil out of the hydraulic tank (3) with filter pump V10-15191.
3 6 7 12 4
• Remove the support (4) so that the bolts (5) for the pump mounting (12) are accessible. • Remove the temperature/speed measuring contacts (6) and power cables (7) from the motor (8). • Remove the hydraulic hose (9) and loosen the hose clamp for the hydraulic hose (10) which is attached to the tank. • Fasten a lifting eye to the motor axle. • Remove the bolts (5) holding the pump mounting (12) to the chassis. • Lift out the hydraulic pump and place it on a clean surface. • Remove both mounting attachments (12) from the pump motor (8). • Remove the screws and dismount the pump (13). • Remove the carrier.
7- 2
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electric Pump Motor — 1710 Removing and Replacing the Pump Motor Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
7.3.2 Assembling • If the O-ring on the pump is damaged, it should be replaced. • Replace the carrier between the pump and the pump motor (8). • Replace the pump module (13) on the pump motor (8).
8
• Replace both mounting attachments (12) on the pump motor (8). • Screw a lifting eye onto the end of the motor axle and connect it to an overhead crane. • Lift the hydraulic pump into the truck while at the same time returning the hydraulic hose (10) to the tank (3).
13 • Tighten the hose clamp. • Fasten the two pump mountings (12) to the chassis using the bolts (5). • Unscrew the lifting eye. • Re-mount the hydraulic hose (9) and the temperature/speed measuring contacts (6) and the power cables (7). • Fill the hydraulic tank with new oil.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
7- 3
Electric Pump Motor — 1710 Bearing Replacement T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
7.4 Bearing Replacement 16
19 13
6 17
22
2 9
26
1 4
11
10
25 24
36
27 3 8 23
7 5
D 30
N
28
20
21
7.4.1 Dismantling Motors without pumps. • Loosen the screws (23) and remove the protective plate (8). • Loosen the stud screws (20) using tool 08-15444. • Remove the shield (3) and washer (7). If both bearings are to be replaced, follow the following points; when replacing only the pulse sensor bearing continue at point A. • Remove the screws (22). • Lift the rotor (4) out of the stator (1). • Dismount the shield (2) radial seal (19). • Remove the lock ring (16) and support ring (17). • Pull off the bearing with a gear puller. A) • Pull off bearing (5) with a gear puller.
7- 4
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electric Pump Motor — 1710 Bearing Replacement Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
7.4.2 Re-Assembly Ensure all parts are intact and clean before re-assembly. Follow all instructions if both bearings have been replaced. • Place the bearing cap (9) on the rotor axle's D-side. • Press the bearing (6) on the rotor axle. • Press the bearing (5) on the rotor axle's N-side. • Mount the support ring (17) and lock ring (16) on the axle's D-side. • Install gasket (19) with the assembly device. NOTE Always use a new gasket when mounting the rotor axle.
• Install the rotor in the bearing shield (2). • Tighten the bearing cap (9) using the screws (22) to a torque of 6 Nm. • Return the rotor (4) to the stator (1). • Put the washer (7) on the bearing (5). Ensure that the terminal block assembly 11 is in position. • Install the bearing shield (3). • Tighten the stud screws (20) and nuts (21) to a torque of 5 Nm. • Install the ferritic steel block on the sensor cable. • Install the protective plate (8) on the N-side. • Bind the cables from the thermocontact and the sensor bearing to one of the power cables. If only the pulse sensor bearing is replaced: • Press the bearing (5) on the rotor axle's N-side. • Put the washer (7) on the bearing (5). Ensure that the terminal block assembly 11 is in position. • Install the bearing shield (3). • Tighten the stud screws (20) and nuts (21). With a torque wrench, tighten the nuts to 5 Nm. • Install the ferritic steel block on the sensor cable. • Install the protective plate (8) on the N-side. • Bind the cables from the thermocontact and the sensor bearing to one of the power cables.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
7- 5
Electric Pump Motor — 1710 Installation Instructions for External Temperature Sensor T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
7.5 Installation Instructions for External Temperature Sensor Number 170384.
7- 6
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electric Pump Motor — 1710 Installation Instructions for External Temperature Sensor Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
• The temperature sensor can be mounted to the right or left of the connection terminal block, depending on which side is easiest to access. • Scrape the surface clean where the new temperature sensor is to be mounted. • Place the temperature sensor as shown in the picture.
• Apply metallic lacquer over the sensor. Ensure that the entire sensor is covered by the metallic lacquer.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
7- 7
Electric Pump Motor — 1710 Installation Instructions for External Temperature Sensor T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
• Fasten the metallic lacquer and the sensor with masking tape and allow it to harden.
• Remove the masking tape. The temperature sensor should now be fixed in place and covered entirely by metallic lacquer. • Remove the ferritic steel block from the old sensor and mount it on the cable to the new sensor. • Remove the contact from the broken sensor which is attached to the motor. • Place the new sensor contact in the old bracket and connect it to the cabling. • Fasten the old contact and its cabling using a binding tie so it cannot damage anything.
7- 8
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electric Steering Motor — 1730 General Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
8- Electric Steering Motor — 1730 8.1 General The steering motor is located on the drive assembly cowling. It receives signals from the steering generator located in the drive panel. The steering motor is equipped with a gear working directly upon the gear ring on the drive axle. It is also equipped with two carbon brushes.
8.2 Replacing the Steering Motor 8.2.1 Dismantling • Shut off the truck using the key. • Disconnect the steering motor electrical contact from the tank console. • Unscrew the four screws that hold the steering motor. • Lift away the steering motor. • Unscrew the screws holding the gear wheel. • Pull off the gear with a gear puller.
8.2.2 Re-Assembly • Replace the O-rings as necessary. • Tap the gear wheel into place on the steering motor. • Tighten the gear wheel to 10 Nm. • Mount the steering motor in the truck. • Tighten the screws on steering motor to 40 Nm. • Reconnect the contact.
8.3 Removing and Replacing the Carbon Brushes • Unscrew the two plastic plugs on the upper surface of the steering motor. • Take out the carbon and examine for wear. • Replace the carbon as necessary. • Insert the carbon and screw in the plastic plugs.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
8- 1
Electric Steering Motor — 1730 Removing and Replacing the Carbon Brushes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
This page is intentionally left blank
8- 2
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electric Drive Motor — 1760 General Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
9- Electric Drive Motor — 1760 9.1 General The drive motor is a three-phase AC motor. In the motor, there is a thermoelement measuring the motor temperature, as well as a bearing with an integrated sensor for measuring rotational speed and direction. The drive motor model designation is D112 - 165. This service manual includes instructions for replacing bearings, axle gaskets and the temperature sensor.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
9- 1
Electric Drive Motor — 1760 Dismantling the Drive Motor T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
9.2 Dismantling the Drive Motor
9- 2
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electric Drive Motor — 1760 Dismantling and Assembling the Drive Motor Order number 244989-040
Date 2013-03-04
63 14 31
Valid from serial number 6004330-
T-code 485, 487
9.3 Dismantling and Assembling the Drive Motor
60
9.3.1 Dismantling the Drive Motor 61
• Cut the voltage by turning off the key and removing the battery plug. • Remove the temperature, braking and speed measurement contacts (14, 31, 63) and power cables (60) from the motor (61). • Fasten a lifting eye to the motor axle.
29 27
• Loosen and remove the motor mounting screws (62). • Lift out the motor using an overhead crane and place it on a clean surface.
7 NOTE
62 51 54
Risk of damage to the gear wheel (51). The gear wheel on the end of the motor is easily damaged. Lift away the motor with care.
• Cover the hole to the transmission when the motor is removed to prevent anything from falling inside the transmission housing.
Removing the gear wheel • Tap loose the nut (54) and unscrew it using tool 10-15639. • Pull off the gear wheel (51) using a gear puller.
55 6 33 37
• Remove the key (7) holding the gear wheel (51) in place. • Remove the lock ring (27) holding the bearing bracket (29) in place. • Pull off the bearing bracket (29) using a gear puller.
Removing the brakes • Loosen the screws (37) so that the brakes (33) can be removed. • Remove the outer lock ring (16) from the motor axle. • Remove the brake hub, key (6), plate and inner lock ring (16).
16
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
9- 3
Electric Drive Motor — 1760 Dismantling and Assembling the Drive Motor T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
9.3.2 Assembling the Drive Motor 55 6 33 37
Assembling the brakes. • Return the inner lock ring (16) and key (6). • Ensure that the friction disk (55) is centred in relation to the magnet housing before you try to install the brakes. It may be necessary to charge the magnet coils with 48 V DC to position the brake disc. • Fit the brake assembly onto the motor. Check that the splines on the friction plate were not damaged during installation. • Tighten the mounting screws (38) for the brake assembly. • Re-mount the outer lock ring (16).
Assembling the gear wheel • Replace the gear cage (29) on the motor axle.
16
• Install the lock ring (27). • Fit the key (7). • Replace the gear wheel (51).
29 27
• Fit a new nut (54). • Use tool 10-15639 and tighten to a torque of 60 Nm.
7
62 51 54
• Lock the nut with a centre punch in the key track. • Attach a lifting eye to the motor axle and lift the motor axle into the transmission using an overhead crane. NOTE Risk of damage to the gear wheel (51). The gear wheel on the end of the motor is easily damaged. Lift away the motor with care.
• Tighten the motor (61) into the transmission to a torque of 20 Nm.
63 14 31 60
• Re-attach the temperature, braking, and speed measurement contacts (14, 31) and power cables (60) to the motor. • Remove the lifting eye. • For adjustment of the brakes, see C-code 3100.
61
9- 4
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electric Drive Motor — 1760 Bearing Replacement Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
9.4 Bearing Replacement 14 31 23 54 51 12 11
2 4 10 1 9
8
24 22
25
3
33
55 34
6
38
D
7
27 26 50 28 29 30 21 20
17
5 18 16
9.1 Dismantling N-side • Loosen the stud screws (20) using tool 08-15444. • Remove the screws (34). • Remove the shield (3). • Remove the lock ring (16) and support ring (18). • Pull off the bearing (5) with a gear puller.
D-side • Remove the lock ring (26) from the bearing housing. • Pull off the bearing housing (29) with a gear puller. • Pull the bearing (28) off from the bearing housing with a Kukko ball bearing puller. • Remove the gasket (30) if it is leaky.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
9- 5
Electric Drive Motor — 1760 Bearing Replacement T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
9.1.1 Assembling Ensure all parts are intact and clean before re-assembly.
N-side • Press the bearing (5) on the rotor axle. • Replace the bearing cap (8) on the motor axle. • Install the flange ring (17). • Re-mount the washer (18) and lock ring (16). • Screw the bearing cap (8) and shield (3) together using the screws (34) to a torque of 6 Nm. • Fit the insulation hose on the sensor bearing cable. • Place the terminal block (10) between the shields. • Tighten the stud bolts (20) to a torque of 5 Nm. • Bind the cables for the thermocontact and the sensor bearing to the middle power cable.
D-side • Install a gasket (30) to the bearing housing (29). • Press the bearing (28) into the bearing housing. • Install lock ring (26).
9- 6
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electric Drive Motor — 1760 Installation Instructions for External Temperature Sensor Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
9.2 Installation Instructions for External Temperature Sensor Number 170384.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
9- 7
Electric Drive Motor — 1760 Installation Instructions for External Temperature Sensor T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
• The temperature sensor can be mounted to the right or left of the connection terminal block, depending on which side is easiest to access. • Scrape the surface clean where the new temperature sensor is to be mounted. • Place the temperature sensor as shown in the picture.
• Apply metallic lacquer over the sensor. Ensure that the entire sensor is covered by the metallic lacquer.
9- 8
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electric Drive Motor — 1760 Installation Instructions for External Temperature Sensor Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
• Fasten the metallic lacquer and the sensor with masking tape and allow it to harden.
• Remove the masking tape. The temperature sensor should now be fixed in place and covered entirely by metallic lacquer. • Remove the ferritic steel block from the old sensor and mount it on the cable to the new sensor. • Remove the contact from the broken sensor which is attached to the motor. • Place the new sensor contact in the old bracket and connect it to the cabling. • Fasten the old contact and its cabling using a binding tie so it cannot damage anything.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
9- 9
Electric Drive Motor — 1760 Installation Instructions for External Temperature Sensor T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
This page is intentionally left blank
9- 10
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Mechanical Drive Gear Unit — 2550 General Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
10- Mechanical Drive Gear Unit — 2550 10.1 General This type of truck is equipped with a drive assembly mounted to the chassis with 6 bolts. The drive transmission is integrated with the motor, brakes, and sensor measuring speed, steering wheel direction and direction of travel, as a complete drive assembly. The drive assembly is equipped with 360° steering. The drive gearing in this truck is a two-step angle transmission with conical roller bearings for the drive shaft and pinion. The bearings are pre-tensioned approximately 5/100ths of a mm to minimise the risk of play in the bearings. This maintenance manual includes instructions for removing and refitting the drive transmission, topping up and changing the oil and responding to leakage. A complete renovation of the drive transmission is so extensive that it must be done in the shop by specially trained personnel.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
10- 1
Mechanical Drive Gear Unit — 2550 Drive/Transmission Assembly's Main Components and Technical Data T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
10.2 Drive/Transmission Assembly's Main Components and Technical Data The drive transmission's main components and technical data are shown in the tables below.
10.2.1 Position of Components
10- 2
Position Nr.
Component
1
Drive motor
2
Drive assembly cowl
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Mechanical Drive Gear Unit — 2550 Drive/Transmission Assembly's Main Components and Technical Data Order number 244989-040
© BT Europe AB
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Position Nr.
Component
3
Steering bearings
4
Upper gear cover with gear ring
5
Gear wheel, primary step
6
Pinion nut
7
Pinion
8
Pinion bearing
9
Shims, pinion bearing
10
Lower gear cover
11
Drive shaft nut
12
Nut washer
13
Crown wheel
14
O-ring
15
Drive shaft bearings
16
Shims, drive shaft bearings
17
Gasket protection
18
Drive shaft gasket
19
Drive shaft
20
Gear housing
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
10- 3
Mechanical Drive Gear Unit — 2550 Drive/Transmission Assembly's Main Components and Technical Data T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
10.2.2 Technical data Type of Truck
VR, VR SF
Transmission
2-step angle transmission
Gear ratio
20.89:1
Oil volume, litre
3.3
Oil type
Hypoid oil
Viscosity, normal temperature
SAE 80W/90
Viscosity, < -15o C
SAE 75W
10.2.3 Dismantling the Transmission
10- 4
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Mechanical Drive Gear Unit — 2550 Replacing the Drive Motor/Drive Transmission Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
10.3 Replacing the Drive Motor/Drive Transmission 63 14 31 60 61
10.3.1 Dismantling the Drive Motor • Cut the voltage by turning off the key and removing the battery plug. • Remove the temperature, braking and speed measurement contacts (14, 31, 63) and power cables (60) from the motor (61). • Fasten a lifting eye to the motor axle. • Loosen and remove the motor mounting screws (62). • Lift out the motor using an overhead crane and place it on a clean surface. NOTE Risk of damage to the gear wheel (A). The gear wheel on the end of the motor is easily damaged. Lift away the motor with care.
• Cover the hole to the transmission when the motor is removed to prevent anything from falling inside the transmission housing.
29 27 53 52
Removing the gear wheel • Bend away the locking tab on the lock washer (53) at the end of the motor, unscrew the nut (54) and remove the washer (52).
7 • Pull off the gear wheel (51) using a gear puller.
62
• Remove the key (7) holding the gear wheel (51) in place.
54
© BT Europe AB
51 A
• Remove the lock ring (27) holding the bearing bracket (29) in place. • Pull off the bearing bracket (29) using a gear puller.
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
10- 5
Mechanical Drive Gear Unit — 2550 Replacing the Drive Motor/Drive Transmission T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
10.3.2 Removal of the Drive Transmission • Unscrew the four screws that hold the support and lift it out of the way. • Hoist the truck using a pneumatic jack and put it on blocks. • If the truck is equipped with steering wheel indicators: Disconnect the indicator for centred steering (8) and steering direction (9). • Disconnect the contact to the steering motor and loosen the contact (10) from its bracket in the plate on the tank. • Unscrew the screws (11) for the steering motor (12) and remove it from the drive transmission. • Remove the 6 bolts (14) holding the drive transmission cowl (15) to the chassis. • Remove the drive transmission (17) with its cowl (15) from the truck. • Unscrew and remove the drive wheel. • Remove the 6 bolts (18) holding the drive transmission (17) to its cowl (15) and lift away the cowl. • Dismantling the steering bearing (16): Unscrew the 15 hexagon socket bolts (19) and remove the steering bearing (16) from the drive shaft (17).
10- 6
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Mechanical Drive Gear Unit — 2550 Replacing the Drive Motor/Drive Transmission Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
10.3.3 Assembling the Drive Transmission • Assembling the steering bearing (16): Replace the steering bearing (16) with the 15 hexagon socket bolts (19) on the drive transmission (17) with LOCTITE 242, to a torque of 25 Nm. • Always replace the lift valve (20) when the steering bearing has been removed or when fitting a new bearing. • Attach the new drive transmission (17) to the cowl (15). Oil the bolts (18) and tighten them to a torque of 80 Nm. • Fasten on the drive wheel, torque 130 Nm. • Insert the drive transmission (17) into position in the truck. • Fasten the drive transmission (17) with its cowl (15) to the chassis with the 6 bolts (14), torque 222 Nm. • Install new O-rings and new plastic packing as needed on the steering motor. • Mount the steering motor (12) on the drive transmission cowl; torque on the screws (11) should be 40 Nm. • Re-connect the contacts to the steering motor (10). • If the truck is equipped with a steering wheel indicator: Turn the steering wheel until an edge is visible through the hole for the centred steering indicator (8). • Screw in the centred steering indicator (8) so that it stops at the edge. Then turn it back 1 1/2 turns and lock it in place with a lock nut. • Screw in the steering wheel direction indicator (9) (red indicator diodes towards to the battery compartment) until it stops, then turn it back 1 1/4 turns and lock it in place with a lock nut.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
10- 7
Mechanical Drive Gear Unit — 2550 Replacing the Drive Motor/Drive Transmission T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
10.3.4 Installing the Drive Motor
29 27 53 52
If you replaced the drive transmission (17), also replace the gear wheel (51) on the drive motor.
7
62 54
51 A
If you replaced the drive motor, use the old gear wheel on the new motor.
Assembling the gear wheel • Replace the bearing bracket (29) on the motor axle. • Fit the lock ring (27). • Fit the key (7).
63 • Replace the gear wheel (51). 14 31 • Put the washer (52), a new lock washer (53), and the nut (54) into 60
place.
• Tighten to a torque of 60 Nm. • Bend out a locking tab on the lock washer.
61
• Attach a lifting eye to the motor axle and lift the it into the transmission using an overhead crane. NOTE Risk of damage to the gear wheel (A). The gear wheel on the end of the motor is easily damaged. Lift the motor in carefully.
• Tighten the motor (61) into the transmission to a torque of 20 Nm. • Re-attach the temperature, braking, and the speed measurement contacts (14, 31) and power cables (60) to the motor. • Remove the lifting eye. • For adjustment of the brakes, see chapter 3100.
10- 8
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Mechanical Drive Gear Unit — 2550 Checking/Replacing the Oil Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
10.4 Checking/Replacing the Oil 10.1 Checking/Refilling the Oil • The oil level in the transmission should be checked after every 250 operating hours. • Check the oil level in the transmission by removing the oil-refill plug on the upper part of the transmission housing. • Fill the oil right up to the opening to reach the correct level. Hypoid oil MP in the drive transmission. • SAE 80W/90 for operation in normal temperature. SAE 75W for operation in cold store, < -15o C. • Oil volume approx. 3.3 litres.
10.1.1 Changing the Oil Replace the oil in the transmission for the first time after 50-100 operating hours and then every 3000 operating hours.
• To drain the old oil, remove the lower transmission cowl completely. • Replace the O-ring gaskets with every oil change. Make sure the new O-ring is not damaged when installed. • Mount the cowl and torque the bolts to 25 Nm. The bolts should be oiled before insertion. • Fill the oil as instructed in the chapter "Checking/Refilling the Oil."
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
10- 9
Mechanical Drive Gear Unit — 2550 Repairs T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
10.2 Repairs 10.1 Replacing the Drive Shaft Gasket Replacing the drive shaft gasket is easiest when the drive assembly is removed from the truck. Follow the instructions below if there is oil leaking from the drive shaft.
Dismantling: • Remove the drive assembly from the truck as described in the chapter "Replacing the Drive Motor/Drive Transmission" • Remove the lower transmission cowl (2) and drain the oil. • Loosen the drive shaft nut (3). Remove the nut and spacer ring. • Carefully tap out the drive shaft (4) using a hammer and brass drift. • Pull the bearing (5) off the drive shaft. NOTE A standard claw gear puller cannot be used to remove the bearing. Use a puller such as a KUKKO bearing puller.
• Check whether the spacer washers (6) on the bearing are damaged. If they were damaged by the gear puller, measure the spacer washers' combined thickness and replace them before re-assembly. • Remove the gasket ring (7) from the drive shaft.
7 6 5
2 3
4
10- 10
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Mechanical Drive Gear Unit — 2550 Repairs Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Re-Assembly: Follow the instructions below when re-assembling after replacement of the drive shaft gasket.
• Insert the drive shaft's outer bearing (1) into place in the transmission housing. • Push the new gasket (2) into the transmission housing. Be careful when pushing in the gasket to seat it properly in position. • Place the spacer washers (3) for the axle bearing on the drive shaft, building the same total thickness as the original ones. Make sure to only use undamaged spacer washers. • Press the drive shaft (4), with the spacer washers, into the transmission. Check that the drive shaft splines correspond with the splines in the crown wheel. • Place the distance ring on the end of the drive shaft, and put the shaft nut (5) into position. Always use a new nut. The drive shaft nut should be oiled before it is placed on the shaft. Torque the nut to 700 Nm and lock it in place with a centre punch in the groove in the axle. • Replace the O-ring before installing the lower cowl (6). Make sure it is not damaged. Mount the cowl and torque the bolts to 25 Nm. The bolts should be oiled before insertion. • Fill the oil as instructed in the chapter "Checking/Refilling the Oil."
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
10- 11
Mechanical Drive Gear Unit — 2550 Repairs T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
10.1.1 Leakage from the Upper Cover Follow instructions below in the event of leakage from the transmission's upper cowl:
• Remove the transmission from the truck as described in the chapter "Replacing the Drive Motor/Drive Transmission" • Loosen all bolts holding the upper cowl to the transmission housing. • Remove the cowl from the transmission housing and clean the sealant surfaces carefully, both on the cowl and the transmission housing. • Apply sealant such as Curil K2 to the surfaces. Follow the instructions on the package. • Mount the cowl and torque the bolts to 46 Nm. The bolts should be greased prior to assembly. • Fill with oil as instructed in the chapter "Checking/Refilling the Oil." • Assemble the drive transmission/drive motor and mount the drive assembly in the truck as described in the chapter "Replacing the Drive Motor/Drive Transmission."
10.1.2 Leakage from the Lower Cover • Drain the remaining oil from the transmission. • Remove the cover from the transmission. • Replace the gasket in the drainage plug and the O-ring on the cover. • Mount the cowl and torque the bolts to 25 Nm. Make sure the O-ring is not damaged. The bolts should be greased before assembly.
10- 12
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Mechanical Drive Gear Unit — 2550 Repairs Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
10.1.3 Replacing Wheel Bolts The wheel bolts on the transmission are stud bolts. To replace the wheel bolts, do as follows:
• Pull out the battery's emergency disconnector. • Remove the fender by the drive wheel from the chassis. • Hoist the machine using a pneumatic jack and put it on blocks. • Remove the drive wheel. • Wheel bolts with damaged threads are removed using the stud bolt tool. • Broken wheel bolts: • Method 1: Drill a hole in the centre of the bolt and screw out the bolt using a screw extractor for M14 bolts. • Method 2: If the bolt will not come loose with a screw extractor, the bolt must be drilled out. - Drive a centre punch into the centre of the bolt. Be careful to centre the centre punch. - Pre-drill a hole through the bolt using a 5 mm bit. Drill out the bolt using an 11.5 mm bit. - Try to remove the remains of the bolt with pliers or the like. If that does not work, remove the remains by clearing the threads with a screw tap M14x1.5. • Put a string of LOCTITE 270 on the threads of the wheel bolt. Mount the new wheel bolt with a stud bolt tool. Torque: 80 Nm • Re-install the drive wheel. Tighten the wheel nuts to 130 Nm. • Remove the blocks and lower the truck. • Re-fit the fender. • Re-connect the emergency battery disconnector.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
10- 13
Mechanical Drive Gear Unit — 2550 Repairs T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
This page is intentionally left blank
10- 14
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Travel brake system — 3100 Brake system Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
11- Travel brake system — 3100 11.1 Brake system 11.1.1 General The truck’s travel brake system can be made up of three different subsystems. 1. Regenerative motor braking with the drive motor. 2. A one-step electromechanical disc brake fitted to the motor. 3. Four analogue electromechanical multiple disc brakes fitted in the support arm wheels (option).
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
11- 1
Travel brake system — 3100 Description of function T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
11.2 Description of function The travel brake system’s primary function is the regenerative motor braking from the drive motor. Braking can take place in three different ways: • When the accelerator is released. • By changing direction with the travel direction control, normal motor braking. • By pressing the brake pedal.
11.2.1 Releasing the accelerator The regenerative motor brake is activated automatically when the accelerator is released. The braking force can be set, via a parameter, by the operator. See Ccode 5000. The force of the motor brake is regulated progressively in relation to the current speed of the truck and how far the accelerator pedal is released. This works as follows: • Braking at high speed, accelerator released fully, results in a high braking force. • Braking at low speed, accelerator released fully, results in a low braking force. • Braking at high speed, accelerator released half way, gives a medium braking force.
11.2.2 Changing travel direction The braking force is regulated by the position of the accelerator pedal, i.e. the more the pedal is pressed the greater the braking force.
11- 2
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Travel brake system — 3100 Description of function Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
11.2.3 Pressing the brake pedal (without support arm brake) When the brake pedal is pressed down approx. 80% of it’s stroke length, full regenerative braking is achieved. If the brake pedal is pressed between 80 - 100%, further braking force is added due to the electro-magnetic disc brake on the drive motor being activated. On the border line of 80%, the motor braking is reduced in proportion to the disc brake’s braking force in order to avoid jerking or locking the wheels, see illustration.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
11- 3
Travel brake system — 3100 Description of function T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
11.2.4 Pressing the brake pedal (with support arm brakes) When the brake pedal is pressed down approx. 50% of it’s stroke length, full regenerative motor braking is achieved. If the brake pedal is pressed more than 50%, further braking force is added, as the disc brakes in the support arm wheels are applied. When the brake pedal is pressed down to 85-90%, even the electromechanical disc brake on the drive motor is activated. At the same time the motor brake is reduced by a level equivalent to the disc brakes’ braking torque in order to avoid jerking or locking the wheels, see illustration.
11- 4
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Travel brake system — 3100 Description of function Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
11.2.5 Parking brake The parking brake is activated/active as follows: • The parking brake is activated automatically when the truck stops, when driving and the truck is brought to a stop with the help of the brake pedal. The brake is released when the accelerator is pressed. • The parking brake is activated automatically when the operator gets out of the truck, a few seconds delay. • The parking brake remains activated after the key switch has been turned on.
11.2.6 Emergency braking Emergency braking of the truck can occur in the event of a system error or a serious fault in the electrical system. • The electromechanical disc brake on the drive motor is the primary emergency brake. • The motor brake can function during emergency braking provided that the power supply is functioning.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
11- 5
Travel brake system — 3100 Electromechanical disc brake, drive motor T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
11.3 Electromechanical disc brake, drive motor The brake is a single-stage electromagnetic spring-assisted brake which is activated when its magnetic coil is not powered. WARNING! The brake is a safety component. Do not interfere with the brake components.
Technical data
Description
8
Nominal torque
90 Nm
Nominal play
0.3 +0.1/-0.1 mm
Maximum play
0.50 mm
Tightening torque for bolts
20 Nm
Minimum thickness for the friction disc
10.5 mm
Resistance of the coil
48 Ohm at 20 °C
9
1 6
2 4 5 3
7
10
11- 6
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Travel brake system — 3100 Disassembly Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
11.4 Disassembly 1. Switch off the truck. 2. Remove the brake cable (8) to the truck's electrical system. 3. Loosen the brake unit's mounting bolts. 4. Lift the brake unit from the shaft and remove it from the truck. 5. Place the brake on a clean and dry workbench with the magnet housing (1) facing upwards. 6. Undo the 3 assembly screws (9). 7. The brake unit can now be dismantled for inspection of the component parts.
11.5 Inspection 1. Check whether the parts are damaged and/or worn. 2. Check the rotor disc (4) and the wear surfaces on the pressure discs (2 and 5) extremely carefully. Check that the rotor disc's friction material is not worn or damaged. 3. 3. Check the springs are intact. 4. Check for any damage to the keyway (7) or the splines on the hub (3) and friction disc (4).
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
11- 7
Travel brake system — 3100 Assembly T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
11.6 Assembly 1. Clean the parts carefully. 2. Assemble the brake in the reverse order to dismantling. 3. Bear in mind the following: 4. The hole in the pressure disc (2) must line up with the corresponding hole in the magnet housing. 5. The right number of springs must be fitted. 6. The play must be set correctly. Some adjustment may be necessary. 7. Mount the brake on the motor shaft. 8. Check before mounting the brake that the friction disc (4) is centred in relation to the magnet housing. 9. It may be necessary to charge the magnetic coil with 48 VDC to position the brake disc correctly. 10. Mount the brake unit in the truck. Check that the splines on the friction disc have not been damaged during installation. 11. Insert the brake unit's mounting bolts and tighten them using a torque of 20 Nm. 12. Check the amount of play between the magnet housing and the pressure plate with the brake engaged. 13. Connect the brake cable (8) to the truck's electrical system. 14. Start the truck and release the parking brake. 15. Check that the friction disc rotates freely. 16. Cut the voltage and check that the pressure plate locks the friction disc and that the play is correct. NOTE: Avoid hitting parts 3 and 7 on the disk on the motor axle (see figure) but press it instead. Otherwise cracks can occur on the brake disk, which will cause it to break
11- 8
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Travel brake system — 3100 Maintenance Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
11.7 Maintenance Maintenance comprises checking wear and braking force, inspection and adjustment of the play between the pressure disc and the magnet housing, and cleaning. NOTE: The friction surfaces must not come into contact with oil or grease as this will seriously reduce the braking force.
11.7.1 Adjusting the play 1. Adjust the play using the adjustment screws. 2. The play may not exceed the maximum permitted value before adjustment is required. Use a feeler gauge to measure. Maximum permitted play LRE300T: 0.50 mm. Nominal play LRE300T: 0.3 +/-0.1 mm 3. Adjust the play using the adjustment screws (6). 4. If the minimum size of the friction disc is less than 10.5 mm, replace it. Remove the three screws (10) on the underside of the brake to release the brake package. 5. Turn anticlockwise to reduce the play and clockwise to increase it. 6. Tighten the assembly screws on the underside to 20 Nm. 7. Check the play again once the bolts have been tightened. 8. Repeat the adjustment stage until play is correct. 9. Check the play all the way around the pressure disc. The maximum permitted deviation from the set play is 0.075 mm.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
11- 9
Travel brake system — 3100 Maintenance T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
11.7.2 Wear
Min 10,5
1. Dismantle the brake in accordance with the dismantling section. 2. Measure the thickness of the friction disc. Minimum thickness: 10.5 mm.
11.7.3 Checking the braking force 1. Lift up the truck so that the drive wheel is free of the ground. 2. Open the motor housing covers. 3. Tighten the M12 bolt into the hole (for lifting) in the motor shaft. Use a torque wrench and an M12 flange bolt or a normal bolt with a flat washer. Torque wrench setting, 90 Nm. NOTE: The bolt quality must be at least 10.9.
4. Turn the motor axle with the torque wrench until the brakes release. 5. The braking force is too low if the brake releases before the torque wrench slips. 6. Adjust the brake play to the correct value – see instructions for adjusting play. 7. Check the braking force once more using the torque wrench.
11- 10
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Travel brake system — 3100 Maintenance Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Troubleshooting chart Fault
Cause
Action
The brake does not release
Too low power supply
Check the power supply
Too large/too small play
Adjust the play
Worn friction discs/rotor disc
Replace/adjust play
Damaged coil
Replace brake
Corrosion between the friction plates and the rotor
This fault may arise in damp environments when the truck has not been used for a few days. Try to drive the truck carefully until the corrosion is worn away. In such cases, inspect the brake to check that the friction material has not come loose. If the fault cannot be remedied, the brake must be replaced.
The current is switched off
Check the power supply
Grease on the friction surfaces
Replace/adjust play
One of the springs is broken
Replace brake
Too low power supply
Check the power supply
The brake is not engaging
Unreliable brake action
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
11- 11
Travel brake system — 3100 Multiple disc brake, support arm T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
11.8 Multiple disc brake, support arm The brake is an analogue electromagnetic multiple disc brake, i.e. the brake is engaged by charging the magnet coil. The voltage in the magnet coil is regulated by a potentiometer in the brake pedal and thereby regulates the braking force. The multiple discs are made of steel. The brake functions as a secondary travel brake and is used when the operator needs to brake hard, >50% of the maximum available braking force. The brake is fitted in the support arm on a hub with splines and a locking heel which takes up the braking force. The support arm wheel must be removed from the truck in order to check and service the brake, see C-code 3550. The magnet coil, however, can be checked with the wheel in place. All instructions given here require that the wheel be removed first.
11.8.1 Assembly • Make sure that the brake engages and releases when intended. Connect the brake to 48 V D.C. Turn the current off and on. • Check that the amount of play between the end plate (6) and the pressure plate (2) is 1.0-1.25 mm with the current on (brake engaged). It may be necessary to adjust the amount of play, see section on adjusting. NOTE! Check the amount of play at two points simultaneously with 180° between check points.
• Fit the brake into the support arm wheel, making sure that the inner disc’s splines are positioned correctly so that they reach the wheel hub without being obstructed. • Fit the wheel in the support arm according to instructions C-code 3550. Make sure that the locking heel (8) is positioned correctly in its recess in the support arm. • Connect the brake cable harness (14) and check the braking function by pressing the brake pedal fully down.
11- 12
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Travel brake system — 3100 Multiple disc brake, support arm Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
11.8.2 Dismantling
• Remove the brake from the support arm wheel. • Place the brake on a clean, dry work surface with the end plate (6) uppermost. NOTE! Take care that the components and cable harness are not damaged during this and following operations.
• Undo and remove the six M6x40 socket head screws (12) and their washers. • Remove the aluminium end plate (6). NOTE! Make note of the number of shims (11) on every spacer (5).
• Lift off the pressure plate (2) and the disc unit which consists of 3 outer discs (3) and two inner discs (4). • Remove the brass plate (7).
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
11- 13
Travel brake system — 3100 Multiple disc brake, support arm T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Inspection • Check the thickness of the discs. The nominal thickness of a new disc = 2.0 mm. Limit for wear = 1.4 mm • When replacing discs: Replace all inner and outer discs at the same time. Never individually. • Check that the discs are flat and that there is no damage to the splines or the recess. • Check the electrical resistance of the magnet coil. Nominally 47.7 Ohm at 20°C. NOTE! The resistance measurement can be made with the brake/wheel fitted in the truck.
Assembling • Clean all parts thoroughly. NOTE! Use only a wire brush and water for cleaning.
• Assemble the brake in the reverse order to which it was dismantled. • Connect the brake to 48 V D.C. • Check the amount of play between the end plate and the pressure plate (brake engaged). Adjust if necessary.
11.8.3 Maintenance The brake is included in the maintenance schedule. For service intervals see Maintenance schedule section P2. Maintenance includes checking and adjusting the amount of play between the pressure plate and the end plate, checking for wear and the magnet coil’s resistance as well as cleaning. • Cleaning and checking/adjustment of play must be carried out after every 1000 hours running time. • Checking for wear and checking the magnet coil’s resistance must be carried out after every 3000 hours running time.
11- 14
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Travel brake system — 3100 Multiple disc brake, support arm Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Adjusting the amount of play • Dismantle the support arm wheel from the truck and remove the brake. • Connect the brake to 48 V D.C.
• Check the amount of play, measurement A, with the brake engaged. NOTE! Check the amount of play at two points simultaneously with 180° between check points.
• Maximum permitted play = 2.25 mm • The nominal amount of play on a newly adjusted brake is 1.0-1.25 mm. • Remove the aluminium end plate before adjusting. • Remove the shims when adjusting due to wear, or add shims when replacing with new discs. Each shim has a thickness of 0.127 mm. • Fit the aluminium end plate, connect to 48 V D.C. and check the amount of play. • When the amount of play is within the nominal permitted limits, assemble the brake in the wheel and the wheel in the truck.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
11- 15
Travel brake system — 3100 Multiple disc brake, support arm T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
This page is intentionally left blank
11- 16
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Drive wheel — 3530 General Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
12- Drive wheel — 3530 12.1 General The drive wheel is made up of a cast rim with a vulcanized tread. When replacing the drive wheel it is important that the wheel nuts are tightened with the correct torque.
12.2 Dismantling the drive wheel • Lift the truck and place on blocks so that the drive wheel is hanging free. • Undo the four screws holding the cover plate in place. • Remove the cover plate. • Undo the nuts holding the drive wheel in place. • Remove the drive wheel.
12.3 Assembling the drive wheel
• Lift the new drive wheel into position. • Apply molykote grease BT number 055-73040 to the wheel bolts. • Fit the spherical washers in place on the wheel bolts. • Screw on the wheel nuts and tighten with a torque of 130 Nm. • Fit the cover plate. • Remove the blocks from under the truck.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
12- 1
Drive wheel — 3530 Assembling the drive wheel T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
This page is intentionally left blank
12- 2
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Fork/support arm wheel – 3550 General Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
13- Fork/support arm wheel – 3550 13.1 General Two different types of support leg wheels are used on the Veflex trucks depending on whether or not the truck is equipped with support leg brakes(*). The wheel is fitted on the support leg on a through shaft using a clamping sleeve. The shaft has a threaded hole that is used for disassembly and reassembly.
13.2 Dismantling the wheel • Remove the cover plate at the support arm. • Lift up the truck and support using blocks so that the support arm wheel/wheels runs free of the ground. • Loosen the connector/cable to the support arm brake.(*) • Loosen the locking bolt for the brake shoe.(*)
• Pull out the wheel axle using tool 08-13585. Use the short punch. • Lift out the wheel. • Take the brake unit out of the wheel.(*)
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
13- 1
Fork/support arm wheel – 3550 Assembling the wheel T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
13.3 Assembling the wheel
For wheels with brakes: • Place the brake unit in position in the wheel.(*) • Place the spacers (1) in position on the hub. • Lift the wheel/wheels in position in the support arm. NOTE! On wheels with brakes, guide in the brake’s locking shoe in its cut-out in the support arm.
• To centre the wheel/wheels vertically, use a jack to adjust the height of the support arm. • Check that the wheel axle (3) is not damaged. Minor longitudinal scratches can be tolerated. If the axle ends have been damaged the axle should be ground or replaced. • Fit a new clamping ring (2) on the wheel axle (3). WARNING Loose wheel. If the wheel is refitted using the old clamping ring the wheel can become loose while driving. Always fit the wheel with a new clamping ring on the wheel axle.
• Fit the extension punch on tool 08-13585 and insert it through the wheel hub and support arm.
13- 2
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Fork/support arm wheel – 3550 Assembling the wheel Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
• Secure the wheel axle using the punch and carefully insert the axle. Make sure the axle is not inserted too far. When the axle is correctly positioned it should be centred in the support arm’s wheel bracket. • Lower the truck. For wheels with brakes? • Tighten the locking bolt for the brake’s locking shoe and connect the brake cable. Secure the cable with a tie on the guard plate bracket so that it does not rub against the wheel. • Fit the cover plate.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
13- 3
Fork/support arm wheel – 3550 Dismantling/assembling the wheel bearings T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
13.4 Dismantling/assembling the wheel bearings Dismantling the bearing • Remove the spacers (1). • Remove the retainer rings (2). • Press out the sleeve (3). • Use a “soft” punch of brass or the like to knock out the bearing (4).
Assembling the bearing • Press in the bearing (4). Use an assembly sleeve of the same outside diameter as the bearing’s outer ring, 90 mm. • Check that the sleeve (3) is not damaged. • Fit one of the retainer rings (2) on the sleeve. • Press in the sleeve until the retainer ring stops against the bearing. • Fit the other retainer ring. • Place the spacers (1) in position on the hub.
13- 4
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electric steering wheel/lever — 4310 General Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
14- Electric steering wheel/lever — 4310 14.1 General The steering generator is located in the steering panel and has direct contact with the steering wheel. When the steering wheel is turned impulses are sent from the steering generator to the steering motor via the logic box.
14.2 Replacement of the steering generator 14.2.1 Dismantling • Undo the 11 screws on the lower panel and remove it. • Disconnect the contactor on the steering motor. • Dismantle the steering wheel by removing the 4 screws round the steering motor. • Undo the screws on the carrier and remove it from the steering motor. • Undo the 4 screws holding the steering motor to the steel console.
14.2.2 Assembly • Fit the steering motor to the steel console with the 4 screws. • Screw the carrier to the steering motor’s axle. • Replace the O-rings on the carrier, if necessary. • Screw the steering wheel in place on the steel console. • Connect the steering motor’s electrical contactor. • Fit the lower panel in place with the 11 screws.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
14- 1
Electric steering wheel/lever — 4310 Replacement of the steering generator T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
This page is intentionally left blank
14- 2
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Steering angle sensor — 4350 General Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
15- Steering angle sensor — 4350 15.1 General These instructions apply to adjustment of the steering angle sensor mounted on the driving gear.
15.2 Procedure The information supplied by the two directional arrows in the display changes as the sensor detects a change between the high and low level in the driving gear. The two-way sensor uses the gear wheel to calculate the steering angle and displays the value in the display's compass rose. NOTE: The sensor may be damaged if it is adjusted against an incorrect surface. Always adjust the sensor against the upper surface.
15.2.1 Adjustment of directional sensor Adjust the sensor to a detection range of 1 mm. • Screw the sensor onto the machined surface until the two touch each other. • Then unscrew one full rotation. • Verify that the LED on the sensor/logic card lights when it is in front of the machined surface.
1 mm
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Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
15- 1
Steering angle sensor — 4350 Procedure T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
15.2.2 Adjustment of the steering angle sensor Roughly adjust the sensor to a detection range of ~1.1 mm. • Measure the supply voltage to the sensor, i.e. connector 810 on the A5 logic card. • Screw the sensor onto the large plate until it touches the right part of the cog. • Then unscrew one full rotation. • Make sure the sensor is mounted with the LEDs set horizontal and the red LED facing the fork direction. • Fine-adjust by turning the outer, large plate. • Measure the voltage on both sensor outputs while the steering wheel is turning and the gear rotating. • To achieve a correct on/off switching pulse, the voltage on the sensor outputs, or connectors 210 and 211 on the A5 logic card, should be half that of the supply voltage. • Finally tighten the large nut and the sensor mounting screws.
1,1 mm
1
15- 2
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Automatic steering system — 4500 General Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
16- Automatic steering system — 4500 Wire guidance
16.1 General Wire guidance is used for automatic steering in narrow aisles. A generator generates alternating current in a cable that is set into the floor and which the truck follows. The cable follows the narrow aisles in a closed loop from the generator in aisle 1, on to aisle 2, etc. From the last aisle it then returns to the generator. The maximum length that a generator can supply is approx. 750-1000 m. A further generator must be installed with a separate loop if more is required.
The current flowing in the laid cable gives rise to a magnetic field around the cable. This field is used to guide the truck. The magnetic field is sensed by means of antennae mounted under the truck. The antennae are connected to the regulator unit that controls the steering. The system is monitored by the ordinary truck computer, which stops the truck if an error should occur.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
16- 1
Automatic steering system — 4500 Generator T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
16.2 Generator The generator is connected to a wall socket with nominal voltage of 220 V (LDU-22). There is also a model for 110 V (LDU-21). Internally the unit consists of a voltage card that converts the mains voltage to a lower operating voltage. A generator card with an output stage that powers the current in the loop. In addition, there is a battery that supplies the unit in the event of a power failure. A buzzer also sounds. Externally there are two LEDs. H1 (yellow) indicators the loop is closed and intact. H2 (green) indicates that the mains voltage is correct. X1 is the output for the main voltage and X2 for the outgoing loop. S1 is a pushbutton for testing the buzzer and battery function.
16.2.1 Technical data
16- 2
Power supply
Model LDU-22 220 V 50Hz
Output current
75 m A +/- 5%
Frequency
6.25 kHz +/- 3.5%
Output current
7.5 Voutput unloaded
Battery
2 x 12 V 3 Ah
Battery backup
> 6 hours
Max cable length
approx. 750 m
Cable cross section
> 0.75 mm2
Fuse
0.4 A (slow burn) on the voltage card
Service Manual
Model LDU-21 110 V 50/60Hz
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Automatic steering system — 4500 Wire guidance system overview Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
16.3 Wire guidance system overview
The wire guidance system is a supplementary system to the truck’s electrical regulator system. The main card’s logic, steering controller and steering motor in the truck’s ordinary system are utilised. Additional components to complete the wire guidance system are the WG-control unit, an antenna in the fork direction and one in the steering wheel direction as well as an extra sensor to sense the steering wheel’s home position and steering angle. Communication between the wire guidance control unit and the truck’s regulator system takes place via CAN (Controller Area Network). Error messages from the wire guidance control unit are transmitted via CAN to the truck’s electronics where they are stored in the error code register and are shown on the instrument panel’s display. The control unit’s original error code can be read off on a display on the control unit. These codes are not stored. See the section error codes. The system is self-learning and automatically adapts to the loop’s frequency and amplitude. Frequencies within the range 1 to 10 kHz and amplitudes within the area 14 mA to 1900 mA RMS.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
16- 3
Automatic steering system — 4500 Wire guidance components T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
16.4 Wire guidance components 16.4.1 Antennae, W1, W2 There are two antennae fitted under the truck. W1 in the fork direction and W2 in the steering wheel direction. It is important that the antennae are fitted in the truck’s centre line (+/- 5 mm), and fitted in the right direction.
Each antenna consists of four coils, which sense the magnetic field around the cable in the floor. The signals from the coils are amplified by a preamplifier card in the antenna to later be processed in the control unit. The nominal mounting height for the antennae is 50 mm above floor level.
16- 4
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Automatic steering system — 4500 Wire guidance components Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Installation of new antenna Antenna in the steering wheel direction, W2 • Pull out the battery halfway so that the antenna is accessible. • Block up the battery so that it does not tip over. • Loosen the antenna cable. • Unscrew the entire antenna bracket from the chassis. • Fit a new antenna on the bracket and refit the bracket on the truck. • Use a 50 mm spacer to set the correct antenna height and tighten the fastening bolts. • Connect the antenna cable. Antenna in the direction of forks, W1 • Remove the guard over the antenna • Loosen the antenna cable. • Loosen the antenna from the bracket. • Fit a new antenna on the bracket. • Check the antenna height with a 50 mm spacer and adjust the bracket if necessary. • Connect the antenna cable. NOTE! Antenna offset learning the must be carried out after installation of the new antenna. See the chapter Parameters.
Antenna cable The antennae are connected by a screened 9 core cable to eliminate external disturbances of the antenna signals.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
16- 5
Automatic steering system — 4500 Wire guidance components T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
16.4.2 Control unit, A3 The card regulates the steering by means of the antennae and signals for steering movement. Information about the system status is signalled to the truck computer for adapting the current travel speed and error handling. The card is digital and all requisite adjustments are made with parameters through learning of the antenna-offset, frequency and amplitude. Learnt data is saved after the learning process is completed and confirmed with auto/manual switch off/on.
Two fixed positions can be set in parameter 36:4: 5.2 kHz/90 mA and 6.25 kHz/75 mA, and position for other frequencies/amplitudes. See Parameter 36:4
Connections See electrical diagrams under C-code 5000.
16- 6
Term.
Typ e
No.
Active
Function
JP1:7
In
132
0 - +5 V
Steering angle, pulse A
JP1:8
In
133
0 - +5 V
Steering angle, pulse B
JP1:12
Out
131
0V
Supply voltage
JP1:21
Out
130
+5 V
Supply voltage
Term.
Typ e
No.
Active
Function
JP2:3
Out
67
+48 V
Wire guidance OK
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Automatic steering system — 4500 Wire guidance components Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Term.
Typ e
No.
Active
Function
JP2:9
In
112
+12 V
Steering angle, reference
JP2:11
In
22
+ 48 V
Supply voltage
JP2:21
Out
111
+ 12V
Supply voltage
JP2:23
Out
113
0V
Supply voltage
JP2:24
In
40
0V
Supply voltage
Term.
Type
JP3:1
In/Out
RS-232 communication
JP3:2
In/Out
RS-232 communication
JP3:4
In/Out
RS-232 communication
No.
Active
Function
Term.
Type
No.
Active
Function
JP4:5
In/Out
120
0 - +5 V
CAN L
JP4:6
In/Out
119
0 - +5 V
CAN H
Term.
Type
Colour
Active
Function
JPW1:1
In
Black
Right-hand coil
JPW1:2
In
Brown
Left-hand coil
JPW1:3
In
Red
Supply voltage
JPW1:5
Out
Orange
Supply voltage, T0
JPW1:6
Out
Yellow
Supply voltage, T1
JPW1:7
Out
Green
Supply voltage T2
JPW1:8
Out
Blue
Supply voltage, T3
JPW1:13
© BT Europe AB
Screen
JPW1:14
Out
Violet
0V
Supply voltage
JPW1:15
Out
Grey
+12 V
Supply voltage
Active
Term.
Type
Colour
JPW2:1
In
Black
Right-hand coil
JPW2:2
In
Brown
Left-hand coil
JPW2:3
In
Red
Supply voltage
Service Manual
Function
Veflex VR, VR SF, VRE150, VRE125SF
16- 7
Automatic steering system — 4500 Wire guidance components T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Active
Order number 244989-040
Term.
Type
Colour
JPW2:5
Out
Orange
Supply voltage, T0
JPW2:6
Out
Yellow
Supply voltage, T1
JPW2:7
Out
Green
Supply voltage T2
JPW2:8
Out
Blue
Supply voltage, T3
JPW2:13
Function
Screen
JPW2:14
Out
Violet
0V
Supply voltage
JPW2:15
Out
Grey
+12 V
Supply voltage
Display The integrated 7 segment display is designed for field usage. When the control unit is voltage fed (active) the segments come on in a rotating pattern. With the detection of an error the error code generated by the control unit is shown on the display. See the chapter Error codes.
Installation of a new WG-control unit The setting of parameters and the learning process must be carried out after the installation of the new control unit. See the chapter parameters.
16.4.3 Home position sensor, S85
When the truck is started the wheel is automatically “straightened“ to calibrate the home position of the steering. The sensor reads against the edge of the processed plane on the top side of the transmission. The signal read by the WG-control unit is when the sensor switches high/low The home position is calibrated every 180o NOTE! The steering’s home position reference does not mean that the wheel 16- 8
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Automatic steering system — 4500 Wire guidance components Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
is physically straight. This can vary from truck to truck depending on the tolerance. See the explanation under Steering angle sensor.
Adjusting the sensor The sensor is adjusted to a reading distance of 1 mm. • Screw down the sensor until it makes contact with the processed plane. • Turn back one turn.
16.4.4 Steering angle sensor, U15
Pulse sensor, fitted on the steering motor, has a resolution of 10 pulses/ turn. This gives 7 pulses/degree.
Straight wheel, electrically-mechanically When “Learn offset“ is carried out, the angle deviation between the electrical straight wheel (home position) and the mechanical straight wheel is also learnt. When the steering is 360o learning of the deviation from both reference positions must be done, transmission to the right and transmission to the left. See Parameter 36. The position of the wheel, in relation to respective home positions, is stored in the control unit’s memory as the home position = straight wheel for active wire guidance.
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Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
16- 9
Automatic steering system — 4500 Operating description T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
16.4.5 Diverse There are four magnetic switches fitted under the truck to set the truck in the wire guidance mode in a narrow aisle, S5/S7 in the front part of the chassis (fork direction) and S6/S8 in the rear of the chassis (steering wheel direction). Both switches, in the pairs S5/S7 or S6/S8, must be activated to put the truck in wire guidance and narrow aisle mode. There is also a switch in the driver cab, S120 for wire guidance, which must be activated before you can drive in the narrow aisle.
16.5 Operating description The wire guidance system has three basic operating modes. Run mode, Service mode and Learn mode. Learn mode is, in this description, included in the parameters where Learn mode is used. The description follows the operating process. See the diagram under C-code 5000.
16.5.1 Run mode “Run mode“ is the normal operating mode, which starts when the ignition is switched on. The system’s first operation command in “Run mode“ is to turn the steering wheel straight to calibrate the wheel’s home position. The WG-control unit, A3, works in the operating modes manual and auto. Switching from manual mode to auto mode is controlled by the Manual/Auto switch, S120. The switch’s status is sent from the truck electronics, A5, via CAN to the control unit.
16- 10
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Automatic steering system — 4500 Operating description Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Manual mode In manual mode, S120 makes, no valid steering command is generated by the WG-control unit. Monitoring of the steering angle, U15, and the home position (calibration), S85, is also active in manual mode. The requested steering set value is set to the current steering angle value from the steering angle sensor S66 The steering wheel is controlled by commands from the steering tachometer through the steering servo in the truck electronics, A5.
Auto mode In auto mode, S120 opens, the WG-control unit A3 searches for the loop. When A3 finds the loop a steering command is generated, calculated from the antenna signals, which are sent via CAN to the truck electronics A5. The steering servo in A5 steers the wheel to the requested position. In auto mode there are three working modes/conditions, seek loop, see loop and lock on loop. Seek loop: starts when the switch S120 is set to Auto. The status lamp in the switch flashes. The driver steers manually towards the loop with a largest angle towards the loop of approx. 20°. When the antennae W1 or W2 approaches the loop the driver presses down switch S120 to request wire guidance. Input 304 on the electronic card A5 is set low. A5 sends a message via CAN to the WG-control unit that wire guidance has been requested. The output JP2:3 receives pulsed output voltage +48 V and A3 searches for the loop. Max speed during “Seek loop“ is 2.5 km/h (crawl speed) in both the fork and steering wheel direction, maximum approach angle in both directions is 20 °. See loop:the control unit has, via the antennae, detected the loop The status lamp in the switch flashes. When the first antenna senses the magnetic field, the signal on JPW1:2 or JPW2:2, switches A3 to auto mode. A5 now switches from manual steering to auto steering and regulates the steering by means of the set value message via CAN from WG-control unit. A3 corrects the steering set value by using information from the steering angle sensor, pulse sensor U15, until the truck’s both antennae are straight over the loop.
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Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
16- 11
Automatic steering system — 4500 Operating description T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Locked on loop:the truck is straight over the loop with both antennae The status lamp in the switch is on. The truck is now steered automatically in 2 antennae mode. Output JP2:3 receives the fixed output voltage +48 V and the status lamp in S120 comes on. The truck corrects the steering to maintain the signal level in the antennae’s coils that the system has learnt in “Learn mode“. Deviations in angle and side are calculated continuously based on the changes in the antenna coils’ signal levels. The max speed when the truck is locked on the loop is 9.0 km/h (top speed) in both directions.
16.5.2 Service mode In “Service mode“ the wire guidance system’s parameters, for example the loop frequency and slowing limit for the angle, can be adjusted to suit the different frequencies and floor conditions. The parameters are opened for adjustment as follows: • Connect the service key to the truck. • Press switch I at the same time as you turn the ignition key. • Step using II (up) and III (down) to the parameter you wish to change. • Press the switch I (the display will flash). • Change the value using the switches II/III. • Press switch I to select the value (the display will stop flashing). If you want to change more parameters, step with switches II/III to the parameter you want to change and repeat from "Press the switch I (the display will flash)". • Leave “Service mode“ by turning the ignition to “off“.
16- 12
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Automatic steering system — 4500 Operating description Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Parameters The following parameters affect wire guidance when adjusted:
No. Parameter type
Unit
Min./max.
Std. value
Comments
36
Wire guidance
0–4
0
0: No wire guidance 1 = Wire guidance 2 = WG learning steering mode (not used) 3: WG learning offset mode 4: WG learning frequency mode Parameter value > = 2 resets to 1 automatically when key is turned after initiating learning mode.
71
Frequency
0–2
1
0: 5.2 kHz 1: 6.25 kHz 2: Another frequency In steps of 1
72
Angle, slowing
Degree s
0.6-2.0
1.6
In steps of 0.2
73
Angle, stop
Degree s
2.0-4.0
3.0
In steps of 0.2
74
Side, slowing
Inch
0.6-1.6
1.6
In steps of 0.2
75
Side, stop
Inch
1.2-3.0
3.0
In steps of 0.2
16.5.3 Parameter 36 Parameter 36 is used to connect the wire guidance function and calibrate the components in WG-control unit through “Learn mode“, antennae and steering offset and frequency. Once the required parameter values have been selected, turn the switch on/off. “Learn mode“ starts and the display on the instrument panel shows “Learn“. This parameter automatically resets to the parameter value 1, wire guidance active, after learning is completed.
Parameter value 0 Wire guidance function is disconnected.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
16- 13
Automatic steering system — 4500 Operating description T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Parameter value 1 With the parameter 36:1 you activate the function and check for wire guidance.
Parameter value 2 Not used.
Parameter value 3, “Learn offset“ Parameter 36:3 is used to calibrate the antennae’s mechanical offset from the truck’s centre line and the steering angle’s offset for the straight wheel in relation to the steering angle reference sensor (home position). The offset can only be learnt when the truck is guided on a loop with suitable frequency and amplitude. If parameter 71 is selected in the mode “another frequency“ the frequency must be learnt before “Learn offset“ can be carried out. The antenna offset must be calibrated according to below if the antenna or WG-control unit has been replaced: • Disconnect the magnetic switches for aisle sensing by the support arm wheel. • Drive the truck in the narrow aisle with the drive wheel first. • Check that parameter 4 is set to 0. No Auto-brake. • Set parameter 1 for steering sensitivity to 1 to reduce the steering movement when correcting to a straight wheel. • Check the steering. The transmission shall be directed towards the pedal area. • Drive the truck, manually as straight as possible over the loop (the truck’s centre line). NOTE! Wire guidance can be used for approximate adjustment, fine adjustment is carried out manually.
• Set the parameter value 3. Turn the ignition off/on. “Learn“ is shown on the display. • Check that S120 is in the Manual/Off mode. • Check that the steering wheel is straight. NOTE! • The wheel’s centre line does not correspond with the truck’s vertical centre line. • Accelerate to at least half-speed in the drive wheel direction and let the truck roll to a stop. Do not brake! • Check that the antenna in the direction of the forks is centred over the loop. 16- 14
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Automatic steering system — 4500 Operating description Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
• Switch S120 on, off and on. The display message “Learn“ disappears. • Set S120 in Manual mode. • Turn the steering slowly so that the transmission turns 180o. The truck should not move sideways. • Set the parameter value 3. Turn the ignition off/on. “Learn“ is shown on the display. • Check that S120 is in the Manual/Off. • Check that the steering wheel is straight. NOTE! • The wheel’s centre line does not correspond with the truck’s vertical centre line. • Accelerate to at least half-speed in the drive wheel direction and let the truck roll to a stop. Do not brake! • Check that the antenna in the direction of the forks is centred over the loop. • Switch S120 on, off and on. The display message “Learn“ disappears. • Test drive the truck in wire guidance mode. Repeat “Learn offset” if deemed necessary. • Drive out of the narrow aisle and connect the magnet switches for aisle sensing.
Parameter value 4, “Learn frequency“ Learning of the frequency is only necessary if parameter 71 is set to “Another frequency“. Proceed as follows: • Check that parameter 71 is set to 0 or 1. • Set the truck straight (centred) above the loop. • Switch 120 on. • Set parameter value 36 to 4 to program the truck for the loop’s frequency. • Turn the switch off/on “Learn is now displayed. The truck now learns the loop’s frequency and signal strength. The learning process takes a few seconds, the display message “Learn“ disappears when finished. • Switch 120 off to save. • Change parameter 71 to 2 after the learning process is completed.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
16- 15
Automatic steering system — 4500 Operating description T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
16.5.4 Parameter 71 You select the loop’s frequency and amplitude using this parameter. The current in the cable, depending on the frequency used, must correspond as set out in the table below to receive the correct reference signal.
Parameter value
kHz
mA RMS
0
5.2
90
1
6.25
75
2
1 - 10
14 - 1900
Notes
See below
Parameter value 2 In order for the truck to learn other frequencies the condition Amp x Hz must be between 390 and 5500. Note: Amp is not RMS but peak-peak.
Example: 28 mA RMS = 79 mA peak-peak 0.079 A (peak-peak) x 7500 Hz = 593 A x Hz
16.5.5 Parameter 72 This parameter is used to set at which angle, in the truck’s direction in relation to the loop, the truck shall reduce speed. The parameter value should be less than parameter 73.
16.5.6 Parameter 73 This parameter is used to set at which angle, the truck’s direction in relation to the loop, the truck shall emergency brake. The parameter value should be greater than parameter 72.
16- 16
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Automatic steering system — 4500 Operating description Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
16.5.7 Parameter 74 This parameter is used to set the distance to the loop when the truck shall reduce speed. The parameter value should be less than parameter 75. NOTE! The parameter unit is in inches. 1 inch = 25.4 mm
16.5.8 Parameter 75 This parameter is used to set the distance to the loop when the truck shall emergency brake (the truck has lost the loop). The parameter value should be greater than parameter 74. NOTE! The parameter unit is in inches. 1 inch = 25.4 mm
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
16- 17
Automatic steering system — 4500 Error Codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
16.6 Error Codes Error handling in the control unit for wire guidance is adapted to show error codes on the instrument panel’s display. The control unit’s own detected error codes are shown on the unit’s 7 segment display, but are not stored. The error codes are stored translated to “BT-codes“ on the main card A5.
16.6.1 Error codes detected by electronic card A5 Code
170
Signal name
Wire guidance unit fault A3
Error mode
Wire guidance error
Error cause
Error type presented on A3’s display See the description of the wire guidance unit for an interpretation of error messages
Comments
Code
171
Description
Wire guidance not requested in wire guidance aisle
Error mode
Wire guidance error
Error cause
Driver error. Switch S120 must be activated in wire guidance aisle Faulty switch S120 Faulty wiring to S120 Faulty A5 electronic card
Comments
16- 18
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Automatic steering system — 4500 Error Codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
172
Signal name
“See loop“ signal not received (loop not detected)
Error mode
Wire guidance error
Error cause
Faulty parameter values for A3 Faulty wiring to A3 Faulty A3 electronics card Faulty wire guidance generator Faulty A5 electronic card
Comments
Perform wire guidance learning, parameter 36
Code
173
Signal name
Lost loop (derailment)
Error mode
Wire guidance error
Error cause
Faulty parameter values for A3 Faulty wiring to A3 Faulty A3 electronics card Faulty A5 electronic card Substandard installation
Comments
Perform wire guidance learning, parameter 36
Code
174
Signal description
Excessive steering movement in wire guidance aisle
Error mode
Wire guidance error
Error cause
Faulty parameter values for A3 Faulty potentiometer Faulty wiring to potentiometer Faulty A5 electronic card Substandard installation
© BT Europe AB
Comments
Perform wire guidance learning, parameter 36
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
16- 19
Automatic steering system — 4500 Error Codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
175
Signal name
Sensor for aisle centre activated outside of narrow aisle (sensor for narrow aisle not activated)
Error mode
General error
Error cause
Sensor S4 or S9 been exposed to mechanical impact Faulty sensor S4 or S9 Faulty wiring to S4 or S9 Faulty A5 electronic card
Comments
Code
176
Signal name
General communications error No communication with electronics card A3 at start-up
Error mode Error cause
Faulty CAN wiring/resistance External CAN unit incorrectly connected Dislodged A3 electronics card Dislodged A5 electronic card Faulty A3 electronics card Faulty A5 electronic card
Comments
16- 20
Service Manual
Restart can reset
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Automatic steering system — 4500 Error Codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
177
Signal name
General communications error No communications with A3 electronics card
Error mode Error cause
Faulty CAN wiring/resistance External CAN unit incorrectly connected Dislodged A3 electronics card Dislodged A5 electronic card Faulty A3 electronics card Faulty A5 electronic card
Comments
Restart can reset Travel speed reduced
16.6.2 Error code detected by electronic card A3, WG-control unit Heading code is the error code shown on the instrument panel’s display. Code, WG-display is the code shown on the 7 segment display on the control unit.
© BT Europe AB
Code
85
WG-display code
1P
Code-name
Steering not learnt
Error
WG parameters outside of limit
How to reset
Perform learning Offset and Frequency, parameter 36
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
16- 21
Automatic steering system — 4500 Error Codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
181
WG-display code
52
Code-name
No communication
Error
Communications are slow (or have stopped), 100 ms has passed without the control unit receiving a message.
How to reset
A restart can reset
Code
182
WG-display code
C2
Code-name
The steering’s home position not detected
Error
No signal from the home position sensor
How to reset
Restart the truck and check the home position sensor.
Code
183
WG-display code
C3
Code-name
No pulses from the steering angle sensor detected
Error
No pulses from the steering angle sensor No signal read off from the home position sensor when centring the steering wheel Fault in the steering motor circuits
16- 22
How to reset
Restart the truck and check the steering angle sensor, home position sensor and steering motor circuits
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Automatic steering system — 4500 Error Codes Order number 244989-040
© BT Europe AB
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
184
WG-display code
C5
Code-name
Short-circuit in the steering control circuits
Error
Steering angle pulses detected without a steering command being given.
How to reset
Restart the truck and check the steering angle sensor. Replace the WG-control unit
Code
185
WG-display code
C6
Code-name
Pulse sensor/steering motor misadjusted
Error
Steering wheel moves opposite to the ordered direction
How to reset
Check the pulse sensor’s and steering motor’s connections
Code
186
WG-display code
96
Code-name
The signal “Locked on loop“ lost
Error
Loop not detected by any of the coil pairs
How to reset
Restart the truck and search for the loop again
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
16- 23
Automatic steering system — 4500 Error Codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
187
WG-display code
9L
Code-name
Field strength from the loop too high for both coil pairs
Error
The generator (Line driver) can be incorrectly adjusted
How to reset
Check the generator
Code
188
WG-display code
92
Code-name
Search limits exceeded
Error
The truck has run outside of the configured values for angle and side signals The truck has run off the loop
16- 24
How to reset
Restart the truck and search for the loop again
Code
189
WG-display code
91
Code-name
Steering angle>10 degrees
Error
Steering angle > 10 degrees when driving on the loop
How to reset
Restart the truck
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Automatic steering system — 4500 Error Codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
190
WG-display code
93
Code-name
Antenna in the steering wheel direction (W2), no signal
Error
Coils in the antenna in the steering wheel direction do not sense the loop when “locked on the loop“ The truck has run off the loop
How to reset
Restart the truck and search for the loop again
Code
191
WG-display code
94
Code-name
Antenna in the fork direction (W1), no signal
Error
Coils in the antenna in the fork wheel direction do not sense the loop when “locked on the loop“ The truck has run off the loop
© BT Europe AB
How to reset
Restart the truck and search for the loop again
Code
192
WG-display code
9C
Code-name
Antenna in the fork direction (W1), no signal
Error
The truck moves, but the signal from the antenna in the fork direction does not vary
How to reset
Restart the truck and search for the loop again
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
16- 25
Automatic steering system — 4500 Error Codes T-code 485, 487
16- 26
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
193
WG-display code
9h
Code-name
Antenna in the steering wheel direction (W2), no signal
Error
The control unit receives no signal from the antenna in the steering wheel direction
How to reset
Restart the truck and search for the loop again
Code
194
WG-display code
9J
Code-name
Antenna in the fork direction (W1), signal too high
Error
The signal “See loop“ higher than 4.75 volt
How to reset
Restart the truck and search for the loop again
Code
195
WG-display code
9K
Code-name
Antenna in the steering wheel direction (W2), signal too high
Error
The signal “See loop“ higher than 4.75 volt
How to reset
Restart the truck and search for the loop again
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Automatic steering system — 4500 Error Codes Order number 244989-040
© BT Europe AB
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
196
WG-display code
9E
Code-name
No “Search and lock“ signal
Error
The truck runs on the loop but the steering signals do not vary
How to reset
Restart the truck and search for the loop again
Code
197
WG-display code
CU
Code-name
Steering angle sensor not connected
Error
The control unit does not sense that the steering angle sensor is connected
How to reset
Check the steering angle sensor’s connections
Code
198
WG-display code
CE
Code-name
Home position sensor not connected
Error
The control unit does not sense that the home position sensor is connected
How to reset
Check the home position sensor’s connections
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
16- 27
Automatic steering system — 4500 Error Codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
199
WG-display code
C1
Code-name
+12 volt supply lost
Error
The control unit does not sense the +12 volt
How to reset
Restart the truck and check the +12 volt LED on the control unit
WG-display code
F9
Code-name
COP time-out
Error
Internal error
How to reset
Restart the truck Replace the control unit
WG-display code
FA
Code-name
OPCODE invalid
Error
Internal error
How to reset
Restart the truck Replace the control unit
WG-display code
Fb
Code-name
WSI, CAN reset
Error
Internal error
How to reset
Restart the truck Replace the control unit
16- 28
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 General Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
17- Electrical System — 5000.1 17.1 General The electrical system for VR/VR SF with AC operation consists of a number of electronic modules (A1–A5) that communicate with one another via CAN (Controller Area Network). Communications are enabled when the truck’s ignition key is in the on-position. The truck’s main card, A5, also communicates with the display on the instrument panel, the height indicator display, the height pre-set and the length indicator display (A6-A6) via an RS485 serial port. The input signals, from the truck’s various functions to the electronic modules, can be both digital (switches and sensors) and analogue (potentiometers and tachometers). The output signals from the electronic modules to the function components can also be both digital (valves, drive-wheel brakes, etc.) and analogue (support arm brakes). The accompanying figure shows the schematic connections between the various electronic modules and between a module and its function components.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
17- 1
Electrical System — 5000.1 General T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
VR SF
17- 2
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 General Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
VR
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
17- 3
Electrical System — 5000.1 Electronics Card, traction controller A1 and lift controller A2 T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
17.2 Electronics Card, traction controller A1 and lift controller A2 17.2.1 General The controller is equipped with a green LED that indicates OK status. The basic software for control of the drive and pump motors is stored in the controller. The controller has an internal system for monitoring of CAN communications, DC voltage levels, its own temperature and motor temperature. Any detected function errors are registered by the controller and the information sent via CAN to the main card A5, which registers the error code and presents the corresponding code on the instrument panel display. The controller can be reprogrammed via CAN.
17- 4
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Electronics Card, traction controller A1 and lift controller A2 Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
17.2.2 Terminal Connections and Pole Bolts I: Input, O: Output
Term.
Cable A1/A2
Designation
Active
Input/output
1
22
Key start/stop
+48 VDC
I
2
NC
3
10/15
Sensor, + voltage
+12 VDC, 50 mA
O
4
11/16
Sensor, -
0V
O
5
12/17
Pulse generator, phase 1
+12 V, 1 kohm
I
6
13/18
Pulse generator, phase 2
+12 V, 1 kohm
I
7
14/19
Motor temp.
8
-/16
CAN ID0 (Not connected when used as A1)
9
NC
10
119
CAN H
0-5 V
I/O
11
120
CAN L
0-5 V
I/O
12
117
CAN + voltage, external
+15 VDC
I
13
118
CAN – voltage, external
0V
I
B+
8
Battery +
+48 VDC
I
B-
40
Battery -
0V
I
U
2/5
Motor winding U
0-33 V
O
V
3/6
Motor winding V
0-33 V
O
W
4/7
Motor winding W
0-33 V
O
© BT Europe AB
I 1: Open 0: Sensor, -
I
I
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
17- 5
Electrical System — 5000.1 Electronics Card, traction controller A1 and lift controller A2 T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
17.2.3 Technical Data Parameter
Setting
Unit
Operating voltage
48
V
Max. operating voltage
65
V
Over-voltage point
Min. operating voltage
30
V
Under-voltage point
Frequency
8/13
kHz
Contactor voltage
48
V
Ambient operating temperature
-35–+55
oC
Current limit, down-regulation at cooling block overheating
85
o
Current limit, down-regulation at cooling block overheating
-20
oC
50% current limiting at start
Current limiting
350
A
2 minutes
Speed
100
%
Modulation
C
Description
0 A at 125o C
17.2.4 Installation of New Controller on Truck Controllers from BT Parts can be delivered in different configurations: 1. Pre-programmed at completion number = part number for controller including program. 2. Unprogrammed at article number = only part number for controller When installing a new card, certain parameters must be reprogrammed so that the truck can be safely operated.
17.2.5 Programming The Truck Com service program is used for downloading new programs to the electronics card. See the Truck Com user manual for a description of the procedure.
17- 6
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Electronics Card, Fork Apparatus, A4 Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
17.3 Electronics Card, Fork Apparatus, A4 17.1 General Settings for the truck’s fork apparatus programmable parameters for the are stored on the A4 electronics card. The A4 card monitors the truck’s hydraulic functions for the fork apparatus and CAN communications. Function errors are detected by the A4 card and the information sent via CAN to the main card A5. The A4 warning codes are presented in original code on the instrument panel display. Error codes are registered by the A5 card but a reference code (C034 for the fork apparatus) is shown on the instrument panel display. To view the actual error code, the A5’s error code register must be read. The A4 card can be reprogrammed via CAN.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
17- 7
Electrical System — 5000.1 Electronics Card, Fork Apparatus, A4 T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
17.1.1 Terminal Connections I: Input, O: Output
17- 8
Term.
Cable
Designation
Active
Input/ output
001
22
Voltage feed from battery
+48 VDC
I
002
NC
+10 V
O
003
NC
0-24 V
O
004
95
+48 V
O
005
NC
+48 V
O
006
NC
+48 V
O
007
NC
0-10 V
I
008
52
Pulse generator for traversing, phase 1
+15 V
I
009
53
Pulse generator for traversing, phase 2
+15 V
I
010
103
Traversing, reference sensor
+15 V
I
011
56
Pulse generator for height measurement free lift, phase 1
+15 V
I
012
55
Pulse generator for height measurement free lift, phase 2
+15 V
I
013
104
Height measurement for free lift, reference sensor
+15 V
I
014
NC
Reserve
(0-10 V or 0-48 V)
I
015
40
Battery -
0V
I
016
NC
0-24 V
O
017
94
+48 V
O
018
NC
+48 V
O
019
NC
+48 V
O
020
150
Switch signal, with twin camera system
021
NC
Reserve
022
NC
Reserve
I
023
NC
Reserve
I
024
NC
Reserve
I
025
NC
Reserve
I
Directional valve, traversing right
Directional valve, traversing left
Service Manual
U (0-20 V)
I
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Electronics Card, Fork Apparatus, A4 Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Term.
Cable
Designation
Active
Input/ output
026
NC
Reserve
(+48 V)
I
027
119
CAN H
0-5 V
I/O
028
20
Voltage feed for sensor
+15 V
O
029
40
Battery -
0V
I
030
NC
Reserve
031
NC
032
NC
Reserve
O
033
NC
Reserve
O
034
NC
Reserve
O
035
NC
Reserve
(0-20 V)
I
036
NC
Reserve
(0-20 V)
I
037
NC
Reserve
I
038
NC
Reserve
I
039
NC
Reserve
I
040
NC
Reserve
(+48 V)
I
041
20
Relay position (connected to terminal 28)
+15 V
I
042
120
CAN L
0-5 V
I/O
© BT Europe AB
O (0-24 V)
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
O
17- 9
Electrical System — 5000.1 Electronics Card, Fork Apparatus, A4 T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Status of inputs and outputs The status of respective inputs/outputs on the electronic card A4 can be read off in display mode on the instrument panel’s display. The display shows respective input/output display segments.
17.1.2 Installation of New Card on Truck The A4 card from BT Parts may be delivered in different configurations:
1. Pre-programmed at completion number = part number for the card including program. 2. Unprogrammed at article number = only part number for the card. When installing a new card, certain parameters must be reprogrammed so that the truck can be safely operated.
17.1.3 Programming The Truck Com service program is used for downloading new programs to the electronics card. See the Truck Com user manual for a description of the procedure.
17- 10
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Electronics Card, Main Card, A5 Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
17.2 Electronics Card, Main Card, A5
17.2.1 General The A5 electronics card features green LEDs at the inputs from the micro-switches and sensors, red LEDs at the outputs to the contactors and valves, and yellow LEDs for voltages. On the electronics card, settings for the truck’s programmable parameters are stored for steering (including loop steering), driving speed, retardation and lift height limitations. The A5 card monitors the truck’s control and driving functions, the hydraulic functions for lifting and lowering, and CAN communications. Errors related to these functions are registered and corresponding error codes are shown on the instrument panel display The A5 card administers registration and display of error codes, pertinent code or reference code generated by the truck’s other electronic components. This information is sent via CAN. The A5 card can be reprogrammed via CAN.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
17- 11
Electrical System — 5000.1 Electronics Card, Main Card, A5 T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
17.2.2 Terminal Connections and Voltages on A5 The LEDs at the connection terminals are indicated in the tables as follows: I:Input, green light emitting diode (LED) O:Output, red light emitting diode (LED) Other:Yellow light emitting diode (LED)
10X
17- 12
Term.
Cable
Description
Active (V)
LED
101
34
Selection of driver/parameter settings
+48
I
102
35
Selection of driver/step up
+48
I
103
36
Selection of driver/step down
+48
I
104
45
Direction of travel for forks-direction at creep speed
+48
I
105
46
Direction of travel for steering wheel-direction at creep speed
+48
I
106
41
In narrow aisles, front switch
+48
I
107
42
In narrow aisles, back switch
+48
I
108
NC
Reserve
I
109
NC
Reserve
I
110
43
Safety pedal (left foot-switch)
+48
I
111
44
At aisle centre (at aisle-end brakes)
+48
I
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Electronics Card, Main Card, A5 Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
20X Term.
Cable
Designation
Active (V)
LED
201
22
Personal protective equipment, strapped as standard
202
-
Indication signal, lift
+48
O
203
49
Seat switch
+48
I
204
81
Weight indication
+48
I
205
100
Lift height limitation, by-pass
+48
I
206
-
Speed reduction, driving
+48
I
207
22
Personal protective equipment, strapped as standard
+48
I
208
-
Indication signal, driving
+48
O
209
57
Steering wheel sensor, 180°
+48
I
210
58
Steering wheel sensor, channel A
+15
I
211
59
Steering wheel sensor, channel B
+15
I
I
30X Term.
Cable
Designation
Active (V)
LED
301
98
Height meter, channel A
0 -(+)15
I
302
99
Height meter, channel B
0 -(+)15
I
303
NC
Reserve
304
66
Loop steering not requested
+48
I
305
91
Half-pallet handling, selected
+48
I
306
92
Indication, half-pallet handling selected
+48
307
107
Electronic fan
+32/48
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
© BT Europe AB
I
17- 13
Electrical System — 5000.1 Electronics Card, Main Card, A5 T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
40X Term.
Cable
Designation
Active (V)
401
117
CAN – Serial (+)
+15
402
118
CAN – Serial (-)
0
403
119
CAN H
0-5
404
120
CAN L
0-5
405
121
RS485 - Serial (+)
406
122
RS485 - Serial (-)
407
125
RS485 - TX (+), transmits data
408
126
RS485 - TX (-), transmits data
409
127
RS485 - RX (+), receives data
410
127
RS485 - RX (-), receives data
411
NC
Reserve, analogue input
LED
(0-10 V or 050 V)
50X Term.
Cable
Designation
Active (V)
501
50
Potentiometer acceleration, set point
+3.7-1.7
502
51
Potentiometer braking, set point
+1.7-4.1
503
82
Potentiometer lift movement, set point
+0.66-3.7-6.6
504
83
Potentiometer traversing movement, set point
+0.77-3.7-6.6
505a
84
Potentiometer rotation of forks, set point
+0.66-3.7-6.6
506a
85
Potentiometer auto-rotation/extra (1) hydraulic function, set point
+0.66-3.7-6.6
507
27
Potentiometer feed
+7.0 - +7.5
508
28
Minus to 501-506, 510
0
509
62
Steering tachometer (+)
Max. ±3
510a
86
Potentiometer extra (2) hydraulic function, set point
+0.66-3.7-6.6
511
129
Steering tachometer (-)
0
LED
a.Used on VR only.
17- 14
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Electronics Card, Main Card, A5 Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
60X Term.
Cable
Designation
Active (V)
601
70
Battery monitor, voltage measurement (+)
+48
602
71
Battery monitor, voltage/current measurement (-)
0
603
72
Battery monitor, current measurement (+)
604
NC
Reserve
605
NC
Reserve, analogue input
LED
(0-10 V or 0-50 V)
70X Term.
Cable
Designation
Active (V)
LED
701
89
Valve, fork lift
+0.5-48
O
702
88
Valve, fork lower
+0.5-48
O
703
90
Valve, selection of fork movement
+0.5-48
O
704
NC
Reserve
(+0.5-48)
O
705
32
Indication, forks in home position
+48
O
706
33
Indication, in narrow aisle mode
+48
O
707
38
Drive alarm
+48
O
708
37
Warning lamp H2
+48
O
709
108
Length indication lamp (in narrow aisles) H96
+48
O
710
101
Valve, cab tilt up (cold storage only)
+0.5-48
O
711
102
Valve, cab tilt down (cold storage only)
+0.5-48
O
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
17- 15
Electrical System — 5000.1 Electronics Card, Main Card, A5 T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
80X Term.
Cable
Designation
Active (V)
LED
801
63
Support arm brake 1, active
0.2 -(+)48
O
802
64
Motor brake, released
1.5-(+)48
O
803
68
Support arm brake 2, active
0.2-(+)48
O
804
31
Main contactor
+48
O
805
21
Battery voltage, (+) 48 V
+48
+48 V
806
NC
807
24
Battery voltage, (+) 48 V after key
+48
808
23
Battery voltage, (+) 48 V after main contactor
+48
809
22
Battery voltage, (+) 48 V after emergency stop
+48
810
29
Voltage meter measurement sensor, (+) 15 V
+15
811
30
Minus feed sensor
0
0 +48 V KEY
+48 V ESO
90X
17- 16
Term.
Cable
Designation
Active (V)
901
25
Battery voltage, (+) 48 V
+48
902
40
Battery voltage, minus
0
903
60
Steering motor, (+)
+48
904
61
Steering motor, (-)
+48
Service Manual
LED
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Electronics Card, Main Card, A5 Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
LED
Colour
Function
+48 V STEER
Yellow
Voltage at steering electronics
+ 48V_SR
Yellow
Steering OK
STEER PWR
Yellow
Steering OK
POWER OK
Yellow
Indicates all voltages available at electronics card
Potentiometer
Function
RV 1
Not used (trimming of proportional valve’s open position)
17.2.3 Installation of New Card on Truck The A5 card from BT Parts can be delivered in different configurations:
1. Pre-programmed at completion number = part number for the card including program. 2. Unprogrammed at article number = only part number for the card. When installing a new card, certain parameters must be reprogrammed so that the truck can be safely operated.
17.2.4 Programming The Truck Com service program is used for downloading new programs to the electronics card. See the Truck Com user manual for a description of the procedure.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
17- 17
Electrical System — 5000.1 Electrical System, Overview T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
17.3 Electrical System, Overview VR SF
17- 18
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Electrical System, Overview Order number 244989-040
© BT Europe AB
Date 2013-03-04
Valid from serial number 6004330-
Service Manual
T-code 485, 487
Veflex VR, VR SF, VRE150, VRE125SF
17- 19
Electrical System — 5000.1 Electrical System, Overview T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
VR
17- 20
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Electrical System, Overview Order number 244989-040
© BT Europe AB
Date 2013-03-04
Valid from serial number 6004330-
Service Manual
T-code 485, 487
Veflex VR, VR SF, VRE150, VRE125SF
17- 21
Electrical System — 5000.1 Symbol List and Wiring Diagrams T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
17.4 Symbol List and Wiring Diagrams 17.1 Symbol List Symbol
Description
Symbol
Description
Battery
17- 22
Brake coil, normally disconnected
Brake coil, normally connected
Switch, normally open
Switch, normally closed
Push-button switch, normally open
Push-button switch, normally closed
Spring-back switch, normally open
Spring-back switch, normally closed
Non-spring-back, pushbutton switch, normally open
Emergency switch
Key switch, normally open
Push-button switch, nonspring-back and springback
Electro-magnetic switch, normally open
Electro-magnetic switch, normally closed
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Symbol List and Wiring Diagrams Order number 244989-040
Symbol
Date 2013-03-04
Valid from serial number 6004330-
Description
Symbol
T-code 485, 487
Description
Pressure-sensitive switch, normally open
Pressure-sensitive switch, normally closed
Capacitive switch, normally open
Capacitive switch, normally closed
Inductive sensor, normally open
Inductive sensor, normally closed
Pulse generator
Seat heater with thermostat
Thermoelectric sensor
Motor, general
Series motor, armature winding, DC
Series motor, DC
Motor, permanent magnet
Three-phase motor, AC
© BT Europe AB
Series winding
Shunt winding
Transducer, AC/DC
Transducer, AC/DC
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
17- 23
Electrical System — 5000.1 Symbol List and Wiring Diagrams T-code 485, 487
Symbol
17- 24
Valid from serial number 6004330-
Description
Date 2013-03-04
Symbol
Order number 244989-040
Description
Variable resistor (potentiometer)
Resistor
Contactor
Horn
Lamp
Valve
Fuse
Diode
Zener diode
Light emitting diode (LED)
Contact
Contact, multiple-poles
Capacitor
Feed cable
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
© BT Europe AB
Service Manual
Sh. 2
22
2
1
MAIN CONTACTOR K10 A1 A2
3
X1
S3 4
3
S2 4
3
S1 4
MEASURING WIRES
G1 48 V + X1
36
35
34
23
31
70
71
72
103
102
101
808
804
601
602
603
Veflex VR, VR SF, VRE150, VRE125SF
209398 1/24, Prod C
INP. SETUP DOWN
INP. SETUP UP
INP. SETUP SELECT
INP. MAIN CONTACTOR
OUT. MAIN CONTACTOR
INP. BATT. INDI. +
INP. BATT. INDI. -, CURRENT -(-)
INP. BATT. INDI. CURRENT -(+)
ELECTRONIC CARD A5
40
Sh. 2
Valid from serial number 6004330-
X30
X30
X30
10A F62
SHUNT WIRE
Date 2013-03-04
8
40
1
Order number 244989-040
Sh. 2
Sh. 3
Electrical System — 5000.1 Symbol List and Wiring Diagrams T-code 485, 487
17.1.1 Wiring diagrams VR SF
17- 25
17- 26
22
40
Service Manual
X30
105
B1
Bk
-
+
Red
11
14
4
7
Wh
13
12
1
6
5
160A F1
+
118 119 120
2 3 4
X31 X31 X31 X31
X45 X45 X45 X45
4
3
2
120
119
118
117
404
403
402
401
INP./OUT. CAN L
INP./OUT. CAN H
OUT. CAN GND
OUT. CAN +15VDC
ELECTRONIC CARD A5
M
3~A
DRIVE MOTOR M1 U V M W
Sh. 7
Sh. 7
Sh. 7
Sh. 7
209398 2/24, Prod C
120
119
118
117
Date 2013-03-04
R100
117
1
11
10
13
12
W
V
U
Valid from serial number 6004330-
SERVICE KEY INTERFACE X41
A
B
Bl
10 3 SPEED MEASURING IN M1 U11
THERMO ELECTRICAL SENSOR IN M1
-
B-
+
B
T-code 485, 487
Sh. 1 3
Sh. 1 4
Sh. 1 7
8
FREQUENCY INVERTER, DRIVE A1
Electrical System — 5000.1
Symbol List and Wiring Diagrams Order number 244989-040
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
© BT Europe AB
Service Manual
22
15
S17
61a
24
1
S21 2
X30
EMERGENCY SWITCH OFF
X25
X32
1
S89
3
2
S26
S23
1
3
3
X25
X32
X32
49
46
45
22
43
24
203
105
104
809
110
807
805
INP. SEAT SWITCH
209398 3/24, Prod C
INP. DRIVE, STEER WHEEL DIRECTION, CREEP
INP. DRIVE, FORK DIRECTION, CREEP
+ 48VDC SUPPLY OUTPUTS
INP. LEFT FOOT SWITCH
INP. KEY
+ 48VDC
Valid from serial number 6004330-
Sh. 2 4
X30
KEY
1
X30
21
Date 2013-03-04
24
10A F60
Order number 244989-040
Sh. 13
Sh. 1 5
1
ELECTRONIC CARD A5
Electrical System — 5000.1 Symbol List and Wiring Diagrams T-code 485, 487
Veflex VR, VR SF, VRE150, VRE125SF
17- 27
Service Manual
Sh. 3 5
Sh. 6
22
28
27
X30
X25
M
1 X25
4
M
M12
S18
Bl -
3 54 3
HORN H1
X32
R1
+R
X32
107
28
50
27
307
508
501
507
209398 3/24, Prod C
OUT. POWER, FAN ELECTRIC PANEL
POT. GND
INP. SPEED REFERENCE VALUE
POT. FEED 7-7,5VDC
40
Sh. 2 5
Date 2013-03-04
IN
FAN PUMPMOTOR M10 X35 X35
SEAT HEATER E10
+
17- 28 Valid from serial number 6004330-
-
Sh. 6
T-code 485, 487
2
ELECTRONIC CARD A5
Electrical System — 5000.1
Symbol List and Wiring Diagrams Order number 244989-040
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
© BT Europe AB
Service Manual
Sh. 3 10
C4
X30
S66 Bk
1
40
22
30A F61
Red
X32
Br
S65 Bk
M
U1
M
M6
Red
X34
129
62
61
60
25
40
57
59
58
511
509
904
903
901
902
806
209
211
210
811
810
GND, TACHO
209398 5/24, Prod C
INP. STEERING WHEEL TACHO +
GND, STEER MOTOR
OUT. + , STEER MOTOR
+ 48VDC STEER SERVO
GND
INP. STEER WHEEL REFERENCE 180 DEG.
INP. STEER WHEEL ANGLE B
INP. STEER WHEEL ANGLE A
GND
+ 15VDC
Valid from serial number 6004330-
Bk
Bk
Wh
30
30
Br
29
29
Date 2013-03-04
Sh. 4 6
Sh. 4 6
Sh. 11
Sh. 11
Bl
Order number 244989-040
Bl
ELECTRONIC CARD A5
Electrical System — 5000.1 Symbol List and Wiring Diagrams T-code 485, 487
Veflex VR, VR SF, VRE150, VRE125SF
17- 29
17- 30
Service Manual
Sh. 4 8
Sh. 4 8
Sh. 5 7
28
27
40
22
X38
DISPLAY A6
3
4
RX -
2
SERIE -
RX +
1
SERIE +
S131 2
RIGHT ARM, OUTER Y6:2
RIGHT ARM, INNER Y5:2
Y1
X46
X46
X46
X46
R2
X38
X38
68
63
51
126
125
122
121
64
803
801
502
408
407
406
405
802
RS 485
125
126
Sh. 10
Sh. 10
Date 2013-03-04
209398 6/24, Prod C
OUT. SUPPORT ARMBRAKE 2
OUT. SUPPORT ARMBRAKE 1
INP. BRAKE REFERENCE VALUE
TX-
TX+
SERIE -
SERIE +
OUT. PARKING BRAKE
ELECTRONIC CARD A5
Valid from serial number 6004330-
LEFT ARM, OUTER Y6:1
LEFT ARM, INNER Y5:1
1
EMERGENCY MODE
1
T-code 485, 487
2
Sh. 5 7
X30
Electrical System — 5000.1
Symbol List and Wiring Diagrams Order number 244989-040
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB 3
© BT Europe AB
Service Manual
Sh. 6 8
22
40
X30
155
Bk
-
+ A
B
Wh
Bl
18
17
15
16
19
Veflex VR, VR SF, VRE150, VRE125SF 1
6
5
3
4
7
+
11
10
13
12
W
V
U
7
6
5
M
3~A
209398 7/24, Prod C
PUMP MOTOR M3 U V M W
120
119
118
117
Sh. 2 12
Sh. 2 12
Sh. 2
Sh. 2
Valid from serial number 6004330-
Red
SPEED MEASURING IN M3 U12
B2
THERMO ELECTRICAL SENSOR IN M3
8 ID
-
+
B-
B
Date 2013-03-04
300A F3
Order number 244989-040
Sh. 6 8
Sh. 2
8
FREQUENCY INVERTER, PUMP A2
Electrical System — 5000.1 Symbol List and Wiring Diagrams T-code 485, 487
17- 31
Service Manual
X14 X16 X49
X30
X30
X32
5
S61
1
R4
5
S33
Y9
1
Y8
X33
X31
X33
X33
95
94
100
81
22
22
83
82
OUT. DATA COLLECT, DRIVE 208
INP. OVERRIDE
INP. WEIGHT
INP. PERS. PROT. 2 (NOT ACTIVE) (WHEN USED, SEE PAGE 21)
004
017
209398 8/24, Prod C
OUT. TRAVERSE RIGHT
OUT. TRAVERSE LEFT
ELECTRONIC CARD A4
205
204
207
INP. PERS. PROT. 1 (NOT ACTIVE) (WHEN USED, SEE PAGE 21)
OUT. DATA COLLECT, LIFT
202
201
INP. SPEED REDUCTION
INP. JOYSTICK TRAVERSE
INP. JOYSTICK FORK
206
504
503
Date 2013-03-04
40
22
28
R6
ELECTRONIC CARD A5
Valid from serial number 6004330-
Sh. 7 9
Sh. 7 9
Sh. 6
X32
X32 1 3 1
27
T-code 485, 487
3
17- 32 2 2
Sh. 6
Electrical System — 5000.1
Symbol List and Wiring Diagrams Order number 244989-040
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
© BT Europe AB
Sh. 8 10
Sh. 8 10
22
40
X30
Service Manual
X69
X14
S5 Bl
STEER WHEEL DIR. RIGHT S156 Br Bk
Br
FORK DIRECTION 1
Y11
S7 Bl
Br
S9 Bl
Y24
S6 Bl
S8 Bl
Veflex VR, VR SF, VRE150, VRE125SF Br
S4
Bl
STEER WHEEL DIRECTION
Br
STEER WHEEL DIRECTION 2
Br
STEER WHEEL DIRECTION 1
FORK DIR. LEFT S178 Br Bk
FORK DIRECTION
Br
FORK DIRECTION 2
X47
Y10
X15
X69
X15
X15
X47
X47
X47
44
42
41
90
89
88
111
107
106
703
701
702
INP. IN AISLE, MIDDLE
209398 9/24, Prod C
INP. IN AISLE, SIGNAL 2
INP. IN AISLE, SIGNAL 1
OUT. SELECT FORK MOVE
OUT. FORK LIFT
OUT. FORK LOWER
Valid from serial number 6004330-
X69
X14
X14
X47
X47
Date 2013-03-04
Bl
Order number 244989-040
Bl
ELECTRONIC CARD A5
Electrical System — 5000.1 Symbol List and Wiring Diagrams T-code 485, 487
17- 33
17- 34
1
40
22
Service Manual
10A F63
X37
X30
X45
40
Y20
-
+
+
9
5
330
920
-
Y21
H96
R31
+
680~E/2W
R34
680~E/2W
2
1
109
-
-
H2
H95
R32
320
47~E/50W
+
+
X45
X45
ID 0V
1 4
2
1
+48V
3
RX-
RX+
LENGTH INDICATOR A9
EXTERNAL EQUIPMENT X42 X42
H3
H18
H90
S90
2
5
40
26
R30
1
S99
X23
X23
680~E/2W
5
191
X37
X36
X30
X30
X31
X31
X31
X30
E4
X45
X45
102
101
108
38
37
33
32
92
91
X46
X46
192
E3
OUT. CABIN LOWER
OUT. CABIN LIFT
OUT. LENGTH INDICATION LAMP (IN AISLE)
OUT. TRAVEL ALARM
OUT. WARNING LAMP (MOTION)
OUT. IN AISLE INDICATION LAMP
OUT. FORKS IN HOME POSITION
OUT. HALF PALLET HANDLING INDI. LAMP
126
125
Sh. 6 11
Sh. 6 11
209398 10/24, Prod C
INP. HALF PALLET HANDLING MODE
WORKING LIGHT
711
710
709
707
708
706
705
306
305
Date 2013-03-04
26
X45
X45
X23
X23
X36
-
10
1
Valid from serial number 6004330-
X31
X31
X31
X31
X31
X31
X31
X45
T-code 485, 487
Sh. 5 13
Sh. 9 11
Sh. 9 11
ELECTRONIC CARD A5
Electrical System — 5000.1
Symbol List and Wiring Diagrams Order number 244989-040
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
© BT Europe AB
Service Manual
20
30
X17
X17
X32
X32
X14 X16 X49
X15
X15
X31
X45
2
4
6
+48V
0V
-
Bk
-
+
Red
Bk
+
Red
U9
U10
5
1
TX+
TX-
3
7
RX-
RX+
PRE SELECTION HEIGHT A7
RX-
0V
4
5
B
A
B
A
Bl
Wh
Bl
Wh
Br
X34
X34
X34
X34
S93 Bl
X45
X45
X17
X17
X46
X46
X15
X15
104
56
55
99
98
128
127
INP. HEIGHT COUNTER > FREELIFT PULSE B
INP. HEIGHT COUNTER > FREELIFT PULSE A
RX- HEIGHT UNIT
RX+ HEIGHT UNIT
013
011
012
Veflex VR, VR SF, VRE150, VRE125SF
209398 11/24, Prod C
INP. FORKS < REFERENCE HEIGHT
INP. HEIGHT COUNTER < FREELIFT PULSE B
INP. HEIGHT COUNTER < FREELIFT PULSE A
ELECTRONIC CARD, TURRET UNIT A4
302
301
410
409
ELECTRONIC CARD A5
126
125
Sh. 10
Sh. 10
Valid from serial number 6004330-
Sh. 12
Sh. 5
Sh. 5
X30
RX+
+48V
3
Date 2013-03-04
29
40
22
LIFTING HEIGHT INDICATOR A8
Order number 244989-040
Sh. 10 12
Sh. 10 12
X45
Electrical System — 5000.1 Symbol List and Wiring Diagrams T-code 485, 487
17- 35
17- 36
Service Manual
Sh. 11 18
Sh. 7 14
Sh. 7 14
Sh. 11 13
Sh. 11 13
20
120
119
40
22
X30
X15
X15
X14
X14
X16
X16
X16
X16
X49
X49
X49
X49
B
A
Wh
Bl
Br
S50 Bk
103
53
52
209398 12/24, Prod C
INP. FORKS IN HOME POS. INDICATOR
INP. TRAVERSE COUNTER PULSE B
Date 2013-03-04
010
008
INP. TRAVERSE COUNTER PULSE A
INP. STEER SAFETY RELAY 041
009
OUT. + 15VDC SUPPLY
INP./OUT. CAN L
120~E / 1W
028
042
R109
INP./OUT. CAN H
GND
015
027
GND
INP. + 48VDC SUPPLY
029
001
Valid from serial number 6004330-
Bk
+
Red
U13
20
120
119
40
22
T-code 485, 487
Bl
ELECTRONIC CARD, TURRET UNIT A4
Electrical System — 5000.1
Symbol List and Wiring Diagrams Order number 244989-040
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
© BT Europe AB
Service Manual
X30
X45
1
S97
5
X45
0/1/2/3
(Bk) S70
(Ye)
(Gn)
(Or)
DEFROST START (1500W)
(Gn)
(Bl)
S68 COMFORT HEATER (1500W) FAN SPEED / MASTER ON/OFF S69 (Wh) (Ye)
(Red)
COLD STORE CABIN
FAN
M
Y1
TIMER
THERMOSTAT 2 4
15
5A
30A
30A
30A
30A
18
750W
750W
750W
209398 13/24, Prod C
750W
Valid from serial number 6004330-
Veflex VR, VR SF, VRE150, VRE125SF
40
X31
E2
E1
157
COURTESY LIGHTS IN CABIN
22
24
1
HEATER IN COLD STORE CABIN
Date 2013-03-04
Sh. 12 14
Sh. 12 14
Sh. 3
Sh. 10 22
E98
A1
Order number 244989-040
A2
OPTION
Electrical System — 5000.1 Symbol List and Wiring Diagrams T-code 485, 487
17- 37
Service Manual
120
119
40
22
X30
X48
X48
X48
X48
Br
S85 Bk
120
119
113
112
111
40
22
JP3:4
INP./OUT. CAN L
INP./OUT. CAN H
GND
209398 14/24, Prod C
INP. STEER WHEEL IN HOME POS.
OUT. + 12VDC
GND
INP. + 48VDC SUPPLY
Date 2013-03-04
JP3:2
JP3:1
JP4:5
JP4:6
JP2:23
JP2:9
JP2:21
JP2:24
JP2:11
Valid from serial number 6004330-
Sh. 12
Sh. 12
Sh. 13 18
Sh. 13 15
WIRE GUIDANCE A3
T-code 485, 487
Bl
17- 38 WIRE GUIDANCE, PAGE 14 TO 17.
OPTION
Electrical System — 5000.1
Symbol List and Wiring Diagrams Order number 244989-040
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
© BT Europe AB
Service Manual
Sh. 14 19
22
X30
X32
-
5
S120
7
H120 10 9
B
A
Ye
Gr
670
R35
680~E/2W
X32
X32
X48
66
67
133
132
OUT. ON WIRE
INP. ENCODER PULSE B
INP. ENCODER PULSE A
304
Veflex VR, VR SF, VRE150, VRE125SF
209398 15/24, Prod C
INP. WIRE GUIDANCE OFF
ELECTRONIC CARD A5
JP2:3
JP1:8
JP1:7
OUT. + 5VDC
GND
Valid from serial number 6004330-
VRSF WITHOUT WIRE GUIDANCE
X32
Wh
+
Br
ENCODER U15
JP1:21
JP1:12
Date 2013-03-04
130
131
WIRE GUIDANCE A3
Order number 244989-040
WIRE GUIDANCE, PAGE 14 TO 17.
OPTION
Electrical System — 5000.1 Symbol List and Wiring Diagrams T-code 485, 487
17- 39
ANTENNA 1 W1
17- 40
Service Manual
J1L:13
GREY
VIOLET
JPW1:13
JPW1:15
JPW1:14
T3
T2
T1
SHIELD
OUT. + 12VDC
GND
JPW1:8 OUT.
JPW1:7 OUT.
JPW1:6 OUT.
T0
LEFT COIL
JPW1:5 OUT.
JPW1:3 INP.
209398 16/24, Prod C
NEAR WIRE COIL
RIGHT COIL
Date 2013-03-04
J1L:15
J1L:14
BLUE
GREEN
YELLOW
ORANGE
RED
JPW1:2 INP.
JPW1:1 INP.
Valid from serial number 6004330-
J1L:8
J1L:7
J1L:6
J1L:5
J1L:3
BROWN
BLACK
WIRE GUIDANCE A3
T-code 485, 487
J1L:2
J1L:1
WIRE GUIDANCE, PAGE 14 TO 17.
OPTION
Electrical System — 5000.1
Symbol List and Wiring Diagrams Order number 244989-040
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
ANTENNA 2 W2
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
J1T:13
J1T:15
GREY
VIOLET
BLUE
GREEN
YELLOW
ORANGE
RED
JPW2:13
JPW2:15
JPW2:14
T3
T2
T1
SHIELD
OUT. + 12VDC
GND
JPW2:8 OUT.
JPW2:7 OUT.
JPW2:6 OUT.
T0
LEFT COIL
NEAR WIRE COIL
RIGHT COIL
JPW2:5 OUT.
JPW2:3 INP.
JPW2:2 INP.
JPW2:1 INP.
209398 17/(24, Prod C
Valid from serial number 6004330-
J1T:14
J1T:8
J1T:7
J1T:6
J1T:5
J1T:3
BROWN
BLACK
Date 2013-03-04
J1T:2
J1T:1
WIRE GUIDANCE A3
Order number 244989-040
WIRE GUIDANCE, PAGE 14 TO 17.
OPTION
Electrical System — 5000.1 Symbol List and Wiring Diagrams T-code 485, 487
17- 41
17- 42
Service Manual
Sh. 23
Sh. 23
114
115
OUT:4
OUT:3
256
115
114
X60
X60
X60
X151
X151
X151
X151
X52
X52
WHEN STEREO/CD
X61
X61
X61
X60
156
115
114
110
X55
X55
X55
X55
156
115
114
110
20
150
INP. 15 VDC
A:2
B:2
B:1
A:1
SHIELD
GND
+ 12VDC
VIDEO SIGNAL
209398 18/24, Prod C
OUT. SWITCH SIGNAL
TV-MONITOR A49
030
020
Date 2013-03-04
40
20
SHIELD
GND
OUT:2
+ 12VDC
X61
PAGE 18 AND 20.
ELECTRONIC CARD, TURRET UNIT A4
Valid from serial number 6004330-
Sh. 14 19
Sh. 12 19
OUT
OUT:1
X14
PAGE 19
VIDEO SIGNAL
X16
PAGE 19
210
40
X49
SET:2
150
PAGE 19
GND
SET:1
CAMERA ON FORKS, BT-BRAND EXCLUDING COLDSTORE CABIN
T-code 485, 487
PAGE 19
SET
INP. SWITCH SIGNAL
CAMERA SELECTOR A54
Electrical System — 5000.1
Symbol List and Wiring Diagrams Order number 244989-040
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
© BT Europe AB
Service Manual
PAGE 19
40
22
20
X30
X30
SHIELD
GND
OUT:4
OUT:3
OUT:2
+ 12VDC
256
115
114
X61
X61
X61
X61
X60
X60
X60
X60 120~E/0,6W
X:A50
X:A50
X:A50
X:A50
Veflex VR, VR SF, VRE150, VRE125SF
114
115
40
22
256
115
114
210
20
150
INP. 15 VDC
OUT. SWITCH SIGNAL
SHIELD
GND
+ 12VDC
VIDEO SIGNAL
+
-
-
+
OUT. + 12VDC
OUT. GND
INP. GND
INP. + 48VDC
VOLTAGE CONVERTER A14
A:2
B:2
B:1
A:1
TV-MONITOR A50
030
020
209398 19/24, Prod C
Valid from serial number 6004330-
Sh. 18 21
Sh. 15 21
Sh. 18
OUT
OUT:1
R49
CAMERA ON FORKS, PAGE 19 AND 20.
ELECTRONIC CARD, TURRET UNIT A4
Date 2013-03-04
VIDEO SIGNAL
X14
X49 X16
210
40
PAGE 19
SET:2
150
PAGE 19
PAGE 19
GND
SET:1
OPTION CAMERA ON FORKS, COLDSTORE CABIN AND TOYOTA BRAND.
Order number 244989-040
SET
INP. SWITCH SIGNAL
CAMERA SELECTOR A54
Electrical System — 5000.1 Symbol List and Wiring Diagrams T-code 485, 487
17- 43
17- 44
Service Manual
101
102
103
104
+ 12VDC
GND
SHIELD
115
256
115
256
IN1:4
IN1:3
IN1:2
IN1:1
SHIELD
GND
+ 12VDC
VIDEO SIGNAL 1
410
114
115
256
410
114
115
256
IN2:4
SHIELD
PAGE 18
GND
+ 12VDC
VIDEO SIGNAL 2
209398 20/24, Prod C
IN 2
PAGE 18
PAGE 18
IN 1
Date 2013-03-04
IN2:3
IN2:2
IN2:1
PAGE 18 VIDEO SIGNAL
114
310
114
310
CAMERA SELECTOR A54
Valid from serial number 6004330-
VIDEO SIGNAL
CAMERA ON FORKS, RIGHT A52
103
GND
104
102
+ 12VDC
SHIELD
101
CAMERAS ON FORKS
T-code 485, 487
VIDEO SIGNAL
CAMERA ON FORKS, LEFT A51
OPTION
Electrical System — 5000.1
Symbol List and Wiring Diagrams Order number 244989-040
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
X2:4
X2:5
X2:6
INP. 0VDC SUPPLY
INP. DRIVE, STEER WHEEL DIRECTION
INP. 0VDC SUPPLY
40
X2:3
X34
X33
INP. DRIVE, FORK DIRECTION
PERSONAL PROTECTION SYSTEM TBM GM-107ECO
166
165
X32
X150
X150
X150
4
3
S33
8
2
7
1
164
163
100
202
208
205
706
OUT. DRIVE, STEER WHEEL DIRECTION
OUT. DRIVE, FORK DIRECTION
INP. OVERRIDE
OUT. IN AISLE INDICATION LAMP
209398 21/24, Prod C
NOTE! OUTPUT FOR AUDIBLE AND VISIBLE ALARM FROM TBM GM-107ECO EQUIPMENT NOT SHOWED.
X33
33
Valid from serial number 6004330-
Sh. 19 22
Sh. 22
Sh. 22
22
X30
OVERRIDE EMERGENCY MODE / OVERRIDE LIFT HEIGHT
X30
Date 2013-03-04
Sh. 19 23
Sh. 22
33
ELECTRONIC CARD A5
Order number 244989-040
PERSONAL PROTECTION SYSTEM, PAGE 21 AND 22.
OPTION
Electrical System — 5000.1 Symbol List and Wiring Diagrams T-code 485, 487
17- 45
17- 46
Service Manual
Sh. 21
166
162
X150
X150
X150
X150
X150
X150
X150
X150
X150
X150
X150
X1:13
8A F
209398 22/24, Prod C
INP. OVERRIDE EMERGENCY MODE
OUT. +24VDC
INP. 0 VDC SUPPLY X2:12
X1:12
INP. IN AISLE
OUT. WARNING RELAY
INP. WARNING RELAY
OUT. EMERGENCY RELAY
INP. EMERGENCY RELAY
OUT. EMERGENCY RELAY
INP. EMERGENCY RELAY
0 VDC SUPPLY
INP. +48VDC SUPPLY
X2:10
X1:7
X1:6
X1:5
X1:4
X1:3
X1:1
X9:2
X9:1
Date 2013-03-04
165
206
INP. SPEED REDUCTION
161
160
9
Valid from serial number 6004330-
Sh. 21
33
207
201
INP. PERSONAL PROTECTION 2
INP. PERSONAL PROTECTION 1
ELECTRONIC CARD A5
40
7,5A F64
PERSONAL PROTECTION SYSTEM GM-107ECO
T-code 485, 487
Sh. 21
Sh. 21 23
Sh. 13
1
PERSONAL PROTECTION SYSTEM, PAGE 21 AND 22.
OPTION
Electrical System — 5000.1
Symbol List and Wiring Diagrams Order number 244989-040
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
© BT Europe AB
W5
LEFT +
X56
X51
Service Manual H5
RIGHT -
RIGHT +
X56
X56
OUT. +12V
B:4
B:3
B:6
B:5
A:8
A:4
A:7
OUT. RIGHT (-)
OUT. RIGHT (+)
OUT. LEFT (-)
OUT. LEFT (+)
INP.GND
INP. +12V KEY
INP. +12VDC
STEREO/CD A11
1
209398 23/24, Prod C
OUT. GND (GALV SEPARATED)
OUT. GND (GALV. SEPARATED)
OUT. +12V
INP. GND
INP. +48V
Valid from serial number 6004330-
X56
340
312
312
312
2
5
4
3
6
Date 2013-03-04
LEFT -
X51
340
115
40
22
115
H4
STEREO/CD
114
X44
X44
114
40
22
DC/DC CONVERTER A10
Order number 244989-040
Sh. 18
Sh. 18
Sh. 22 24
Sh. 21 24
OPTION
Electrical System — 5000.1 Symbol List and Wiring Diagrams T-code 485, 487
Veflex VR, VR SF, VRE150, VRE125SF
17- 47
17- 48
Sh. 23
Sh. 23
40
22
W5
X:A9
X:A9
Service Manual 340
312
312
312
340
40
22
OUT. +12V
OUT. GND
INP. GND
INP. +48V
OUT. RIGHT (+)
OUT. (-) B:4
OUT. LEFT (-) B:6
B:3
OUT. LEFT (+)
INP. GND
INP. KEY +12V
INP. +12V
209398 24/24, Prod C
Valid from serial number 6004330-
B:5
A:8
A:4
A:7
STEREO/CD A11
+
-
-
+
DC/DC CONVERTER A10
T-code 485, 487
H5
H4
STEREO/CD ON COLDSTORE CABIN
OPTION
Electrical System — 5000.1
Symbol List and Wiring Diagrams Date 2013-03-04 Order number 244989-040
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
© BT Europe AB
Service Manual
22
1
3
S3 4
3
S2 4
3
S1 4
MEASURING WIRES
G1 48 V + X1
X30
X30
X30
10A F62
SHUNT WIRE
36
35
34
23
31
70
71
72
103
102
101
808
804
601
602
603
Veflex VR, VR SF, VRE150, VRE125SF
209397 1/24, Prod C
INP. SETUP DOWN
INP. SETUP UP
INP. SETUP SELECT
INP. MAIN CONTACTOR
OUT. MAIN CONTACTOR
INP. BATT. INDI. +
INP. BATT. INDI. -, CURRENT -(-)
INP. BATT. INDI. CURRENT -(+)
ELECTRONIC CARD A5
40
Sh. 2
Valid from serial number 6004330-
Sh. 2
2
MAIN CONTACTOR K10 A1 A2
X1
Date 2013-03-04
8
40
1
Order number 244989-040
Sh. 2
Sh. 3
Electrical System — 5000.1 Symbol List and Wiring Diagrams T-code 485, 487
17.1.2 Wiring diagrams VR
17- 49
17- 50
22
40
X30
B1
Service Manual
Bk
-
+
Red
11
14
4
7
Wh
13
12
1
6
5
+
118 119 120
2 3 4
X31 X31 X31 X31
X45 X45 X45 X45
4
3
2
120
119
118
117
404
403
402
401
INP./OUT. CAN L
INP./OUT. CAN H
OUT. CAN GND
OUT. CAN +15VDC
ELECTRONIC CARD A5
M
3~A
DRIVE MOTOR M1 U V M W
209397 2/24, Prod C
120
119
118
117
Sh. 7
Sh. 7
Sh. 7
Sh. 7
Date 2013-03-04
R100
117
1
11
10
13
12
W
V
U
Valid from serial number 6004330-
SERVICE KEY INTERFACE X41
A
B
Bl
10 3 SPEED MEASURING IN M1 U11
THERMO ELECTRICAL SENSOR IN M1
-
B-
+
B
160A F1
T-code 485, 487
Sh. 1 3
Sh. 1 4
Sh. 1 7
8
FREQUENCY INVERTER, DRIVE A1
Electrical System — 5000.1
Symbol List and Wiring Diagrams Order number 244989-040
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
© BT Europe AB
Service Manual
22
15
S17
61a
24
1
S21 2
X30
EMERGENCY SWITCH OFF
X25
X32
1
S89
3
2
S26
S23
1
3
3
X25
X32
X32
49
46
45
22
43
24
203
105
104
809
110
807
805
Veflex VR, VR SF, VRE150, VRE125SF
209397 3/24, Prod C
INP. SEAT SWITCH
INP. DRIVE, STEER WHEEL DIRECTION, CREEP
INP. DRIVE, FORK DIRECTION, CREEP
+ 48VDC SUPPLY OUTPUTS
INP. LEFT FOOT SWITCH
INP. KEY
+ 48VDC
Valid from serial number 6004330-
Sh. 2 4
X30
KEY
1
X30
21
Date 2013-03-04
24
10A F60
Order number 244989-040
Sh. 14
Sh. 1 5
1
ELECTRONIC CARD A5
Electrical System — 5000.1 Symbol List and Wiring Diagrams T-code 485, 487
17- 51
Service Manual
Sh. 3 5
Sh. 6
22
28
27
X30
X25
IN
M
1 X25
4
M
M12
S18
Bl -
3 54 3
HORN H1
X32
R1
+R
X32
107
28
50
27
307
508
501
507
40
Sh. 2 5
209397 4/24, Prod C,
OUT. POWER, FAN ELECTRIC PANEL
POT. GND
INP. SPEED REFERENCE VALUE
POT. FEED 7-7,5VDC
Date 2013-03-04
FAN PUMPMOTOR M10 X35 X35
SEAT HEATER E10
+
17- 52 Valid from serial number 6004330-
-
Sh. 6
T-code 485, 487
2
ELECTRONIC CARD A5
Electrical System — 5000.1
Symbol List and Wiring Diagrams Order number 244989-040
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
© BT Europe AB
Service Manual
Sh. 3 10
C4
X30
S66 Bk
1
40
22
30A F61
Red
X32
Br
S65 Bk
M
U1
M
M6
Red
X34
129
62
61
60
25
40
57
59
511
509
904
903
901
902
806
209
211
210
811
810
GND, TACHO
209397 5/24, Prod C
INP. STEERING WHEEL TACHO +
GND, STEER MOTOR
OUT. + , STEER MOTOR
+ 48VDC STEER SERVO
GND
INP. STEER WHEEL REFERENCE 180 DEG.
INP. STEER WHEEL ANGLE B
INP. STEER WHEEL ANGLE A
GND
+ 15VDC
Valid from serial number 6004330-
Bk
Bk
Wh
58
30
30
Br
29
29
Date 2013-03-04
Sh. 4 6
Sh. 4 6
Sh. 11
Sh. 11
Bl
Order number 244989-040
Bl
ELECTRONIC CARD A5
Electrical System — 5000.1 Symbol List and Wiring Diagrams T-code 485, 487
Veflex VR, VR SF, VRE150, VRE125SF
17- 53
17- 54
Service Manual
Sh. 4 8
Sh. 4 8
Sh. 5 7
28
27
40
22
X38
DISPLAY A6
3
4
RX -
2
SERIE -
RX +
1
SERIE +
S131 2
RIGHT ARM, OUTER Y6:2
RIGHT ARM, INNER Y5:2
Y1
X46
X46
X46
X46
R2
X38
X38
68
63
51
126
125
122
121
64
803
801
502
408
407
406
405
802
RS 485
125
126
Sh. 10
Sh. 10
Date 2013-03-04
209397 6/24, Prod C
OUT. SUPPORT ARMBRAKE 2
OUT. SUPPORT ARMBRAKE 1
INP. BRAKE REFERENCE VALUE
TX-
TX+
SERIE -
SERIE +
OUT. PARKING BRAKE
ELECTRONIC CARD A5
Valid from serial number 6004330-
LEFT ARM, OUTER Y6:1
LEFT ARM, INNER Y5:1
1
EMERGENCY MODE
1
T-code 485, 487
2
Sh. 5 7
X30
Electrical System — 5000.1
Symbol List and Wiring Diagrams Order number 244989-040
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB 3
© BT Europe AB
Service Manual
Sh. 6 8
22
40
X30
Bk
-
+
A
B
Wh
Bl
18
17
15
16
19
Veflex VR, VR SF, VRE150, VRE125SF 1
6
5
3
4
7
+
11
10
13
12
W
V
U
7
6
5
M
3~A
PUMP MOTOR M3 U V M W
209397 7/24
120
119
118
117
Sh. 2 12
Sh. 2 12
Sh. 2
Sh. 2
Valid from serial number 6004330-
Red
SPEED MEASURING IN M3 U12
B2
THERMO ELECTRICAL SENSOR IN M3
8 ID
-
+
B-
B
Date 2013-03-04
300A F3
Order number 244989-040
Sh. 6 9
Sh. 2
8
FREQUENCY INVERTER, PUMP A2
Electrical System — 5000.1 Symbol List and Wiring Diagrams T-code 485, 487
17- 55
Sh. 7 9
Sh. 6
22
28
27
X32
X32
X30
X30
X32
5
R6
1
3
R4
1
3
R5
1
3
R14
1
3
Service Manual
S61
R15
1
1
2 2 2 2
17- 56
3
5
S33 1
OUT. DATA COLLECT, DRIVE
INP. PERS.PROT. 1 (NOT ACTIVE) (WHEN USED SEE PAGE 24) INP. PERS. PROT. 2 (NOT ACTIVE) (WHEN USED SEE PAGE 24)
208
201
207
205
209397 8/24, Prod C
INP. OVERRIDE
INP. WEIGHT
OUT. DATA COLLECT, LIFT 202
204
INP. SPEED REDUCTION
INP. JOYSTICK SPARE 2
INP. JOYSTICK SPARE 1/AUTO ROTATE
INP. JOYSTICK ROTATE
INP. JOYSTICK TRAVERSE
INP. JOYSTICK FORK
206
510
506
505
504
503
Date 2013-03-04
100
81
86
85
84
83
82
Valid from serial number 6004330-
X33
X31
X33
X33
X33
X33
X33
ELECTRONIC CARD A5
T-code 485, 487
2
Sh. 6
Electrical System — 5000.1
Symbol List and Wiring Diagrams Order number 244989-040
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
© BT Europe AB
Sh. 8 10
Sh. 7 10
22
40
X30
Service Manual
X14
X69
S5 Bl
STEER WHEEL DIR., RIGHT S156 Br Bk
Br
FORK DIRECTION 1
Y11
S7 Bl
FORK DIR., LEFT S178 Br Bk
Br
FORK DIRECTION 2
Br
S9 Bl
FORK DIRECTION
X69
X47
S6 Bl
S8 Bl
Veflex VR, VR SF, VRE150, VRE125SF Br
S4
Bl
STEER WHEEL DIRECTION
Br
STEER WHEEL DIRECTION 2
Br
STEER WHEEL DIRECTION 1
Y24
Y10
X15
X15
X15
X47
X47
X47
44
42
41
90
89
88
111
107
106
703
701
702
INP. IN AISLE, MIDDLE
INP. IN AISLE, SIGNAL 2
INP. IN AISLE, SIGNAL 1
209397 9/24, Prod C
OUT. SELECT FORK MOVE
OUT. FORK LIFT
OUT. FORK LOWER
Valid from serial number 6004330-
X69
X14
X14
X47
X47
Date 2013-03-04
Bl
Order number 244989-040
Bl
ELECTRONIC CARD A5
Electrical System — 5000.1 Symbol List and Wiring Diagrams T-code 485, 487
17- 57
17- 58
1
40
22
Service Manual
10A F63
X37
X30
X45
40
Y20
-
+
+
9
5
330
920
-
Y21
H96
R31
+
2
1
109
-
-
H2
H95
R32
320
ID 0V
1 4
2
1
+48V
3
RX-
RX+
2
5
47 ohm/50W
+
+
X45
X45
LENGTH INDICATOR A9
680 ohm/2W
R34
680 ohm/2W
EXTERNAL EQUIPMENT X42 X42
H3
H18
H90
S90
40
26
R30
1
S99
X23
X23
680 ohm/2W
5
191
X37
X36
X30
X30
X31
X31
X31
X30
E4
X45
X45
102
101
108
38
37
33
32
92
91
X46
X46
192
E3
209397 10/24, Prod C
OUT. CABIN LOWER
OUT. CABIN LIFT
126
125
Sh. 6 11
Sh. 6 11
OUT. LENGTH INDICATION LAMP (IN AISLE)
OUT. TRAVEL ALARM
OUT. WARNING LAMP (MOTION)
OUT. IN AISLE INDICATION LAMP
OUT. FORKS IN HOME POSITION (L,R OR CENTER)
OUT. HALF PALLET HANDLING INDI. LAMP
INP. HALF PALLET HANDLING MODE
WORKING LIGHT
711
710
709
707
708
706
705
306
305
Date 2013-03-04
26
X45
X45
X23
X23
X36
-
10
1
Valid from serial number 6004330-
X31
X31
X31
X31
X31
X31
X31
X45
T-code 485, 487
Sh. 5 14
Sh. 9 11
Sh. 9 11
ELECTRONIC CARD A5
Electrical System — 5000.1
Symbol List and Wiring Diagrams Order number 244989-040
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
© BT Europe AB
Service Manual
20
30
X14
X15
X15
X31
X45
X16
X17
X17
X32
X32
X49
2
4
6
+48V
0V
-
Bk
-
+
Red
Bk
+
Red
U9
U10
5
1
TX+
TX-
3
7
RX-
RX+
PRE SELECTION HEIGHT A7
RX-
0V
4
5
B
A
B
A
Bl
Wh
Bl
Wh
Br
X34
X34
X34
X34
S93 Bl
X45
X45
X17
X17
X46
X46
X15
X15
104
56
55
99
98
128
127
INP. HEIGHT COUNTER > FREELIFT PULSE B
INP. HEIGHT COUNTER > FREELIFT PULSE A
RX- HEIGHT UNIT
RX+ HEIGHT UNIT
013
011
012
Veflex VR, VR SF, VRE150, VRE125SF
209397 11/24, Prod C
INP. FORKS < REFERENCE HEIGHT
INP. HEIGHT COUNTER < FREELIFT PULSE B
INP. HEIGHT COUNTER < FREELIFT PULSE A
ELECTRONIC CARD, TURRET UNIT A4
302
301
410
409
ELECTRONIC CARD A5
126
125
Sh. 10
Sh. 10
Valid from serial number 6004330-
Sh. 12
Sh. 5
Sh. 5
X30
RX+
+48V
3
Date 2013-03-04
29
40
22
LIFTING HEIGHT INDICATOR A8
Order number 244989-040
Sh. 10 12
Sh. 10 12
X45
Electrical System — 5000.1 Symbol List and Wiring Diagrams T-code 485, 487
17- 59
17- 60
Service Manual
Sh. 11
Sh. 7 15
Sh. 7 15
Sh. 11 13
Sh. 11 14
20
120
119
40
22
X15
X15
X14
X30
X16
X16
X16
X14
X49
X49
X49
X16
X49
-
B
A
Wh
Bl
Br
S50 Bk
010
008
009
209397 12/24, Prod C
INP. FORKS IN HOME POS. INDICATOR
INP. TRAVERSE COUNTER PULSE B
INP. TRAVERSE COUNTER PULSE A
INP. STEER SAFETY RELAY 041
Date 2013-03-04
103
53
52
OUT. + 15VDC SUPPLY
INP./OUT. CAN L
120 ohm/ 1W
028
042
R109
INP./OUT. CAN H
GND
015
027
GND
INP. + 48VDC SUPPLY
029
001
Valid from serial number 6004330-
Bk
+
Red
U13
20
120
119
40
22
T-code 485, 487
Bl
ELECTRONIC CARD, TURRET UNIT A4
Electrical System — 5000.1
Symbol List and Wiring Diagrams Order number 244989-040
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Sh. 12 14
40
X14 X16 X49
© BT Europe AB
Service Manual X64
Y16
Y27
R8
Y17
Y28
Y26
X64
X64
X63
X63
X63
X63
X63
X63
X63
65
39
77
76
75
74
73
95
94
93
007
002
019
018
005
006
003
004
017
016
Veflex VR, VR SF, VRE150, VRE125SF
209397 13/24, Prod C
INP. ROTATION ANGLE
OUT. POT. FEED + 10VDC
OUT. SPARE 1B
OUT. SPARE 1A
OUT. ROTATE, CLOCKWISE
OUT. ROTATE, COUNTER CLOCKWISE
OUT. PROPORTIONAL VALVE ROTATE
OUT. TRAVERSE RIGHT
OUT. TRAVERSE LEFT
OUT. PROPORTIONAL VALVE TRAVERSE
Valid from serial number 6004330-
X62
X62
X62
X62
X62
Y9
Y8
X63
Date 2013-03-04
X62
Y25
Order number 244989-040
X62
X62
ELECTRONIC CARD A4
Electrical System — 5000.1 Symbol List and Wiring Diagrams T-code 485, 487
17- 61
17- 62
Service Manual
Sh. 13 15
Sh. 12 15
22
24
1
X30
X45
1
S97
5
X45
0/1/2/3
(Bk) S70
(Ye)
(Gn)
(Or)
DEFROST START (1500W)
(Gn)
(Bl)
S68 COMFORT HEATER (1500W) FAN SPEED / MASTER ON/OFF S69 (Wh) (Ye)
(Red)
COLD STORE CABIN
FAN
M
Y1
TIMER
THERMOSTAT 2 4
15
5A
30A
30A
30A
30A
18
750W
750W
750W
Date 2013-03-04
209397 14/24, Prod C
750W
HEATER IN COLD STORE CABIN
Valid from serial number 6004330-
40
X31
E2
E1
157
COURTESY LIGHTS IN CABIN
Sh. 3
Sh. 10 24
E98
A1
T-code 485, 487
A2
OPTION
Electrical System — 5000.1
Symbol List and Wiring Diagrams Order number 244989-040
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
© BT Europe AB
Service Manual
Sh. 12
Sh. 12
Sh. 14 19
Sh. 14 16
120
119
40
22
X30
X48
X48
X48
X48
Br
S85 Bk
120
119
113
112
111
40
22
Veflex VR, VR SF, VRE150, VRE125SF
JP3:4
JP3:2
209397 15/24, Prod C
INP./OUT. CAN L
INP./OUT. CAN H
GND
INP. STEER WHEEL IN HOME POS.
OUT. + 12VDC
GND
INP. + 48VDC SUPPLY
Valid from serial number 6004330-
JP3:1
JP4:5
JP4:6
JP2:23
JP2:9
JP2:21
JP2:24
JP2:11
WIRE GUIDANCE A3
Date 2013-03-04
Bl
Order number 244989-040
WIRE GUIDANCE, PAGE 15-18
OPTION
Electrical System — 5000.1 Symbol List and Wiring Diagrams T-code 485, 487
17- 63
17- 64
Service Manual
Sh. 15 19
22
X30
X32
-
S120
7
Ye
Gr
670
R35
680~E/2W
X32
X32
X48
66
67
133
132
OUT. ON WIRE
INP. ENCODER PULSE B
INP. ENCODER PULSE A
304
209397 16/24, Prod C
INP. WIRE GUIDANCE OFF
ELECTRONIC CARD A5
JP2:3
JP1:8
JP1:7
OUT. + 5VDC
GND
Date 2013-03-04
5
H120 10 9
B
A
JP1:21
JP1:12
Valid from serial number 6004330-
VR WITHOUT WIRE GUIDANCE
X32
Wh
+
Br
ENCODER U15
130
131
WIRE GUIDANCE A3
T-code 485, 487
WIRE GUIDANCE, PAGE 15-18
OPTION
Electrical System — 5000.1
Symbol List and Wiring Diagrams Order number 244989-040
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
LOAD ANTENNA W1
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
J1L:13
J1L:15
GREY
VIOLET
BLUE
GREEN
YELLOW
ORANGE
JPW1:13
JPW1:15
JPW1:14
T3
T2
T1
SHIELD
OUT. + 12VDC
GND
JPW1:8 OUT.
JPW1:7 OUT.
JPW1:6 OUT.
T0
LEFT COIL
209397 17/24, Prod C
NEAR WIRE COIL
RIGHT COIL
JPW1:5 OUT.
JPW1:3 INP.
JPW1:2 INP.
JPW1:1 INP.
Valid from serial number 6004330-
J1L:14
J1L:8
J1L:7
J1L:6
J1L:5
RED
BROWN
BLACK
Date 2013-03-04
J1L:3
J1L:2
J1L:1
WIRE GUIDANCE A3
Order number 244989-040
WIRE GUIDANCE, PAGE 15-18
OPTION
Electrical System — 5000.1 Symbol List and Wiring Diagrams T-code 485, 487
17- 65
TRACTOR ANTENNA W2
17- 66
Service Manual
J1T:13
GREY
VIOLET
JPW2:13
JPW2:15
JPW2:14
T3
T2
T1
SHIELD
OUT. + 12VDC
GND
JPW2:8 OUT.
JPW2:7 OUT.
JPW2:6 OUT.
T0
LEFT COIL
JPW2:5 OUT.
JPW2:3 INP.
NEAR WIRE COIL
RIGHT COIL
209397 18/24, Prod C
Date 2013-03-04
J1T:15
J1T:14
BLUE
GREEN
YELLOW
ORANGE
RED
JPW2:2 INP.
JPW2:1 INP.
Valid from serial number 6004330-
J1T:8
J1T:7
J1T:6
J1T:5
J1T:3
BROWN
BLACK
WIRE GUIDANCE A3
T-code 485, 487
J1T:2
J1T:1
WIRE GUIDANCE, PAGE 15-18
OPTION
Electrical System — 5000.1
Symbol List and Wiring Diagrams Order number 244989-040
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
© BT Europe AB
103
104
GND
SHIELD
X31
X67
X67
X67
X67
Service Manual X45
X45
X61
X61
X61
X61
X60
X60
X60
X60 120~E/0,6W
X:A50
X:A50
X:A50
X:A50
SHIELD
GND
+ 12VDC
VIDEO SIGNAL
+
115
114
+
OUT. + 12VDC
209397 19/24, Prod C
Valid from serial number 6004330-
OUT. GND
INP. GND
INP. + 48VDC
VOLTAGE CONVERTER A10
A:2
B:2
B:1
A:1
40
22
156
115
114
110
TV-MONITOR A50
Date 2013-03-04
40
22
102
101
+ 12VDC
VIDEO SIGNAL
R50
Order number 244989-040
Sh. 15 21
Sh. 16 21
CAMERA A51
CAMERA ON FORKS. COLDSTORE CABIN.
OPTION
Electrical System — 5000.1 Symbol List and Wiring Diagrams T-code 485, 487
Veflex VR, VR SF, VRE150, VRE125SF
17- 67
17- 68
Service Manual
102
103
104
SCREEN
+12VDC
GND
X52
X61
X61
X61
X61
X60
X60
X60
X60
X55
X55
X55
X55
115
114
156
110
B:2
B:1
A:2
A:1
GND
+12VDC
SCREEN
VIDEO SIGNAL
209397 20/24, Prod C
Date 2013-03-04
X52
WHEN STEREO/CD
X67
X67
X67
X67
Valid from serial number 6004330-
115
114
101
VIDEO SIGNAL
TV-MONITOR A50
T-code 485, 487
Sh. 21
Sh. 21
CAMERA A51
CAMERA ON FORKS.
OPTION
Electrical System — 5000.1
Symbol List and Wiring Diagrams Order number 244989-040
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
© BT Europe AB
Service Manual
W5
H4 X56
X56
X56
B:4
B:3
B:6
B:5
A:8
A:4
A:7
OUT. RIGHT (-)
OUT. RIGHT (+)
OUT. LEFT (-)
OUT. LEFT (+)
INP. GND
INP. +12V KEY
INP. +12VDC
209397 21/24, Prod C
Valid from serial number 6004330-
H5
X56
340
312
OUT. +12VDC
OUT. GND (GALV. SEPARATED)
OUT. GND (GALV. SEPARATED)
OUT. +12VDC
INP. GND
INP. +48VDC
STEREO/CD A11
1
2
5
4
3
6
Date 2013-03-04
312
312
340
115
40
22
115
STEREO/CD
114
X44
X44
114
40
22
DC/DC CONVERTER A10
Order number 244989-040
Sh. 20
Sh. 20
Sh. 19 22
Sh. 19 22
OPTION
Electrical System — 5000.1 Symbol List and Wiring Diagrams T-code 485, 487
Veflex VR, VR SF, VRE150, VRE125SF
17- 69
17- 70
Sh. 21 23
Sh. 21 23
40
22
W5
X:A9
X:A9
Service Manual 340
312
312
312
340
OUT. +12VDC
OUT.GND
INP. GND
INP. +48VDC
OUT. RIGHT (+)
OUT. RIGHT (-) B:4
OUT. LEFT (-) B:6
B:3
OUT. LEFT (+)
INP. GND
INP. +12V KEY
INP. +12VDC
209397 22/24, Prod C
Valid from serial number 6004330-
B:5
A:8
A:4
A:7
STEREO/CD A11
+
-
-
+
DC/DC CONVERTER A10
T-code 485, 487
H5
H4
STEREO/CD COLDSTORE CABIN.
OPTION
Electrical System — 5000.1
Symbol List and Wiring Diagrams Date 2013-03-04 Order number 244989-040
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
X2:4
X2:5
X2:6
INP. 0VDC SUPPLY
INP. DRIVE, STEER WHEEL DIRECTION
INP. 0VDC SUPPLY
40
X2:3
X34
X33
X32
INP. DRIVE, FORK DIRECTION
PERSONAL PROTECTION SYSTEM TBM GM-107ECO
166
165
X30
X150
X150
X150
4
3
S33
8
2
7
1
164
163
100
33
202
208
205
706
OUT. DRIVE, STEER WHEEL DIRECTION
OUT. DRIVE, FORK DIRECTION
INP. OVERRIDE
OUT. IN AISLE INDICATION LAMP
209397 23/24, Prod C
NOTE! OUTPUT FOR AUDIBLE AND VISIBLE ALARM FROM TBM GM-107ECO EQUIPMENT NOT SHOWED.
X33
OVERRIDE EMERGENCY MODE / OVERRIDE HEIGHT
X30
Valid from serial number 6004330-
Sh. 22 24
Sh. 24
Sh. 24
22
33
ELECTRONIC CARD A5
Date 2013-03-04
Sh. 22
Sh. 24
OPTION
Order number 244989-040
PERSONAL PROTECTION SYSTEM, PAGE 24 AND 25.
Electrical System — 5000.1 Symbol List and Wiring Diagrams T-code 485, 487
17- 71
17- 72
Service Manual
166
X150
X150
X150
X150
X150
X150
X150
X150
X150
X150
X150
X1:13
209397 24/24, Prod C
INP. OVERRIDE EMERGENCY MODE
OUT. +24VDC
INP. 0 VDC SUPPLY X2:12
X1:12
INP. IN AISLE
OUT. WARNING RELAY
INP. WARNING RELAY
OUT. EMERGENCY RELAY
INP. EMERGENCY RELAY
OUT. EMERGENCY RELAY
INP. EMERGENCY RELAY
0 VDC SUPPLY
INP. +48VDC SUPPLY
X2:10
X1:7
X1:6
X1:5
X1:4
X1:3
X1:1
X9:2
X9:1
8A F
Date 2013-03-04
Sh. 23
165
162
161
160
9
Valid from serial number 6004330-
Sh. 23
33
206
207
INP. PERSONAL PROTECTION 2
INP. SPEED REDUCTION
201
INP. PERSONAL PROTECTION 1
ELECTRONIC CARD A5
40
7,5A F64
PERSONAL PROTECTION SYSTEM GM-107ECO
T-code 485, 487
Sh. 23
Sh. 23
Sh. 14
1
PERSONAL PROTECTION SYSTEM, PAGE 24 AND 25.
OPTION
Electrical System — 5000.1
Symbol List and Wiring Diagrams Order number 244989-040
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Symbol List and Wiring Diagrams Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
17.1.3 Component List, standard truck Symbol
Description/function
Component figure
A1
Frequency inverter, M1
4
A2
Frequency inverter, M3
4
A3
Electronics card, loop steering
A4
Electronics card, fork apparatus
6
A5
Electronics card
4
A6
Display, instrument panel
1
A7
Height pre-set
2
A8
Height indication display
7
A9
Length indication display
7
A10
Voltage converter, 48/12 V
A12
Filter card
A13
Filter card
A14
Voltage converter, 48/12 V
A49
TV monitor, arm mounted cameras
A50
TV-monitor
7
A51
TV-camera
7
A52
TV camera, arm mounted, left
A53
TV camera, arm mounted, right
A54
Camera switching unit
B1
Thermoelectric sensor, M1
4
B2
Thermoelectric sensor, M3
4
E1, E2
Cab lighting
E3, E4
Work spotlight
7
E10
Seat heater
3
F1
Drive motor fuse, 160 A
4
F3
Pump motor fuse, 300 A
4
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
17- 73
Electrical System — 5000.1 Symbol List and Wiring Diagrams T-code 485, 487
17- 74
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Symbol
Description/function
Component figure
F60
Operating fuse for A5 card, 10 A
4
F61
Steering motor fuse, 30 A
4
F62
Operating fuse for K10, 10 A
4
F63
Operating fuse for extra equipment, 10/16 A
4
G1
Battery, 48 V
7
H1
Horn
4
H2
Warning lamp
7
H18
Indication lamp, in narrow aisle mode
1
H90
Indication lamp, half-pallet handling
H95
Indication lamp, forks in home position
H96
Length indication lamp
H120
Indication lamp, wire guidance
K10
Main contactor
4
M1
Drive motor
4
M3
Pump motor
4
M6
Steering motor
4
M10
Fan for pump motor
4
M12
Fan for electrical panel
4
R1
Potentiometer, acceleration
4
R2
Potentiometer, braking
4
R4
Potentiometer, traversing
2
R5 (VR only)
Potentiometer, rotation
2
R6
Potentiometer, forks raised/lowered
2
R8 (VR only)
Potentiometer, rotation angle
6
R14 (VR only)
Potentiometer, extra hydraulic function/auto-rotation
2
Service Manual
1
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Symbol List and Wiring Diagrams Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Symbol
Description/function
Component figure
R15 (VR only)
Potentiometer, extra hydraulic function
2
R30
Series resistor, H95
R31
Series resistor, H18
R32
Series resistor, H96
R34
Series resistor, H90
R35
Series resistor, H120
R100
Resistor, service key
7
R102
Resistor, emergency lowering of forks
4
S1
Micro-switch, driver number/programming
1
S2
Micro-switch, driver number/step up
1
S3
Micro-switch, driver number/step down
1
S4
Electro-magnetic switch, aisle centre, steering wheeldirection
5
S5
Electro-magnetic switch, aisle indication 1, fork-direction
5
S6
Electro-magnetic switch, aisle indication 1, steering wheel-direction
5
S7
Electro-magnetic switch, aisle indication 2, fork-direction
5
S8
Electro-magnetic switch, aisle indication 2, steering wheel-direction
5
S9
Electro-magnetic switch, aisle centre, fork-direction
5
S17
Key switch
1
S18
Micro-switch, horn
2
S21
Emergency switch
1
S23
Safety switch, left foot-pedal
4
S26
Micro-switch, direction of travel selector at creep speed
2
S33
Micro-switch, by-pass max. lift height
2
S50
Inductive sensor, forks in home position, traversing
6
S61
Micro-switch, load weighing
1
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
17- 75
Electrical System — 5000.1 Symbol List and Wiring Diagrams T-code 485, 487
17- 76
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Symbol
Description/function
Component figure
S65
Pulse generator, steering wheel centre
4
S66
Pulse generator, steering wheel-direction
4
S68
Micro-switch, fan speed
S69
Micro-switch, main heater
S70
Micro-switch, additional heater
S85
Pulse generator, home position steering wheel
See C-kod 4500
S89
Micro-switch, seat
3
S90
Micro-switch, half-pallet handling
7
S93
Electro-magnetic switch, reference height
6
S97
Micro-switch, cab lighting
S99
Micro-switch, work spotlight
7
S120
Micro-switch, loop steering request
2
S131
Micro-switch, released parking brakes
4
S156
Photo cell, aisle indication 1
S178
Photo cell, aisle indication 2
U1
Tachometer, steering
2
U9
Pulse generator, height measurement within free lift
6
U10
Pulse generator, height measurement over free lift
7
U11
Pulse generator, drive motor
4
U12
Pulse generator, pump motor
4
U13
Pulse generator, traversing movement
7
U15
Pulse generator, steering angle, wire guidance
See C-kod 4500
W1
Wire guidance antenna, fork direction
W2
Wire guidance antenna, steering wheel direction
X1
Contact, battery connector
X8
Contact, to height indication display
X11
Contact, for joystick in steering wheel console Service Manual
7
2
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Symbol List and Wiring Diagrams Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Symbol
Description/function
Component figure
X14
Contact, at tank, to mast
4
X15
Contact, at tank, to mast
4
X16
Contact, at mast
5
X17
Contact, at mast
5
X23
Contact
X25
Contact, seat
3
X30
Contact, at electrical panel
4
X31
Contact, at electrical panel
4
X32
Contact, at electrical panel
4
X33
Contact, at electrical panel
4
X34
Contact, at electrical panel
4
X35
Contact, at fan in motor compartment
4
X36
Contact, warning lamp
X37
Contact, panel alarm
X38
Contact, at tank for support arm brake
X39
Contact, support arm brake Y5:1, Y5:2
X40
Contact, support arm brake Y6:1, Y6:2
X41
Contact, roof CAN contact
7
X42
Contact, Aux at electrical panel
4
X45
Contact, roof upright
1
X46
Contact, at electrical panel
4
X47
Contact, at tank to pump valve block
4
X48
Contact, at tank for loop steering
4
X49
Contact, at A4
6
X60
Contact, at mast
6
X61
Contact, for camera at A4
6
X62 (VR only)
Contact, valve block fork apparatus
6
X63 (VR only)
Contact, valve block fork apparatus
6
X64 (VR only)
Contact, for rotary potentiometer
6
X65 (VR only)
Contact, for traversing pulse generator
6
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
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Electrical System — 5000.1 Symbol List and Wiring Diagrams T-code 485, 487
17- 78
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Symbol
Description/function
Component figure
X67 (VR only)
Contact, for camera, on fork apparatus
6
Y1
Magnet, parking brakes
4
Y5:1
Magnet, support arm brake
7
Y6:1
Magnet, support arm brake
7
Y5:2
Magnet, support arm brake
7
Y6:2
Magnet, support arm brake
7
Y8
Electro-magnetic valve, traversing left
6
Y9
Electro-magnetic valve, traversing right
6
Y10
Electro-magnetic valve, lower
4
Y11
Electro-magnetic valve, lift
4
Y16 (VR only)
Electro-magnetic valve, extra hydraulic function 1A
Y17 (VR only)
Electro-magnetic valve, extra hydraulic function 1B
Y24
Electro-magnetic valve, fork movement
4
Y25 (VR only)
Proportional valve, traversing
6
Y26 (VR only)
Proportional valve, rotation
6
Y27 (VR only)
Electro-magnetic valve, counter clockwise rotation
6
Y28 (VR only)
Electro-magnetic valve, clockwise rotation
6
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Symbol List and Wiring Diagrams Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
17.1.4 Component identification Figure 1
Figure 2
Figure 3
© BT Europe AB
Service Manual
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Electrical System — 5000.1 Symbol List and Wiring Diagrams T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Figure 4
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Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Symbol List and Wiring Diagrams Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Figure 5 (VR SF)
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
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Electrical System — 5000.1 Symbol List and Wiring Diagrams T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Figure 5 (VR)
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Electrical System — 5000.1 Symbol List and Wiring Diagrams Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Figure 6 (VR SF)
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
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Electrical System — 5000.1 Symbol List and Wiring Diagrams T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Figure 6 (VR)
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Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Symbol List and Wiring Diagrams Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Figure 7 (VR SF)
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
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Electrical System — 5000.1 Symbol List and Wiring Diagrams T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Figure 7 (SF)
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Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Functional Description Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
17.2 Functional Description The electronics card for VR/VR SF AC has a microprocessor that monitors switch status, control voltages, etc., and provides instructions for external electronics, contactors, valves, etc. So that pre-set information remains in the electronics module after battery power has been switched off, the module is equipped with an internal battery. Any errors registered by the micro-processor are shown on the display. Error codes are explained in conjunction with the electronics card. The electronics card’s inputs and outputs are marked with connection numbers and can be easily connected and disconnected using connectors. The inputs and outputs, which have two fixed position, have LEDs indicators: green is used for inputs, red for outputs and yellow for others.
© BT Europe AB
Description
Diode number
Designations for card inputs/outputs in accordance with wiring diagrams
Diode number/name indicating the card’s active inputs/outputs
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
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Electrical System — 5000.1 Functional Description T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
17.2.1 Key in Position 0 When the battery is connected to the truck via the charging connector, the electronics cards A4/805 and A5/901 receive a voltage of +48 V and the LEDs (shown in the table) light. Voltage of 15 V is supplied by A5/810 to sensors S66 and U10. LEDs 210, 211, 301 and 302 light depending on if the respective sensor is influenced or not. Voltage of +7.35 V is supplied by A5/507 to potentiometer R1 in the acceleration controller, the braking controller R2 and the hydraulic controllers R4–R6, R14–R15.
Description
Diode number
STEER WHEEL ANGLE
210, 211
HEIGHT COUNTER
301, 302
+48 VDC
+48 V
+48 VDC STEER SERVO
+48 V STEER STEER PWR POWER OK
17.2.2 Key in Position I, Driver Seated Truck power is switched on when the driver turns the key to the I position. For the direction of travel selector and the hydraulics to be used, the driver must be seated on the truck seat so that contact S89 is closed. Current passes through the operating fuse F60, the ignition lock S17 and the emergency switch S21, to the electronics card A5/807 and 809, via S89 to A5/203, the frequency inverters A1 and A2, the height electronics A7 and A8, and the fan M10 (which begins to spin). The A5 electronics card checks that the internal safety function are functioning and closes the main contactor K10, output A5/804, which provides power to the drive and pump motors. The A5 electronics card starts communications with the height electronics A7 and A8, the length indicator A9 and provides +32 V to the fan M12, which begins to rotate at half-speed. A5 checks that the voltage from the potentiometers is +3.65 V and sends control pulses to tachometer U1 and steering motor M6. If the seat has built-in heating, a voltage of +48 V is also supplied to the thermostat and the seat heater E10.
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Electrical System — 5000.1 Functional Description Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
The display turns on and the software version number is shown before the display enters its normal mode. The normal mode shows the time of day, operating time, battery status and any error codes. The length of time that the truck key is in the I position is monitored and stored in the electronics module. The LEDs in the following table will light: Nr. 706–711 light if the valves are not installed on the truck. LEDs for the frequency inverters A1 and A2 light. .
Description
Diode number
LEFT FOOT SWITCH
110
SEAT SWITCH
203
WIRE GUIDANCE OFF
304
CABIN LIFT
710
CABIN LOWER
711
SUPPORT ARM BRAKE
801 (lights dimly)
FORK LOWER
803 (lights dimly)
MAIN CONTACTOR
804
KEY
+48 V KEY
+48 VDC SUPPLY OUTPUTS
+48 V ESO +48 V_SR
17.2.3 Direction of Travel Selection When the S26 switch is pressed, voltage passes from the switch to A5/ 104 or 105. If the switch is depressed for at least three seconds, the truck runs at creep speed.
Description
Diode number
DRIVE, FORK DIR CREEP
104
DRIVE, STEER WHEEL DIR CREEP
105
The display shows the direction of travel.
© BT Europe AB
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Electrical System — 5000.1 Functional Description T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
17.2.4 Driving When the acceleration controller R1 is manoeuvred, the drive motor brakes are released. If safety switch S23 is not tripped (+48 V at A5/ 110) when the parking brakes release, a buzzer will sound at the display. If the driver presses the accelerator pedal as the key is turned to I, the pedal must be returned to the neutral position before the truck can be driven. When the accelerator pedal is pressed, potentiometer R1 is affected. The more the pedal is pressed, the lower the voltage from R1 to A5/ 501. The voltage decreases from 3.7 to 1.7 V, which results in 0–100% higher speed. A1 controls drive motor revolutions using information from A5 via CAN. Current passes through A1’s fuse F1 and is converted to 3-phase AC, which goes to till M1. Drive motor speed is measured by sensor U11. If the direction of travel lever on the control console is held down for at least three seconds, the truck runs at creep speed. If the driver is unseated for more than 3 seconds, A5 cuts current to Y1, output 802, which applies the parking brakes. The drive motor’s running time is monitored and stored in the electronics module.
17- 90
Description
Diode number
PARKING BRAKE
802
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Functional Description Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
17.2.5 Travel speeds Outside narrow aisles and the forks in the “home position” - Fork height 1.2 m but 10o = the speed is reduced to max 2.5 km/h (0.7 m/s). - Fork height >3.0 m = speed reduced to max 2.5 km/h (0.7 m/s). - Forks not in the "home position" = always gives a speed reduced to max 2.5 km/h (0.7 m/s).
Rail guided trucks Trucks with support arm brakes: - Driving in the direction of the drive wheel, fork height 3.0 m but 6.9 m = speed reduced to max 2.5 km/h (0.7 m/s). - Forks not in “home position” = always gives a speed reduced to max 2.5 km/h (0.7 m/s). - m = speed reduced to max 9.0 km/h (2.5 m/s). - Fork height >3.0 m but 6.9 m = speed reduced to max 2.5 km/h (0.7 m/s). - Forks not in “home position” = always gives a speed reduced to max 2.5 km/h (0.7 m/s).
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Electrical System — 5000.1 Functional Description Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Wire guided truck - Fork height 3.0 m but 6,9 m = speed reduced to max 2.5 km/h (0.7 m/s). - Forks not in “home position” = always gives a speed reduced to max 2.5 km/h (0.7 m/s).
© BT Europe AB
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Veflex VR, VR SF, VRE150, VRE125SF
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Electrical System — 5000.1 Functional Description T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
17.2.6 Steering When the wheel is turned, voltage is supplied by tachometer U1 to A5/ 509, which provides progressive power to steering motor M6. This means that the faster the steering motion, the faster the steering motor runs. Progression also entails that the higher the driving speed, the lower the steering speed. Drive motor speed is measured by sensor U11. When the steering wheel is turned, the steering wheel sensor S65 is influenced and voltage sent to A5/209. The opposite direction of travel is shown on the display. The electronics automatically indicate the correct travel direction in that switch S65 transmits signals for 180° of the possible 360. So that the electronics can determine the direction of the steering wheel and indicate the travel direction, sensor S65 must pass one of the reference points. The function is initiated by a turn of the wheel. This must be done at the initial start and after service. LEDs 209, 210 and 211 light depending on if the respective sensor is influenced or not.
Description
Diode number
STEER WHEEL REF. 180°
209
STEER WHEEL ANGLE A
210
STEER WHEEL ANGLE B
211
Sensors S65 and S66 have their own adjustment instructions, see C-code 5850.
Steering wheel indicator When the wheel is turned, sensor S66 sends signals to A5/210 and 211, which indicate the travel direction on the display. So that the electronics can determine the direction of the steering wheel and indicate the travel direction, sensor S65 must pass one of the reference points. The function is initiated by a turn of the wheel. This must be done at the initial start and after service. When the travel direction is changed using the lever, the arrows switch on the display. LEDs 209, 210 and 211 light depending on if the respective sensor is influenced or not.
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Electrical System — 5000.1 Functional Description Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Track-guided narrow aisle When driving into narrow, track-guided aisles, the truck must be steered so that it is straight. The steering angle must be less than 15°. When the truck has come into the narrow aisle, S5/S7 or S6/S8 are activated by floor magnets, or if photo cells are used, S156/ S178. Voltage of +48 V is at A5/106 and 107. Manual steering is disabled when the truck is facing straight ahead. Steering is now taken over by sensor S66, which sends signals to the steering servo on A5 to correct for angle deviations from straight ahead. LED 209 lights depending on if the sensor is influenced or not.
Description
Diode number
IN AISLE SIGNAL 1
106
IN AISLE SIGNAL 2
107
STEER WHEEL REF. 180°
209
STEER WHEEL ANGLE A
210
STEER WHEEL ANGLE B
211
Wire guidance Wire guidance has its own description, see C-code 4500 Automatic control system and C-code 8200 Wire equipment. Observe that when wire guidance is not fitted a strap must be connected instead of S120. Input A5/304 shall be high (+48 V) when wire guidance is not fitted.
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Electrical System — 5000.1 Functional Description T-code 485, 487
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Date 2013-03-04
Order number 244989-040
17.2.7 Braking The truck employs various braking systems:
Auto-brakes When the driver releases the accelerator pedal, the drive motor automatically brakes the truck to the desired speed. Auto-braking and braking power can be set with parameters.
Motor brakes (electric) When the driver changes directions using the lever, the drive motor functions as a generator/brake and sends current back to the battery. Braking power is determined with the help of the accelerator pedal. The A5 electronics card receives information from A1 that motor braking is underway and changes regulation of A1.
Foot brakes When the driver pushes the brake pedal, potentiometer R2 is influenced. Voltage climbs from 1.7 to 4.1 V at input A5/502, which results in 0–100% braking power. Down to 85% of the pedal action, the truck is braked by reversing the drive motor. When the pedal is fully depressed, the parking brakes are also activated, output 802 falls.
Support arm brakes If the truck has brakes in the support arm wheels, these are applied at 60% of pedal action. Voltage 0–48 V at outputs A5/801 and 803. When the pedal is depressed to approximately 90%, the parking brakes are also activated, output 802 falls. LEDs 801 and 803 shine progressively brighter as braking power increases.
Description
Diode number
SUPPORT ARM BRAKE 1
801
SUPPORT ARM BRAKE 2
803
Parking brakes When the truck is standing still and the brake pedal is depressed, the parking brakes are activated, output 802 falls. If the driver is unseated for more than three seconds, A5 breaks current to Y1, output 802 falls, which applies the parking brakes.
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Electrical System — 5000.1 Functional Description Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
17.2.8 Aisle-End Slowdown When driving in narrow aisles, no automatic speed reduction occurs. When driving out from a narrow aisle, as the truck passes a predefined point from the aisle-end (approx. 7 m.), acceleration is disabled and braking begins if the speed when passing this point is higher than half speed. When the truck passes the “braking point”, a warning signal sounds for about two seconds. Slowing is by reversing the motor. When the truck has reached a low speed, slowing is deactivated. To continue out from the aisle, the driver must reapply pressure to the accelerator pedal. The maximum speed when exiting a narrow aisle is half speed. If the running speed is half speed or lower, the truck passes the braking point without slowing. Bistable, electro-magnetic switches, S4 and S9, are mounted on the truck. Permanent magnets are placed in the narrow aisle floors.
17.2.9 Fork Lifting When the driver manoeuvres the hydraulic lever R6, A5 receives a voltage of 3.7–6.6 V at input A5/503, the direction valve Y11 opens, +48 V at output A5/702, and A5 sends a signal to the transistorised regulator A2. The pump motor M3 starts and pumps oil to the lifting cylinders. If the battery monitor has detected 20% or lower battery capacity, lifting speed is reduced. Lifting speed is reduced at the transition from free lift (programmed with parameter 19) to main lift. The speed of M3 is measured by sensor U12. The fork lift has a programmable, electric lift stop; the pump motor stops. Max. height set by parameter 29.
© BT Europe AB
Description
Diode number
FORKLIFT
701
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Electrical System — 5000.1 Functional Description T-code 485, 487
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Date 2013-03-04
Order number 244989-040
17.2.10 Height Indication Height measurement checks the lift height from the lowest fork position (floor level) to the highest. Measurement begins when the height reference switch S93 (after turning the ignition key) passes the magnet mounted on the mast. The pulse generator U9 sends pulses to A4. Information is sent via CAN to A5, which indicates the height on the A8 display. Each time S93 passes the magnet, height measurement is calibrated to the value set by parameter 54. When the forks reach the main lift range, the pulse generator U9 stops and U10 begins sending pulses to A5. A5 adds U10’s pulse count to the height calculated by the pulses from U9. LEDs 301 and 302 light depending on if the respective sensor is influenced or not.
Description
Diode number
HEIGHT COUNTER
301
HEIGHT COUNTER
302
17.2.11 Lift height limit The forks stop when the preprogrammed limit heights (2) are reached, parameters 17 and 18. If the forks are to be lifted above these heights, switch S33 must be depressed, which sends a signal to A5 and movement continues. Start must occur within fifteen seconds. LEDs 301 and 302 light depending on if the respective sensor is influenced or not.
17- 98
Description
Diode number
HEIGHT COUNTER
301
HEIGHT COUNTER
302
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Electrical System — 5000.1 Functional Description Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
17.2.12 Height Pre-Set Height measurement is performed as described for height indication. The current lifting height is shown both on displays A7 and A8. The forks stop at the first pre-programmed height when A5, via pulse generator U9 or U10, reaches the correct height. The stop is made by A5’s regulation of the pump motor speed with A2 and of the valves for fork lifting and lowering. The driver picks up or deposits the load manually. When the driver again manoeuvres the hydraulic lever to lift or lower, the forks continue to the next pre-programmed level. See Chapter 9390.
© BT Europe AB
Description
Diode number
HEIGHT COUNTER
301
HEIGHT COUNTER
302
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Electrical System — 5000.1 Functional Description T-code 485, 487
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Date 2013-03-04
Order number 244989-040
17.2.13 Fork Lowering When the driver manoeuvres the hydraulic lever R6, a voltage of 3.7– 0.66 V is supplied to A5/503, direction valve Y10 opens, +48 V at output A5/702, and A5 sends a signal to the transistorised regulator A2. The pump motor M3 starts and runs at a maximum speed that corresponds to the potentiometer value from R6. Before the lowering movement begins, the lifting cycle is run momentarily to build torque in M3. Torque in M3 is used to brake the hydraulic pump. The driver can vary the lowering speed by changing the position of lever R6, thus varying the braking torque. Braking torque generates a current that is fed back to the battery (regenerative lowering). At the transition from the main lift range to free lift range, lowering speed is reduced automatically in that M3’s braking torque increases. When the forks are within the free lift range and U9 begins to count down, the braking torque decreases and the lowering speed increases. Close to the forks’ bottom position, the braking torque increases anew so as to reduce the lowering speed and attain a soft stop. The speed of M3 is measured by sensor U12. The LEDs shine dimly in the neutral position and brightly when lowering begins.
17- 100
Description
Diode number
FORK LOWER
702
Service Manual
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Electrical System — 5000.1 Functional Description Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
17.2.14 Lateral Movement/Traversing of Forks (VR SF) When the driver manoeuvres the hydraulic lever R4, a voltage (left = 3.7–0.66 V, and right = 3.7–6.6 V) is supplied to A5/504, the direction valve Y24 opens, +48 V at output A5/703, and sends a signal to the frequency inverter A2. Pump motor M3 starts.
Description
Diode number
SELECT FORK MOVE
703
Information that traversing movement is desired is sent via CAN to A4. A4 provides a voltage of +48 V at output A4/017, traverse left, to open the direction valve Y8 or A4/004, traverse right, to open the direction valve Y9. A4/016 supplies PWM +24 V to proportional valve Y25, which opens fully. The speed is reduced to give a smooth stop close to the traversing movement’s end position and the centre position. The braking ramp is adjustable using parameter 50. Even with a stop in the middle of the travel or when changing direction there is also a ramp function on the braking of the fork travel, which can be adjusted using parameter 57.
Parameters to check/adjust
© BT Europe AB
Parameter
Function
44
Action length (pre-set at factory)
45
Action length for half pallet (pre-set at factory)
46
Height-dependent speed reduction
50
Braking ramp at the end and centre positions
55
Traversing speed
57
Braking ramp when changing direction or stopping
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
17- 101
Electrical System — 5000.1 Functional Description T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
17.2.15 Lateral Movement/Traversing of Forks (VR) When the driver manoeuvres the hydraulic lever R4, a voltage (left = 3.7–0.66 V, and right = 3.7–6.6 V) is supplied to A5/504, the direction valve Y24 opens, +48 V at output A5/703, and sends a signal to the lift controller A2. Pump motor M3 starts.
Description
Diode number
SELECT FORK MOVE
703
Information that traversing movement is desired is sent via CAN to A4. A4 provides a voltage of +48 V at output A4/017, traverse left, to open the direction valve Y8 or A4/004, traverse right, to open the direction valve Y9. A4/016 supplies PWM 0-24 V, relative to the voltage from R4, to the proportional valve Y25 for regulation of rotation speed. The pump motor M3 runs at a fixed speed, which is measured by sensor U12. Close to the traversing movement’s end position, speed is braked to attain a soft stop. Braking distances and abruptness are adjustable with parameters.
Parameters to check/adjust
17- 102
Parameter
Function
44
Action length (pre-set at factory)
45
Action length for half pallet (pre-set at factory)
46
Height-dependent speed reduction
50
Braking distance at end position
55
Traversing speed
57
Braking ramp
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Functional Description Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
17.2.16 Rotating the Forks (VR) When the driver manoeuvres the hydraulic lever R5, a voltage (rotation clockwise = 3.7–0.66 V, and counter clockwise = 3.7–6.6 V) is supplied to A5/505, the direction valve Y24 opens, +48 V at output A5/703, and sends a signal to the lift controller A2. Pump motor M3 starts.
Description
Diode number
SELECT FORK MOVE
703
Information that rotation movement is desired is sent via CAN to A4. A4 provides a voltage of +48 V at output A4/005, clockwise rotation, to open the direction valve Y28; or at A4/006, counter clockwise rotation, to open the direction valve Y27. A4/003 supplies PWM 0-24 V, relative to the voltage from R5, to proportional valve Y26 for regulation of rotation speed. Rotation speed is measured by potentiometer R8. Pump motor M3 runs at a fixed speed that is measured by sensor U12. Close to the rotation movement’s end position, speed is braked to attain a soft stop. Braking distances and abruptness are adjustable with parameters.
Parameters to check/adjust
© BT Europe AB
Parameter
Function
51
Braking distance at end position
56
Rotation speed
58
Braking ramp
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
17- 103
Electrical System — 5000.1 Functional Description T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
17.2.17 Simultaneous Traversing and Rotation Movement (VR) Manual When the driver manoeuvres the hydraulic levers R4 and R5 simultaneously, regulation of traversing movement passes from revolution control to regulation of proportional valve control. The revolutions of M3 are fixed, higher than for rotation alone, and A4/ 016 supplies PWM 0–24 V to the proportional valve Y25, which now regulates traversing speed.
Auto-rotation Activated by parameter 59. When the driver manoeuvres the hydraulic Lever R14, a voltage is supplied to A5/506, the direction valve Y24 opens, +48 V at output A5/703, and sends a signal to the lift controller A2. Pump motor M3 starts. NOTE The auto-rotation function follows the traversing direction.
Description
Diode number
SELECT FORK MOVE
703
Information that auto-rotation movement is desired is sent via CAN to A4. Rotation angle and speed is measured by potentiometer R8. Traversing speed is measured by sensor U13. Pump motor M3 runs at a fixed speed that is measured by sensor U12.
Parameters to check/adjust Parameter
Function
53
Symmetries right/left for selected rotation angle according to parameter 59.
59
Activation and setting of rotation angle when traversing starts.
60
Maximum lift height at which auto-rotation is permitted.
61
Activation and angle adjustment of auto-rotation 90°
66
Start speed for rotation movement before traversing starts
Auto-rotation right (traversing right/rotation coun17- 104
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Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Functional Description Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
ter clockwise) R14 supplies a voltage of 3.7–6.6 V to A5/506. A4 provides a voltage of +48 V at outputs A4/004 and A4/006 to open the direction valves Y9 and Y27. A4/016 and A4/003 supply PWM 0-24 V, relative to the voltage from R14, to proportional valves Y25 and Y26 for regulation of traversing and rotation speed.
Auto-rotation left (traversing left/rotation clockwise) R14 supplies a voltage of 3.7-0.66 V to A5/506. A4 provides a voltage of +48 V at outputs A4/017 and A4/005 to open the direction valves Y8 and Y28. A4/016 and A4/003 supply PWM 0-24 V, relative to the voltage from R14, to proportional valves Y25 and Y26 for regulation of traversing and rotation speed.
Auto-rotation with stop straight ahead, 90o Activated by parameter 61. If the hydraulic lever R14 is manoeuvred (forwards/backwards) onethird of maximum lever action, auto-rotation stops with the forks straight forward and traversing halfway. More than one-third lever action results in 180° auto-rotation. Any angle deviations are adjusted with parameter 61.
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Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
17- 105
Electrical System — 5000.1 Functional Description T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
17.2.18 Extra Hydraulic Functions (VR) When the driver manoeuvres the hydraulic levers R14/R15, a voltage (3.7–6.7 V, alternatively 3.7–0.66 V) is supplied to A5/510. The direction valve opens Y24, +48 V at output A5/703, and sends a signal to the lift controller A2. The pump motor M3 starts and pumps oil to the extra function. A4 supplies a voltage of +48 V at outputs A4/018/019 to open the direction valves Y16/Y17. NOTE If the auto-rotation function is used, only R15 can be used for extra hydraulic functions.
Description
Diode number
SELECT FORK MOVE
703
Parameters to check/adjust
17- 106
Parameter
Function
62
Pump motor speed, extra function 1
63
Pump motor speed, extra function 2
64
Pump motor torque, extra function 1
65
Pump motor torque, extra function 2
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Functional Description Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
17.2.19 Weighing • Collect load on forks. • Lift forks free from the floor. • Press the weighing button. • ---- is shown in the text window for time measurement. • Lift the load. The load’s weight will be shown in the text window at intervals of 50 kg., with a tolerance of ± 25 kg. Display automatically reverts to time measurement after 10 seconds. For calibration, see parameter 37.
17.2.20 Driver Identification Login can be performed in two different ways: Without a PIN code: • Press one of the switches I, II, or III to select driver 1 to 3 With a PIN code: • Enter a four-digit combination with the switches I, II, and III (for example, I, II, III and III to select driver 1 to 10) For programming of driver combinations, see parameters 10 and 39.
© BT Europe AB
Description
Diode number
SETUP SELECT
101
SETUP UP
102
SETUP DOWN
103
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17- 107
Electrical System — 5000.1 Parameter T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
17.3 Parameter 17.1 Parameter Settings • Connect the service key to the truck. • Press switch I at the same time as you turn the start key. • Step using II (up) and III (down) to the parameter you wish to change. • Press switch I (the display will blink). • Change the value using the switches II/III. • Press switch I to select the value (the display will stop blinking). If you want to change more parameters, step with switches II/III to the parameter you want to change and repeat from ”Press switch I (the display will blink)”. NOTE: Truck operating characteristics. Changing the truck-specific parameters changes the truck’s operating characteristics. Do not change any parameters unless you have the necessary competence.
Nr.
Parameter type
01
Steering sensitivity
02
Drive motor, max. speed in the direction of the drive wheel
03
Min./max.
Std. value
Comments
1–6
3
1 = Several wheel turns 5 = Few wheel turns 6 = No progression In steps of 1
%
10–100
100
See paragraph 7.5 In steps of 5
Drive motor, acceleration
%
10–100
100
In percent of max. acceleration In steps of 5
04
Drive motor, speed retardation
%
0–100
*
Percentage of speed retardation > 0 = no retardation In steps of 5
05
Drive motor, retardation when reversing
%
35–100
80
Percentage of max. retardation In steps of 5
06
Max. speed in the direction of the drive wheel in a narrow aisle
%
10–100
100
See paragraph 7.5 In steps of 5
17- 108
Unit
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Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Parameter Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Nr.
Parameter type
Unit
Min./max.
Std. value
Comments
07
Drive motor, max. speed in the direction of the forks
%
10–100
100
See paragraph 7.5 In steps of 5
08
Max. speed in the direction of the forks in a narrow aisle
%
10–100
100
See paragraph 7.5 In steps of 5
10
PIN code for driver selection
0000–3333
0000
0000 = PIN code not used. > 0 = PIN code used.
11
Drive motor, speed reduction
%
10–100
100
Percentage of max. speed In steps of 5
12
Reduced narrow aisle speed
%
10–100
80
Percentage of max. narrow aisle speed In steps of 5
13
Half speed
%
10–100
100
Percentage of max. half speed In steps of 5
14
Creep speed
%
10–100
100
Percentage of max. creep speed In steps of 5
15
Optipace-height in narrow aisle
%
0,5–3,0
3,0
Break point for Optipace speed 9 km/h. In steps of 0.05
16
Final speed, aisle end slowdown
0-1
0
The truck speed after completed slowdown 0 = 0 m/s 1 = 0.7 m/s
17
Lift height limitation level 1
m.
0–13.5
13.5
0 = not connected > 0 = connected In steps of 0.05
18
Lift height limitation level 2
m.
0–13.5
13.5
0 = not connected > 0 = connected In steps of 0.05 Set greater or equal to Lift height limitation 1.
19
Forks’ free lift height
m.
1.0–4.5
See table
Top side of fork to floor when inner-guide is at top. In steps of 0.01
20
Time indication
1–5
2
1 = key time (A) 2 = total movement time (b) 3 = drive motor time (c) 4 = pump motor time (d) 5 = service time (S)
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17- 109
Electrical System — 5000.1 Parameter T-code 485, 487
Valid from serial number 6004330-
Nr.
Parameter type
Unit
21
Date 2013-03-04
Order number 244989-040
Min./max.
Std. value
Comments
Battery size
1–20
12 See table.
Selection of size/type of battery, increased parameter values result in deeper discharge of battery See table.
22
Support arm brakes
0–1
0
0 = Truck without support arm brakes 1 = Truck with support arm brakes
23
Running warning, truck in motion
0–3
0
0: No warning 1 = Warning in fork-direction 2 = Warning in steering wheeldirection 3 = Warning in both directions 4: Warning in steering wheel direction outside of the narrow aisles 5: Warning in fork direction outside of the narrow aisles 6: Warning in both directions outside of the narrow aisles
24
Left foot-switch
0–1
0
0 = Activates buzzer 1 = Also cuts drive motor
25
Service interval
0–20
1
0 = No service counter In steps of 100 h.
26
Cab tilt
0/1
0
0 = No 1 = Yes
27
Lift priority
0/1
1
0 = Fork lift prioritised 1 = Fork lift not prioritised
28
Data collection
0/1
For TLS 0: Disengaged 1: Enganed
29
Max lift height
m
0–13,5
In steps of 0,05
3034
Not used
35
Bottom offset par
mm
0-500
17- 110
100 h.
Service Manual
0
In increments of 10. Earlier slow-down of the lowering movement close to the bottom position.
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Parameter Order number 244989-040
Date 2013-03-04
Nr.
Parameter type
36
Wire guidance
37
Calibration weight for weighing
38
Valid from serial number 6004330-
Unit
T-code 485, 487
Min./max.
Std. value
Comments
0–4
0
0: No wire guidance 1 = Wire guidance 2 = Not used 3 = WG learning offset mode 4 = WG learning frequency mode Parameter value > = 2 resets to 1 automatically when key is turned after initiating learning mode.
100–5000
1000
In steps of 10
Calibration of acceleration/brake pedal or forks
2
0
Set 1 or 2 for calibration See instructions
39
Driver access
1–4
1
1 = no PIN code, open 2 = no PIN code, locked 3 = PIN code, open 4 = PIN code, locked
40
Time, years
Years
0–99
In steps of 1
41
Time, days
Days
1–31
In steps of 1
42
Time, months
Months
1–12
In steps of 1
43
Type of fork apparatus
44
Action length, traversing movement
45
Action length, half pallet handling
46
kg.
0–1
0
Specify used apparatus type: 0 = Rotating fork apparatus 1 = Telescoping fork apparatus
mm
1000–2500
Set to current
Factory parameter (pre-set at factory) In steps of 2
mm
500–2500
900
Factory parameter (pre-set at factory) In steps of 2
Speed reduction, traversing movement
0–1
1
Speed reduction depending on current lift height Limit height = 5.0, 7.0 and 9.0 m 0 = Not connected 1 = Connected
47 (VR)
Pump motor speed, rotation
0-90
34
In steps of 2
48 (VR)
Pump motor speed, traversing and combined movement
0-90
46
In steps of 2
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Electrical System — 5000.1 Parameter T-code 485, 487
Valid from serial number 6004330-
Nr.
Parameter type
Unit
49 (VR SF)
Date 2013-03-04
Order number 244989-040
Min./max.
Std. value
Comments
Pump motor speed, telescopic forks
0-90
24
In steps of 2
50
Braking distance, end position traversing movement
0–4
4
Distance controlled, end position-end position In steps of 1
51 (VR)
Braking distance, end position rotation movement
0–4
4
Distance controlled, end position-end position In steps of 1
52
Not used
53 (VR)
Rotation angle symmetry, angle centring for parameter 59.
0–20
0
See instructions In steps of 1
54
Reference height free lift
mm
400–800
500
Calibration height for height measurement within free lift range In steps of 2
55
Max. speed, traversing speed
%
60–100
100
Percentage of max. speed In steps of 5
56
Not used
57
Braking ramp, traversing movement
0–4
0
Time for closing of proportional valve In steps of 1
58 (VR)
Braking ramp, rotation movement
0–4
0
Time for closing of proportional valve In steps of 1
59 (VR)
Start of traversing movement at autorotation
Deg.
0–50
0
0: Auto-rotation not connected >0: Angle at which traversing may start In steps of 2
60 (VR)
Max. permitted lift height for auto-rotation
m.
1–12
2
In steps of 1
61 (VR)
Auto-rotation to straight ahead position
0–10
0
0: Auto-rotation to middle, not connected >0 = Auto-rotation to middle, connected Select parameter value for correction of angle deviation
62 (VR)
Extra hydraulic function 1, pump motor speed
10–100
10
Max. pump motor speed extra hydraulic function, pot 1 In steps of 5
17- 112
%
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Parameter Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Nr.
Parameter type
Unit
Min./max.
Std. value
Comments
63 (VR)
Extra hydraulic function 2, pump motor speed
%
10–100
20
Max. pump motor speed extra hydraulic function, pot 2 In steps of 2
64 (VR)
Extra hydraulic function 1, pump motor torque
%
0–100
0
Max. pump motor torque, extra hydraulic function, pot 1 0 = No extra function In steps of 5
65 (VR)
Extra hydraulic function 2, pump motor torque
%
0–100
0
Max. pump motor torque, extra hydraulic function, pot 2 0 = No extra function In steps of 5
66 (VR)
Start auto rotation
0-255
50
Start speed for rotation with auto rotation In steps of 1
67
Camera switching unit
0-255
0
0: Not fitted >0: Fitted In steps of 1
6870
Not used
17.1.1 Parameter 1 The higher the number you program, the fewer turns required steering wheel to turn the drive wheel. With a value of 6, steering is non-progressive (less sensitive at higher speeds).
17.1.2 Parameter 2 With this parameter you set the maximum permitted running speed in the direction of the drive wheel outside of narrow aisles.
17.1.3 Parameter 3 The lower the number you program, the longer the truck will require to come up to maximum speed.
17.1.4 Parameter 4 With this parameter, you determine the force at which the truck will stop when you release the accelerator pedal. Note 1: Driver 1 has 20%, drivers 2–10 have 50% as std.values.
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Service Manual
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Electrical System — 5000.1 Parameter T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
17.1.5 Parameter 5 With this parameter, you determine the force at which the truck will stop when you change directions and use the drive motor to stop the truck.
17.1.6 Parameter 6 With this parameter you set the maximum permitted running speed in the direction of the drive wheel in narrow aisle mode.
17.1.7 Parameter 7 With this parameter you set the maximum permitted running speed in the direction of the forks, outside of narrow aisles.
17.1.8 Parameter 8 With this parameter you set the maximum permitted running speed in the direction of the forks in narrow aisle mode.
17.1.9 Parameter 10 Value 0000 means that three drivers are chosen. The table below shows the combinations for the first six PIN codes. These values are attained by stepping up and down with the switches I and II.
Value
Driver number
0000
No PIN code with max. three drivers
1111
First PIN code with max. 10 drivers
1112
Second PIN code with max. 10 drivers
1113
Third PIN code with max. 10 drivers
1121
Fourth PIN code with max. 10 drivers
1122
Fifth PIN code with max. 10 drivers
1123
Sixth PIN code with max. 10 drivers
etc.
etc.
17.1.10 Parameter 11 With this parameter, you set the maximum permitted running speed when input 206 is activated.
17.1.11 Parameter 12 With this parameter, you set the maximum permitted running speed in narrow aisle mode when input 206 is activated.
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Electrical System — 5000.1 Parameter Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
17.1.12 Parameter 13 With this parameter, you set the maximum permitted running speed in the half speed range.
17.1.13 Parameter 14 With this parameter, you set the maximum permitted running speed in the creep speed range.
17.1.14 Parameter 15 With this parameter, you set the lift height at which running speed begins to decrease as determined by the truck’s OPTIPACE system.
17.1.15 Parameter 16 Using this parameter you set the truck's running speed after the completed aisle-end slowdown.
17.1.16 Parameters 17 and 18 If the truck is equipped with height measurement, these parameters can be set to two different maximum lift heights. Max. height 2 must be equal to or greater than max. height 1. The height activated last is normally used as the maximum height before the mast top is reached.
17.1.17 Parameter 19
© BT Europe AB
Lift height
Basic settings, free lift height
4300
1.57
4900
1.77
5500
1.97
6100
2.17
7000
2.605
7600
2.805
8200
3.005
8800
3.205
9400
3.54
10000
3.74
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Electrical System — 5000.1 Parameter T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
17.1.18 Parameter 20 With this parameter you specify the time (A-d or S) that will be displayed when the driver uses the truck.
17.1.19 Parameter 21 This parameter specifies the truck’s battery type. You may also compensate for different driving styles. To set the battery monitor’s break point: 1. Check acid density for fully charged battery (to determine battery quality). 2. Check density when the battery indicator shows 80% discharge (min. acid level is 1.14). The acid density can vary with the battery type.
Value
Function
Battery (Ah)
Less discharge
900 730, 700, 580 CSM 600
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
More discharge
480, 450 360
WARNING Parameter must be properly set. Battery can be destroyed. If the parameters are set to values higher than those recommended, battery discharge will be excessive and the battery destroyed.
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Electrical System — 5000.1 Parameter Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
17.1.20 Parameter 22 This parameter activates the function and control of the braking coils.
17.1.21 Parameter 23 When the parameter is set to >0, the warning signal for truck in motion is activated. 1. Warning signal sounds when the truck moves in the steering wheel-direction only. 2. Warning signal sounds when the truck moves in the fork-direction only. 3. Warning signal sounds for motion in both directions. 4. Only the waring signal when the truck travels in the steering wheel direction outside of the narrow aisle. 5. Only the waring signal when the truck travels in the fork direction outside of the narrow aisle. 6. Warning signal sounds for travel in both directions outside narrow aisles.
17.1.22 Parameter 24 If you set the parameter to 1, you will be able to stop the truck with the drive motor but not be able to drive it again if the safety pedal is not depressed.
17.1.23 Parameter 25 With this parameter, you specify the truck’s service interval. The buzzer sounds and “C029” is shown on the display when the service counter is at zero. The counter will show the time that has passed since the truck was last serviced. If the previous service time will be used, the parameter is activated only; the time is not changed.
17.1.24 Parameter 26 When you set the parameter to 1, you activate the function and control of valves for cab tilt on trucks with cold storage cabs.
17.1.25 Parameter 27 When you set the parameter to 1, you cancel the lift function’s priority, meaning that the hydraulic function you are currently using will continue, regardless of if you activate lift.
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Electrical System — 5000.1 Parameter T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
17.1.26 Parameter 28 This parameter is used to engage the data collection function for TLS
17.1.27 Parameter 29 Electric stop at max lifting height.
17.1.28 Parameter 35 The Parameter has been introduced to enable earlier slow-down of the lowering movement close to the bottom position. To prevent “phantom movement”, a delay has been introduced prior to the subsequent hydraulic movement following lifting or lowering, and to prevent false alarms, increased filtering of the signal received from the steering wheel has been introduced.
17.1.29 Parameter 36 When you set the parameter to 1, you activate the function and control for wire guidance. - Parameter value two has no function. - Set the parameter value to 3 to program the truck’s offset mode. - Set the parameter value to 4 to program the truck for the loop’s frequency. This parameter automatically resets to 1, wire guidance active, after programming.
17.1.30 Parameter 37 • Set the parameter to the weight with which the truck will be calibrated. • Terminate programming in the normal way. • Press the weighing switch at the same time as you turn the start key. “0000” will be displayed in the time window. • Lift the unloaded forks in the free lift range until the set parameter weight is shown in the time window. • Use the forks to lift the calibration weight approximately 100 mm. • Press the weighing switch and lift until time measurement is again shown in the window. Weighing is now calibrated.
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Electrical System — 5000.1 Parameter Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
17.1.31 Parameter 38 This parameter automatically resets to 0 after calibration.
Calibration of acceleration and braking potentiometers • Set the parameter to 1. • Turn the key on and off once. The acceleration and braking potentiometers will now be calibrated. NOTE Calibration error. Incorrect calibration value. Do not move the lever when calibration begins.
Calibration of fork movement (VR) Fork rotation • Rotate forks to end position. • Set the parameter to 2. • Turn the key on and off once. • Rotate 180° to the other end position. Note that movement accelerates slowly at first, but that speed gradually increases. Rotation speed is reduced before the end position. • Press switch I after the forks have stopped. NOTE If the lever for traversing is moved during rotation calibration, the proportional valves for traversing must be calibrated.
Proportional valves, traversing • Run the fork apparatus out to one of the end positions. • Set the parameter to 2. • Move the lever to its extreme position to traverse the fork apparatus to the other end position. Movement begins at creep speed but accelerates to full speed. Movement slows again to creep speed. Continues at creep speed to the end position. • Press switch I after the traversing movement has stopped.
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Electrical System — 5000.1 Parameter T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
17.1.32 Parameter 39 Set the parameter to 1 or 2 if only three drivers/truck profiles will be programmed. If up to ten drivers/truck profiles will be programmed, set the value to 3 or 4. With up to ten drivers, the value must be programmed for each driver. See parameter 10.
Show/programming choices with parameter 39. Parameter
Key S17 switched on, then switch I
Switch I and key S17 switched on simultaneously
P39-
Clock
Parameter
Driver
Clock
Parameter
Drivers
-1 U. CAN -1 M. CAN -2 U. CAN -2 M. CAN -3 U. CAN -3 M. CAN -4 U. CAN -4 M. CAN
Reprgm.
See See
Selected reprgm. All reprgm.
Reprgm.
See
Reprgm.
See
Reprgm.
See
Reprgm.
See
Reprgm.
See
Reprgm.
See
Not reprgm. Not reprgm. Not reprgm. Not reprgm. Not reprgm. Not reprgm. Not reprgm. Not reprgm.
Reprgm.
Reprgm.
See selected See selected See selected See selected See selected See selected See selected See selected
Reprgm. Not reprgm. Reprgm. Reprgm. Reprgm. Not reprgm. Reprgm.
See selected All reprgm. Selected reprgm. All reprgm. See selected All reprgm.
17.1.33 Parameters 40 to 42 With these parameters, you can set the year, day and month for error code logging.
17.1.34 Parameter 43 Factory parameter dependent on fork apparatus type. NOTE Do not change.
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Electrical System — 5000.1 Parameter Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
17.1.35 Parameter 44 This parameter limits travel of traversing movement for the fork apparatus. The parameter controls the travel-dependent braking at the end positions. See parameter 50. Factory parameter set to appropriate travel of fork apparatus. NOTE If the fork apparatus is exchanged for another with a different travel length, the parameter value must be adjusted.
17.1.36 Parameter 45 This parameter adjusts the travel length for handling half pallets. Factory parameter set to half travel length based on the total travel length for the fork apparatus. NOTE If the fork apparatus is exchanged for another with a different travel length, the parameter value must be adjusted.
17.1.37 Parameter 46 With this parameter, you can choose if the traversing speed of the forks will be reduced at pre-determined lift heights (at five, seven and nine meter lift heights). Appropriate when handling high or fragile loads at high heights.
17.1.38 Parameter 47 (VR) With this parameter you can adjust the pump motor’s speed with fork rotation. Higher parameter values give a higher pump motor speed.
17.1.39 Parameter 48 (VR) With this parameter you can adjust the pump motor’s speed for the traversing movement and with combined fork movement. Higher parameter values give a higher pump motor speed.
17.1.40 Parameter 49 (VR SF) With this parameter you can adjust the pump motor’s speed for the traversing movement. Higher parameter values give a higher pump motor speed.
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Electrical System — 5000.1 Parameter T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
17.1.41 Parameter 50 With this parameter, you can adjust the distance between the end position and the braking point or centre point for traversing movement. The lower the parameter value, the longer the braking distance.
17.1.42 Parameter 51 (VR) With this parameter, you can adjust the distance between the end position and the braking point for rotation movement. The lower the parameter value, the longer the braking distance. See parameter 58.
17.1.43 Parameter 53 (VR) Use this parameter to calibrate the rotation symmetry angle, right and left positions, selected in parameter 59. Procedure: - Forks parked in the home position, traversing in left home position. - Parameter 59 set to 20°. - Start auto-rotation, checking the rotation angle when traversing begins. - Run the apparatus to the right home position. - Start auto-rotation, checking the rotation angle when traversing begins. - If the start angle for the left position is less than that for the right position, reduce the parameter value. If the opposite is true, increase the parameter value. - Adjust the parameter value until the start angles are the same.
17.1.44 Parameter 54 The parameter is used to calibrate the position for the free lift reference switch, S93. Lift the fork apparatus to the point where the reference switch is centred on the magnet. Measure the forks’ height from the floor, measuring from the upper edge of the forks. Set the height measurement as the parameter value.
17.1.45 Parameter 55 With this parameter, you set the maximum permitted traversing speed.
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Electrical System — 5000.1 Parameter Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
17.1.46 Parameter 56 (VR) With this parameter, you set the maximum permitted rotation speed.
17.1.47 Parameter 57 With this parameter, you set the ramp/time for braking the traversing movement when stopping in the middle of the movement or when changing the direction of movement. With lower parameter values the braking time is shorter and braking more abrupt.
17.1.48 Parameter 58 (VR) With this parameter, you set the ramp/time for closing of the rotation movement’s proportional valve. With lower parameter values, braking time is shorter and braking more abrupt. If the braking time is set so that it is shorter than the braking distance, parameter 51, rotation is at creep speed to the end position.
17.1.49 Parameter 59 (VR) With this parameter, you set the rotation angle at which traversing movement may start for auto-rotation.
17.1.50 Parameter 60 (VR) With this parameter, you set the maximum lift height at which auto-rotation is permitted.
17.1.51 Parameter 61 (VR) With this parameter, you activate or deactivate the auto-rotation function to the straight ahead position. Parameter value >0. Select a parameter value to adjust the angle deviation from 90o rotation. - Select a value for the parameter (5 is an appropriate start value). - Run the function from the left home position, fork tips to the left. - Check the forks’ deviation from 90°. - Increase the parameter value if the forks rotate more than 90°, reduce the value if rotation is less. - Test-run the function. - Repeat the procedure until a rotation angle of 90° is attained.
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Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
17.1.52 Parameter 62 (VR) With this parameter, you choose the pump motor speed for the first extra hydraulic function.
17.1.53 Parameter 63 (VR) With this parameter, you choose the pump motor speed for the second extra hydraulic function.
17.1.54 Parameter 64 (VR) With this parameter, you choose the pump motor torque for the first extra hydraulic function.
17.1.55 Parameter 65 (VR) With this parameter, you choose the pump motor torque for the second extra hydraulic function.
17.1.56 Parameter 66 (VR) With this parameter the start speed for the rotation movement can be adjusted with engaged auto rotation function. Higher parameter values give a higher rotation speed up until the start of the traversing movement.
17.1.57 Parameter 67 This parameter is used for the connection of the mounted camera switching unit.
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Electrical System — 5000.1 Instrument Panel and Display Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
17.2 Instrument Panel and Display 17.2.1 Show The show function allows you to view the driver/machine-specific registers, but does not permit reprogramming of the registers. The clock, however, may be programmed. To program the driver/truck parameters, see the chapter ”Parameter Settings”. To view the register: • Turn the start key so that voltage is supplied to the electronics card. • Specify the driver number using the switches I–III. • Press and hold switch I until the clock begins to blink (approximately five seconds). • Press switch I again to step up to the next function. The text window will display the various functions: • Time of day (C) • Warning codes and Error codes (D). • Parameters (D). • Operating time and service time (D). • Status inputs/outputs A4. For the functions “Warning codes and error codes” and “Parameters”, the address register number is shown to the left and the value to the right. .
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Electrical System — 5000.1 Instrument Panel and Display T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
17.2.2 Operating Time When the time measurement setting is displayed, text box (E) lights. Time is presented as set out below:
Character
Time Key time
Total movement time
Drive motor time Pump motor time
Service time
17.2.3 Programming Clock When the clock is in programming mode, the text widow for hours blinks, and after pressing switch I, the window for minutes blinks. • Make changes by stepping up with switch II and down with III. • Store the programmed values and show function by pressing I.
Function
Value
Hours
09 = 9 hours
Minutes
35 = 35 minutes
When error codes are shown in the text window (D), text box (G) lights. When parameters are presented in text window (D), text box (I) lights. Parameters, however, cannot be reprogrammed in this mode. To make changes, see the chapter “Parameter Settings”. Terminate programming by turning the start key off and on. Programming is terminated automatically if no buttons are pressed for 20 seconds. NOTE Truck operating characteristics. Changing the truck-specific parameters changes the truck’s operating characteristics. Do not change any parameters unless you have the necessary com17- 126
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Electrical System — 5000.1 Instrument Panel and Display Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
petence.
Driver parameters (1–7) To reprogram driver parameters (when permitted): • Turn the start key so that voltage is supplied to the electronics card. • Specify the applicable driver number with the switches (I-III). • Turn the start key so that voltage is cut to the electronics card. • Press switch I at the same time as you turn the start key. The driver number will be shown in the text box (E). • Step using switch II (up) and switch III (down) to the parameter you want to change. • Press switch I (the parameter number will blink). • Change the value using switches II and III. • Press the switch I to select the value (the parameter number will stop blinking). If you want to change more parameters, step with switches II and III to the parameter you want to change and repeat from ”Press switch I (the parameter number will blink)”. Terminate programming by turning the start key off and on. The common truck parameters can only be reprogrammed using a service key. See the chapter “Parameter Settings”.
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Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
17.3 Codes 17.3.1 Warning Codes Character
Error Warning
When an error occurs, a buzzer sounds and a code is displayed for 10 seconds at the right side of the text window (D). The error is also displayed in the text box (G). If the error is still present after one minute, the buzzer will sound again for two seconds. This will be repeated until the error is corrected, as described in the following table. The truck, however, is fully operational. WARNING Ignoring error indication jeopardises truck safety. Always check truck functions before operation.
17.3.2 Error mode
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Error mode
Explanations/corrective actions
Start error
Driving and hydraulic functions inoperable
Critical error
Steering safety relay falls Main contactor opens Parking brakes activated
General error
Current function stops
Height error
Fork lift at low speed
Emergency switch on
Main contactor opens Parking brakes activated
Steering error
Steering safety relay falls Drive motor reverses to stop
Drive regulator error
Main contactor opens Lift regulator error Steering enabled Parking brake activated at braking
Lift regulator error
Hydraulics stop Valves closed
Loop steering error
Emergency braking
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Warning signals for warning codes 11–99 are at 2 Hz. Warning signals for error codes 100– are at 4 Hz.
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Electrical System — 5000.1 Codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
17.3.3 Safety Logic This applies to the following functions: X = Corrective action -- = Function disabled
Action: Function:
K10 open
Y1 activated
Reversing with M1
Emergency switch
X
X
--
Key
X
X
--
X
X
X
Steering error Error at A1
X
Steering disabled
--
--
--
--
Error at A2
Error at A5
Function at A2 halted
X (and el. valves off) X
X
--
X
--
17.3.4 Warning Codes without Registration Code
11
Description
Overheating of cooling flange on electronics card
Error mode
Maximum current to steering motor reduced
Error cause
Binding steering/gear Binding steering bearings Defective steering motor Defective electronic card A5
Comments
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Cool and check motor/gear
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
12
Description
Fault in the steering measurement has been detected
Error mode
No corrective action
Error cause
The steering angle pulse sensor has missed pulses Pulse sensor adjusted incorrectly Sensor affected by external disturbances
Comments
Reset when the steering reference sensor passes
Steering angle sensor, S66
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Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
13
Description
No/too few pulses from the height measurement sensor at fork lift or fork lower
Error mode
No corrective action
Error cause
Defective reference switch Defective sensor/wiring Incorrect hydraulic oil quality Defective electronic card A4 Defective electronic card A5
Comments
Actual lifting height is set to 13 m Max. running speed, creep speed
Height sensor U9/U10 and reference sensor S93
1. Check whether +15 V is received on A4 input 013, when S93 is closed. If not, inspect S93 and its cabling. 2. Check whether the LD301 and LD302 LEDs, on A5, blink when the forks are lifted and lowered. The blinking pattern is irregular because the pulses are 90 degrees out of phase. If this is OK, proceed to step 3. a: If LD301 and LD302 remain extinguished, check whether U10 receives a +15 V voltage feed. The red cable is plus and the black cable is 0 V. If no voltage is applied, check that the cables are intact and that the contact pins in the X15 and X17 terminals 17- 132
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Electrical System — 5000.1 Codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
b: c:
d: e:
f:
g:
T-code 485, 487
are not loose or oxidized. If the blinking pattern is sporadic, check whether the wire slips on the height sensor roller. If the mechanical system is working correctly, then check to make sure the cables from U10, i.e. the white cable 98 to input 301 and the blue cable 99 to input 302, are intact. Check whether the contact pins in the X17 and X15 terminals are loose or oxidized. If the cables and terminals are intact, replace the U10 height sensor. Inspect whether pulses are received by measuring the inputs A4/ 011 and 012 when the forks are lifted and lowered (approx. 15 V). If this is OK, proceed to step 4. If inputs A4/011 and 012 remain at 0 V all the time, check whether U9 receives a +15 V voltage feed. The red cable is plus and the black cable is 0 V. If no voltage is applied, check that the cables are intact and that the contact pins in the X49, X16 and X14 terminals are not loose or oxidized. If the cables and terminals are intact, replace the U9 height sensor.
3. If the oil is too thick (refers to standard oil in a truck with cold-store specifications), especially fork lowering will be too slow. 4. If nothing else rectifies the problem, then replace the A4 electronic card.
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Electrical System — 5000.1 Codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
14
Description
Seat switch closed more than 20 minutes without moving the truck
Error mode
No corrective action
Error cause
Bypassed switch Defective switch/wiring Defective electronic card A5
Comments
Seat switch S89
1. If the LD203 LED lights continuously. - Check whether the seat switch has been strapped. - Disconnect cable 49 at switch S89, connection 3. If LD203 goes out, then verify correct functioning of S89. 2. If LD203 does not go out, then inspect the cable by disconnecting it at terminal 203. 3. If LD203 does not go out, then replace the A5 electronic card.
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Electrical System — 5000.1 Codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
15
Description
Safety switch affected more than 20 minutes without moving the truck
Error mode
No corrective action
Error cause
Bypassed switch Defective switch/wiring Defective electronic card A5
Comments
Safety switch (left foot switch), S23
1. If the LD110 LED lights continuously. - Check whether the safety switch has been strapped. - Disconnect cable 43 at switch S23, connection 3. If LD110 goes out, then verify correct functioning of S23. 2. If LD110 does not go out, then inspect the cable by disconnecting it at terminal 110. 3. If LD110 does not go out, then replace the A5 electronic card.
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Electrical System — 5000.1 Codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
16
Description
Voltage from accelerator pedal’s potentiometer R1 is outside of calibrated value at start (+/-0.2 V).
Error mode
Start error
Error cause
Depressed pedal at start Defective potentiometer/bracket/wiring Calibration error. Defective electronic card A5
Comments
Manoeuvre to neutral position
Speed control, R1
1. Check to make sure that the speed control is not stuck in the depressed position. 2. Check to make sure that R1 is correctly seated in its mount. Check whether the contact pins in the terminal are loose or oxidized. The voltage on input 501 should be 3.7 +/- 0.2 VDC when the mechanical installation of R1 is correct. 3. Speed control calibration. Verify that both the speed control and brake control as well as the hydraulic operation joysticks are set to the neutral positions. (Position with no actuation). - Connect the service key to the truck. - Depress the switch I while turning the start key. - Use switch II to advance the display indication to parameter 38. - Depress the switch I. The display blinks. - Change the value to 1 using switches II/III. - Depress switch I to enter the value. The display stops blinking. - Use the key switch to switch the power off and then on again. 17- 136
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Electrical System — 5000.1 Codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
- The speed and brake potentiometers as well as the hydraulic operation joystick potentiometers are then calibrated. - Retract the reach carriage to the inner stop, i.e. the battery wall. - Extend the reach carriage to the outer stop. The reach carriage travel distance has now been calibrated. 4. If input 501 receives the correct voltage and the calibration does not rectify the problem, then replace the A5 electronic card.
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Electrical System — 5000.1 Codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
17
Description
Voltage from brake pedal potentiometer R2 is outside of calibrated value at start (+/-0.2 V).
Error mode
Start error
Error cause
Depressed pedal at start Defective potentiometer/bracket/wiring Calibration error. Defective electronic card A5
Comments
Manoeuvre to neutral position
Brake control, R2
1. Check to make sure that the brake pedal is not stuck in the depressed position. 2. Check to make sure that R2 is correctly seated in its mount. Check whether the contact pins in the terminal are loose or oxidized. The voltage on input 502 should be 1.7 +/- 0.2 VDC when the mechanical installation of R2 is correct.
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Electrical System — 5000.1 Codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
3. Brake control calibration. Verify that both the speed control and brake control as well as the hydraulic operation joysticks are set to the neutral positions. (Position with no actuation). - Connect the service key to the truck. - Depress switch I while turning the start key. - Use switch II to advance the display indication to parameter 38. - Depress the switch I. The display blinks. - Change the value to 1 using switches II/III. - Depress switch I to enter the value. The display stops blinking. - Use the key switch to switch the power off and then on again. - The speed and brake potentiometers as well as the hydraulic operation joystick potentiometers are then calibrated. - Retract the reach carriage to the inner stop, i.e. the battery wall. - Extend the reach carriage to the outer stop. The reach carriage travel distance has now been calibrated. 4. If input 502 receives the correct voltage and the calibration does not rectify the problem, then replace the A5 electronic card.
Code
18
Description
Battery voltage for electronics card A5 too low
Error mode
Internal clock stops
Error cause
Battery voltage too low
Comments
Code
19
Description
Previously programmed values missing
Error mode
Standard values have been loaded
Error cause
Displaced A5 electronics card
Comments
Program A5 card
1. See the section 11 "Parameter settings" in this manual.
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Electrical System — 5000.1 Codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
21
Description
Potentiometer R6 for fork lift/lower supplies incorrect voltage when key turned on (+/-0.6 V).
Error mode
Start error
Error cause
Joystick not in neutral position at start Defective potentiometer/bracket/wiring Defective electronic card A5
Comments
Manoeuvre to neutral position
Fork controls, joystick R6
1. Check to make sure that the fork operation joystick is not stuck in an actuated position. 2. Check to make sure that R6 is correctly seated in its mount. Check whether the contact pins in terminal X11 are loose or oxidized. The voltage on input 503 should be 3.7 +/- 0.6 VDC when R6 is correctly adjusted. 3. Fork control calibration. - Make sure that the joystick is not actuated and that it is in the neutral position. - Use the key switch to switch the power off and then on again. The joystick is then calibrated. 4. If input 503 receives the correct voltage and the calibration does not rectify the problem, then replace the A5 electronic card.
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Electrical System — 5000.1 Codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
22
Description
Potentiometer R4 for traversing movement supplies incorrect voltage when key turned on (+/-0.6 V).
Error mode
Start error
Error cause
Joystick not in neutral position at start Defective potentiometer/bracket/wiring Defective electronic card A5
Comments
Traversing, joystick R4
1. Check to make sure that the traversing operation joystick is not stuck in an actuated position. 2. Check to make sure that R4 is correctly seated in its mount. Check whether the contact pins in terminal X11 are loose or oxidized. The voltage on input 504 should be 3.7 +/- 0.6 VDC when R4 is correctly adjusted. 3. Traversing control calibration. - Make sure that the joystick is not actuated and that it is in the neutral position. - Use the key switch to switch the power off and then on again. The joystick is then calibrated. 4. If input 504 receives the correct voltage and the calibration does not rectify the problem, then replace the A5 electronic card.
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Electrical System — 5000.1 Codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
23 (VR only)
Description
Potentiometer R5 for rotation movement supplies incorrect voltage when key turned on. (+/-0.6V)
Error mode
Start error
Error cause
1. Joystick not in neutral position at start 2. Defective potentiometer/bracket/wiring 3. Defective electronic card A5
Comments
Mast rotation control, joystick R5
1. Check to make sure that the fork rotation operation joystick is not stuck in an actuated position. 2. Check to make sure that R5 is correctly seated in its mount. Check whether the contact pins in terminal X11 are loose or oxidized. The voltage on input 505 should be 3.7 +/- 0.6 VDC when R12 is correctly adjusted. 3. Rotation control calibration. - Make sure that the joystick is not actuated and that it is in the neutral position. - Use the key switch to switch the power off and then on again. The joystick is then calibrated. 4. If input 505 receives the correct voltage and the calibration does not rectify the problem, then replace the A5 electronic card.
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Electrical System — 5000.1 Codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
24 (VR only)
Description
Potentiometer R14 or R15 for extra function “autorotation” and “2” supplies incorrect voltage when key turned on. (+/-0.6V)
Error mode
Start error
Error cause
1. Joystick not in neutral position at start 2. Defective potentiometer/bracket/wiring 3. Calibration error 4. Defective electronic card A5
Comments
Manoeuvre to neutral position
Auxiliary hydraulic function, joysticks R14 and R15
1. Check to make sure that both joysticks for the auxiliary hydraulic function are not stuck in an actuated position. 2. Check to make sure that R14 and R15 are correctly seated in their mounts. Check whether the contact pins in terminal X11 are loose or oxidized. The voltage on inputs 506 and 510 should be 3.7 +/- 0.6 VDC when R14 and R15 are correctly adjusted.
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Electrical System — 5000.1 Codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
3. Calibration of the extra hydraulic function controls. - Make sure that neither of the two joysticks are actuated and that both are in the neutral position. - Use the key switch to switch the power off and then on again. The joysticks are then calibrated. 4. If inputs 506 and 510 receive the correct voltage and the calibration does not rectify the problem, then replace the A5 electronic card.
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Electrical System — 5000.1 Codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
25
Description
Output stage errors
Error mode
General error
Error cause
See codes 50-62 for more information
Comments 1. Proceed as follows to look up warning codes and recorded information in the registers: - Turn the start key to power up the electronic card. - Using the pushbuttons I-II, input the driver ID number. - Now, keep switch I depressed until the clock starts blinking (after approx. 5 seconds). - Depress switch I once more to advance to the next function. The display then displays the available functions: • Time of day (C). • Warning codes and Error codes (D). • Parameters (D). • Operating hours and time for service (D). In case of "Warning codes/Error codes" and "Parameters", the address register number is displayed on the left side and the recorded value on the right side.
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Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
26
Description
Output stage errors
Error mode
General error
Error cause
See codes 90-94 for more information
Comments 1. Proceed as follows to look up warning codes and recorded information in the registers: - Turn the start key to power up the electronic card. - Using the pushbuttons I-III, input the driver ID number. - Now, keep switch Idepressed until the clock starts blinking (after approx. 5 seconds). - Depress switch Ionce more to advance to the next function. The display then displays the available functions: • Time of day (C). • Warning codes and Error codes (D). • Parameters (D). • Operating hours and time for service (D). In case of "Warning codes/Error codes" and "Parameters", the address register number is displayed on the left side and the recorded value on the right side.
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Electrical System — 5000.1 Codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
27
Description
Defective battery feed.
Error mode
Battery display blinks
Error cause
Poor contact at battery feed cables Defective electronic card A5 Defective battery
Comments
Measuring the battery
1. Inspect the voltage feed (+48 VDC) to the battery indicator. Cable 70 feeds plus to terminal 601, while cable 71 feeds minus to terminal 602. 2. Check to make sure that cable 72 and its contact pins provide good contact from the shunt to terminal 603. Also make sure that cable 71 has good contact with the shunt. 3. If no errors are detected in steps 1 and 2, try installing a new A5 electronic card. 4. Please contact the battery manufacturer for instructions on testing the battery.
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Electrical System — 5000.1 Codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Code
28
Description
Emergency switch is activated
Error mode
Emergency switch on
Error cause
Driver action
Order number 244989-040
Defective switch/wiring Defective electronic card A5 Comments
Reset S21 and turn S17 on/off
Emergency stop switch, S21
1. Check to make sure that S21 is not actuated. 2. If LED 809 does not light, the circuit is interrupted. If LED 809 lights, the error code may be caused by poor contact in the circuit. Inspect cable 22 by disconnecting it at terminal 809 and measure the ohm resistance at terminal 2 on S21. Also make sure the contact pins are not loose or oxidized. If the cable is intact, then continue to measure ohm resistance through S21 to terminal 1. The circuit should not be interrupted when S21 is not depressed. If everything is OK, then check whether the connection between S17 and S21 is intact. 3. If S21 and its cables are OK, replace the A5 electronic card.
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Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
29
Description
Service time (S) is zero
Error mode
No corrective action
Error cause Comments
Reset with parameter
1) Resetting of parameter 25: - - Connect the service key to the truck. - - Press switch I at the same time as you turn the start key. - - Step up using II until parameter 25 is reached. - - Press switch I (the display will blink). - - To verify the previous value, press the switch only one more time. - - To change the value, press switches II/III. Set the new value by pressing switch I. - - Once the desired value has been set, the display stops blinking. - The recommended service interval is 500.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
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Electrical System — 5000.1 Codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
31
Description
Phase fault, pulse counter for traversing movement
Error mode
No corrective action
Error cause
Wiring fault Sensor fault Defective electronic card A4
Comments
Creep speed only permitted for fork movement
Pulse transducer, U13
1. Inspect whether pulses are received by measuring the inputs A4/ 008 and 009 when the forks are lifted and lowered (approx. 15 V). If this is OK, proceed to step 2. a.) If inputs A4/008 and 009 remain at 0 V all the time, check whether U13 receives a +15 V voltage feed. The red cable is plus and the black cable is 0 V. If no voltage is applied, check that the cables are intact and that the contact pins in the X49, X16 and X14 terminals are not loose or oxidize. 2. If the cables and terminals are intact, replace the height sensor U13. 3. If nothing else rectifies the problem, then replace the A4 electronic card.
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Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
33
Description
Previously programmed values missing
Error mode
Standard values been loaded
Error cause
Displaced A4 electronics card
Comments
Program A4 card, creep speed only permitted for fork movement
Code
34
Description
Output stage error
Error mode
General error
Error cause
See codes 63-81 for more information
Comments 1. Proceed as follows to look up warning codes and recorded information in the registers (code 63-81): - Turn the start key to power up the electronic card. - Using the pushbuttons I-III, input the driver ID number. - Now, keep switch I depressed until the clock starts blinking (after approx. 5 seconds). - Depress switch I once more to advance to the next function. The display then displays the available functions: • Time of day (C). • Warning codes and Error codes (D). • Parameters (D). • Operating hours and time for service (D). In case of "Warning codes/Error codes" and "Parameters", the address register number is displayed on the left side and the recorded value on the right side.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
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Electrical System — 5000.1 Codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
35
Description
Defective signal from one of the doubled aisle sensors
Error mode
No measure
Error cause
One of the sensors is in the wrong position.
Comments
Check LED 106/107 on A5 to determine which input has the faulty signal. Reset the aisle sensors by running a magnet past the sensor.
Aisle indication switches S5, S6, S7 and S8
1. Observe LED 106/107 on A5 to determine which aisle provides an incorrect signal. Reset the aisle transmitters by sweeping a magnet across the transmitters. 2. If the error remains, inspect the cabling from the transmitters. If the cabling is intact, replace the transmitter.
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Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
36
Description
Learning of wire guidance has failed
Error mode
No measure
Error cause Comments
Carry out “learn” wire guidance again
Code
37
Description
Wire guidance limit value exceeded
Error mode
General error
Error cause
The truck has drifted over the set limits for angle and side signals
Comments
Speed reduced to 4.0 km/h. The warning code disappears when the truck is within the limit valies again
Code
38
Description
Wire guidance requested, but wire guidance parameters not set
Error mode
No measure
Error cause
Parameter 36 is not set for activation of wire guidance
Comments
Code
39
Description
The inputs for personal safety system have been dead for more than 20 s. Inputs 202 and 207
Error mode
Critical error
Error cause
Cable breakage Defective personal safety system
© BT Europe AB
Comments
The emergency brakes are applied on the truck
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
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Electrical System — 5000.1 Codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
40
Description
Warning temperature for drive motor
Error mode
Maximum current reduced
Error cause
Overheated drive motor Defective temperature sensor/wiring Fault frequency converter Defective electronic card A5
Comments
Temperature sensor B1 in the drive motor M1
1. Check whether the ventilation is OK, especially the M10 fan in the motor compartment. 2. Inspect B1. - Disconnect the cable at the terminal. Measure the ohm resistance at B1, which should be approx. 570 ohms at 20oC. - Check whether cable 11 is intact between B1 and terminal 4 on A1. - Check whether cable 14 is intact between B1 and terminal 7 on A1. - Check to make sure that the contact pins in the connectors are not loose or oxidized. 3. If B1 and its cabling are OK, replace A1.
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Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
41
Description
Warning temperature in drive motor’s frequency inverter
Error mode
Maximum current reduced
Error cause
Overheated frequency inverter Defective fan Defective temperature sensor/wiring Fault frequency converter Defective electronic card A5
Comments 1. Check to make sure that the ventilation is OK. 2. Inspect the M12 fan next to the controllers. 3. If the ventilation is OK, replace A1.
Code
42
Description
Current calibration error in drive motor’s frequency inverter
Error mode
No corrective action
Error cause
Faulty frequency inverter
Comments 1. Replace the traction controller, A1.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
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Electrical System — 5000.1 Codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
43
Description
Incorrect number of pulses from the drive motor's pulse transducer bearing
Error mode
General error
Error cause
Defective sensor/wiring
Comments
Fault frequency converter
Drive motor pulse transducer layer, U11
1. Inspect the cabling to U11. - Disconnect terminals 3 and 4 on A1 and cables 10 and 11. - Check to make sure that cable 10 is intact all the way to the connection at A12. Measure the ohm resistance at A12, which should be 100 ohms. Inspect cable 105 between A12 and U11. - Check to make sure that cable 11 is intact all the way to the connection at U11. - Check whether cable 12 is intact between U11 and terminal 5 on A1. - Check whether cable 13 is intact between U11 and terminal 6 on A1. - If the cables are intact, replace the transducer layer U11. 2. If the error remains, replace A1
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Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
45
Description
Warning temperature for lift motor
Error mode
Maximum current reduced
Error cause
Overheated lift motor Defective temperature sensor/wiring Fault frequency converter Defective electronic card A5
Comments
Temperature sensor B2 in the pump motor M3
1. Check whether the ventilation is OK, especially the M10 fan in the motor compartment. 2. Inspect B2. - Disconnect terminals 4, 7 and 8 on A2. Measure the ohm resistance at B2 between cables 16 and 19. The resistance should be approx. 570 ohms at 20oC. - Check whether cable 16 is intact between X12 and terminal 4 on A1. 3. If B2 and its cables are OK, replace A2.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
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Electrical System — 5000.1 Codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
46
Description
Warning temperature in pump motor’s frequency inverter
Error mode
Maximum current reduced
Error cause
Overheated frequency inverter Defective fan Defective temperature sensor/wiring Fault frequency converter Defective electronic card A5
Comments 1. Check to make sure that the ventilation is OK. 2. Inspect the M12 fan next to the motor controllers. 3. If the ventilation is OK, replace A2.
Code
47
Description
Current calibration error in pump motor’s frequency inverter
Error mode
No corrective action
Error cause
Faulty frequency inverter
Comments 1. Replace the A2 lift controller.
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Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
48
Description
Incorrect number of pulses from the pump motor's pulse transducer bearing
Error mode
General error
Error cause
Defective sensor/wiring
Comments
Fault frequency converter
Pump motor pulse transducer layer, U12
1. Inspect the cabling to U12. - Disconnect terminals 3 and 4 on A2 and cables 15 and 16. - Check to make sure that cable 16 is intact all the way to the connection at A13. Measure the ohm resistance at A13, which should be 100 ohms. Inspect cable 155 between A13 and U12. - Check to make sure that cable 16 is intact all the way to the connection at U12. Check whether cable 17 is intact between U12 and terminal 5 on A2. - Check whether cable 18 is intact between U12 and terminal 6 on A2. - If the cables are intact, replace the U12 transducer layer. 2. If the error remains, replace A2.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
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Electrical System — 5000.1 Codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
17.3.5 Warning Codes with Registration When a warning code is registered, it is displayed automatically. Registration is at the first of the 50 possible locations and moves previous errors one step down. Warning codes 50–62 are for wire breaks and short circuits to the valves and support arm brakes. Warning codes 90-94 are for wire breaks and short circuits to the valves and support arm brakes. Applicable functions only are disabled; other function are unaffected.
Code
50
Description
Output 710 short circuit/wire break
Error mode
General error
Error cause
Defective wiring/valve Y20 Defective electronic card A5
Comments
Hydraulic valve Y20 does not engage cab lifting
1. Disconnect cable 101 from output 710. - Check whether the contact pins have proper contact and are not loose or oxidized. - Check whether cable 101 is intact between terminal 701 and the X23 terminal. - Measure the ohm resistance in the Y20 coil between the blue and black cables at X23. The resistance should be approx. 70 ohms. - Check whether cable 40 is intact from X23 to battery minus. 2. If the error remains, replace A5. 17- 160
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
51
Description
Output 711 short circuit/wire break
Error mode
General error
Error cause
Defective wiring/valve Y21 Defective electronic card A5
Comments
Hydraulic valve Y21 does not engage cab lowering
1. Disconnect cable 102 from output 711. - Check whether the contact pins have proper contact and are not loose or oxidized. - Check whether cable 102 is intact between terminal 711 and the X23 terminal. - Measure the ohm resistance on the Y21 coil between the blue and black cables at X30. The resistance should be approx. 70 ohms. - Check whether cable 40 is intact from X23 to battery minus. 2. If the error remains, replace A5.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
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Electrical System — 5000.1 Codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
52
Description
Output 701 short circuit/wire break
Error mode
General error
Error cause
Defective wiring/valve Y10 Defective electronic card A5
Comments
Hydraulic valve Y11 does not engage fork lifting
1. Disconnect cable 89 from output 701. - Check whether the contact pins have proper contact and are not loose or oxidized. - Check whether cable 89 is intact between terminal 701 and the X47 terminal. - Measure the ohm resistance on the Y11 coil between the grey and black cables at X47. The resistance should be approx. 105 ohms. - Check whether cable 40 is intact from X47 to battery minus. 2. If the error remains, replace A5.
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Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
53
Description
Output 703 short circuit/wire break
Error mode
General error
Error cause
Defective wiring/valve Y24 Defective electronic card A5
Comments
Hydraulic valve Y24 , reversing valve
1. Disconnect cable 90 from output 703. - Check whether the contact pins have proper contact and are not loose or oxidized. - Check whether cable 90 is intact between terminal 703 and the X47 terminal. - Measure the ohm resistance on the Y24 coil between the yellow and black cables at X47. The resistance should be approx. 90 ohms. - Check whether cable 40 is intact from X47 to battery minus. 2. If the error remains, replace A5.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
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Electrical System — 5000.1 Codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
61
Description
Output 702 short circuit/wire break
Error mode
General error
Error cause
Defective wiring/valve Y10 Defective electronic card A5
Comments
Hydraulic valve Y10 does not engage fork lowering
1. Disconnect cable 88 from output 702. - Check whether the contact pins have proper contact and are not loose or oxidized. - Check whether cable 88 is intact between terminal 702 and the X47 terminal. - Measure the ohm resistance on the Y10 coil between the white and black cables at X47. The resistance should be approx. 27 ohms. - Check whether cable 40 is intact from X47 to battery minus. 2. If the error remains, replace A5.
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Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
62
Description
Output 801 and/or 803 short circuit/wire break
Error mode
General error
Error cause
Broken wiring/braking magnet Y5/Y55 and/or Y6/ Y66 Defective electronic card A5
Comments
Fault at one side of the two support arm brakes restricts max. speed to 9 km/h.
Y5/Y6 are coils in the support arm brakes
1. Disconnect cable 63 from output 801. - Check whether the contact pins have proper contact and are not loose or oxidized. - Check whether cable 63 is intact between terminal 801 and the X38 terminal. - Disconnect terminal X38. Measure the ohm resistance in the Y5:1 and Y5:2 coils. The resistance should be approx. 50 ohms. If resistance is measured with the coils connected in parallel, then the resistance should be approx. 25 ohms. - Disconnect terminal X40. Measure the ohm resistance in the Y6 coil. The resistance should be 50 ohms. - Check whether cable 40 is intact from X38 to battery minus. 2. If the error remains, replace A5.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
17- 165
Electrical System — 5000.1 Codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
63 (VR only)
Description
Output 016 short circuit/wire break
Error mode
General error
Error cause
Defective wiring/coil to Y25 Defective electronic card A4
Comments
Y25, proportional valve, fork traversing
1. Disconnect cable 93 from output 016 on A4. - Check whether the contact pins have proper contact and are not loose or oxidized. - Check whether cable 93 is intact between terminal 016 and the X63 terminal. - Disconnect terminal X63. Measure the ohm resistance in the Y25 coil. The resistance should be approx. 50 ohms. - Check whether cable 40 is intact from X62 to battery minus. 2. If the error remains, replace A4
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Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
64 (VR only)
Description
Output 003 short circuit/wire break
Error mode
General error
Error cause
1. Defective wiring/coil to Y26 2. Defective electronic card A4
Comments
Y26, proportional valve, fork rotation
1. Disconnect cable 73 from output 003 on A4. - Check whether the contact pins have proper contact and are not loose or oxidized. - Check whether cable 73 is intact between terminal 003 and the X63 terminal. - Disconnect terminal X63. Measure the ohm resistance in the Y26 coil. The resistance should be approx. 50 ohms. - Check whether cable 40 is intact from X62 to battery minus. 2. If the error remains, replace A4.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
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Electrical System — 5000.1 Codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
66
Description
Output 004 short circuit/wire break
Error mode
General error
Error cause
Defective wiring to Y9 Short circuit/wire break at direction valve Y9 Defective electronic card A4
Comments
Y9, valve for traversing to right
1. Disconnect cable 95 from output 004 on A4. - Check whether the contact pins have proper contact and are not loose or oxidized. - Check whether cable 95 is intact between terminal 004 and the X63 terminal. - Disconnect terminal X63. Measure the ohm resistance in the Y9 coil. The resistance should be approx. 90 ohms. - Check whether cable 40 is intact from X62 to battery minus. 2. If the error remains, replace A4.
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Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
67
Description
Output 017 short circuit/wire break
Error mode
General error
Error cause
Defective wiring to Y8 Short circuit/wire break at direction valve Y8 Defective electronic card A4
Comments
Y8, valve for traversing to left
1. Disconnect cable 94 from output 017 on A4. - Check whether the contact pins have proper contact and are not loose or oxidized. - Check whether cable 94 is intact between terminal 017 and the X3 terminal. - Disconnect terminal X63. Measure the ohm resistance in the Y8 coil. The resistance should be approx. 90 ohms. - Check whether cable 40 is intact from X62 to battery minus. 2. If the error remains, replace A4.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
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Electrical System — 5000.1 Codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
68 (VR only)
Description
Output 005 short circuit/wire break
Error mode
General error
Error cause
1. Defective wiring/coil to Y28 2. Defective electronic card A4
Comments
Y28, valve for clockwise rotation
1. Disconnect cable 75 from output 005 on A4. - Check whether the contact pins have proper contact and are not loose or oxidized. - Check whether cable 75 is intact between terminal 005 and the X63 terminal. - Disconnect terminal X63. Measure the ohm resistance in the Y28 coil. The resistance should be approx. 90 ohms. - Check whether cable 40 is intact from X62 to battery minus. 2. If the error remains, replace A4.
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Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
69 (VR only)
Description
Output 006 short circuit/wire break
Error mode
General error
Error cause
1. Defective wiring/coil to Y27 2. Defective electronic card A4
Comments
Y27, valve for counterclockwise rotation
1. Disconnect cable 74 from output 006 on A4. - Check whether the contact pins have proper contact and are not loose or oxidized. - Check whether cable 74 is intact between terminal 006 and the X63 terminal. - Disconnect terminal X63. Measure the ohm resistance in the Y27 coil. The resistance should be approx. 90 ohms. - Check whether cable 40 is intact from X62 to battery minus. 2. If the error remains, replace A4.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
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Electrical System — 5000.1 Codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
70 (VR only)
Description
Output 018 short circuit/wire break
Error mode
General error
Error cause
1. Defective wiring/coil to direction valve Y16 2. Defective electronic card A4
Comments
Y16, valve for 1A spare
1. Disconnect cable 76 from output 018 on A4. - Check whether the contact pins have proper contact and are not loose or oxidized. - Check whether cable 76 is intact between terminal 018 and the X63 terminal. - Disconnect terminal X63. Measure the ohm resistance in the Y16 coil. The resistance should be approx. 90 ohms. - Check whether cable 40 is intact from X62 to battery minus. 2. If the error remains, replace A4.
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Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
71 (VR only)
Description
Output 019 short circuit/wire break
Error mode
General error
Error cause
1. Defective wiring/coil to direction valve Y17 2. Defective electronic card A4
Comments
Y17, valve for 1B spare
1. Disconnect cable 77 from output 019 on A4. - Check whether the contact pins have proper contact and are not loose or oxidized. - Check whether cable 77 is intact between terminal 019 and the X63 terminal. - Disconnect terminal X63. Measure the ohm resistance in the Y17 coil. The resistance should be approx. 90 ohms. - Check whether cable 40 is intact from X62 to battery minus. 2. If the error remains, replace A4.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
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Electrical System — 5000.1 Codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
76
Description
Defective check-sum in parameter memory at start-up
Error mode
Critical error
Error cause
Displaced A4 electronics card Defective electronic card A4
Comments
Restart can reset error Reset a parameter and restart Download new program
Code
77
Description
Communications error between I/O processor and master processor
Error mode
Critical error
Error cause
External interference (static electricity) Defective electronic card A4
Comments
Restart can reset error
Code
78
Description
Error at test of safety relay (main circuit) at start-up
Error mode
Critical error
Error cause
Defective electronic card A4
Comments
Restart can reset error
Code
79
Description
Safety relay (main circuit) has opened
Error mode
Critical error
Error cause
Electronics card A4 dislodged/jarred No +48 V feed Defective electronic card A4
Comments
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Service Manual
Restart can reset error
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
80
Description
General communications error No communications with A5 electronics card
Error mode Error cause
Defective CAN wiring/resistance External CAN unit incorrectly connected Displaced A4 electronics card Displaced A5 electronics card Defective electronic card A4 Defective electronic card A5
Comments
Restart can reset error Speed for fork movement reduced
Code
81
Description
General communications error No communications with A5 electronics card
Error mode Error cause
Defective CAN wiring/resistance External CAN unit incorrectly connected Displaced A4 electronics card Displaced A5 electronics card Defective electronic card A4 Defective electronic card A5
© BT Europe AB
Comments
Restart can reset error Running speed reduced
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
17- 175
Electrical System — 5000.1 Codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
90
Description
Potentiometer R6 for fork lift/fork lower supplies incorrect voltage (7.0 V).
Error mode
General error
Error cause
Defective potentiometer/wiring Activated input without connected potentiometer Defective electronic card A5
Comments
Fork controls, joystick R6
1. Check to make sure that R6 is correctly seated in its mount. - Check to make sure the voltage across R6 (yellow and grey cable ) is 7-7.5 VDC. - Check whether the contact pins in terminal X11 are loose or oxidized. - The voltage on input 503 should be 3.7 +/- 0.6 VDC when R6 is correctly adjusted. 2. If input 503 receives the correct voltage and the error remains, then replace the A5 electronic card.
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Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
91 (VR only)
Description
Potentiometer R5 for rotation movement supplies incorrect voltage (7.0 V).
Error mode
General error
Error cause
1. Defective potentiometer/wiring or activated input without connected potentiometer 2. Defective electronic card A5
Comments
Fork rotation control, joystick R5
1. Check to make sure that R5 is correctly seated in its mount. - Check to make sure the voltage across R5 (yellow and grey cable ) is 7-7.5 VDC. - Check whether the contact pins in terminal X11 are loose or oxidized. - The voltage on input 505 should be 3.7 +/- 0.6 VDC when R5 is correctly adjusted. 2. If input 505 receives the correct voltage and the error remains, then replace the A5 electronic card.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
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Electrical System — 5000.1 Codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
92
Description
Potentiometer R4 for traversing movement supplies incorrect voltage (7.0 V).
Error mode
General error
Error cause
Defective potentiometer/wiring Activated input without connected potentiometer Defective electronic card A5
Comments
Fork traversing control, joystick R4
1. Check to make sure that R4 is correctly seated in its mount. - Check to make sure the voltage across R4 (yellow and grey cable ) is 7-7.5 VDC. - Check whether the contact pins in terminal X11 are loose or oxidized. - The voltage on input 504 should be 3.7 +/- 0.6 VDC when R4 is correctly adjusted. 2. If input 504 receives the correct voltage and the error remains, then replace the A5 electronic card.
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Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
93 (VR only)
Description
Potentiometer R14 for extra functiuon 1/”auto-rotation” or R15 för extrafunktion ”2” supplies incorrect voltage (7.0 V).
Error mode
General error
Error cause
1. Parameters 15/16 >0, no potentiometer connected 2. Defective potentiometer/wiring 3. Defective electronic card A5
Comments
Auxiliary hydraulic function, joysticks R14 and R15
1. If no valve is connected, parameter 15/16 should remain 0. Verify parameter 16 as follows: - If no valve is connected, parameter 15/16 should remain 0. - Verify parameter 16 as follows: - Connect the service key to the truck. - Depress the switch I while turning the start key. - Use switch II to advance and switch III to back up to the parameter to be changed. - Depress the switch. The display blinks. - Change the value using switches II/III. - Depress switch I to enter the value. The display stops blinking. © BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
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Electrical System — 5000.1 Codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
2. Check to make sure that both joysticks for the extra hydraulic function are not stuck in an actuated position. 3. Check to make sure that R14 and R15 are correctly seated in their mounts. Check whether the contact pins in terminal X11 are loose or oxidized. The voltage on inputs 506 and 510 should be 3.7 +/- 0.6 VDC when R14 and R15 are correctly adjusted. 4. If inputs 506 and 510 receive the correct voltage, then replace the A5 electronic card.
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Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
94
Description
Potentiometer R1 for accelerator pedal supplies incorrect voltage (4.6 V).
Error mode
General error
Error cause
Defective potentiometer/wiring Defective electronic card A5
Comments
Speed control, R1
1. Check to make sure that R1 is correctly seated in its mount. Check whether the contact pins in terminal X19 are loose or oxidized. The voltage on input 501 should be 3.7 +/- 0.2 VDC when the mechanical adjustment of R1 is correct. 2. If input 501 receives the correct voltage and the error remains, then replace the A5 electronic card.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
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Electrical System — 5000.1 Codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
17.3.6 Error Codes Character
Error Error
When an error occurs, a buzzer sounds and an error code is displayed at the right side of the text window (D). The error is also displayed in the text box (G). The buzzer sounds until the key is tuned off, cutting power to the truck. If the error remains when the truck is restarted, the code will be shown again and the buzzer will sound. The truck’s hydraulic functions shown in the table will be inoperable. When an error code is registered, it is automatically displayed in the error register. (Explanations of the error codes are listed in the table.) Registration is at the first of the 50 possible locations and moves previous errors one step down. When the registry is shown in the text window, the most recent error will be shown first, along with the error code. .
To see the date when the error occurred, press III once. To see the time, press III a second time. .
To view more registered errors, press II. .
WARNING Ignoring error indication jeopardises truck safety. Always check truck functions check before operation.
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Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
17.3.7 Error Codes with Registration Code
104
Description
Output 802 short circuit/wire break
Error mode
Critical error
Error cause
Emergency switch for Y1 activated Defective wiring/valve Y1 Defective electronic card A5
Comments
Parking brake, Y1
1. Check to make sure switch S131 is open. 2. Disconnect cable 64 from output 802. - Check whether the contact pins have proper contact and are not loose or oxidized. - Check whether cable 64 is intact between terminal 802 and the Y1 coil. - Measure the ohm resistance on the Y1 coil between the X37 terminals. The resistance should be approx. 33 ohms. - Check whether cable 40 is intact all the way to battery minus. 3. If the error remains, replace A5.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
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Electrical System — 5000.1 Codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
106
Description
Output 804 short circuit/wire break
Error mode
Critical error
Error cause
Defective wiring/contactor K10 Defective electronic card A5
Comments
Main connector, K10, coil
1. Disconnect cable 31 from output 804. - Check whether the contact pins have proper contact and are not loose or oxidized. - Check to make sure that cable 31 is intact all the way to the contactor K10:A2. - Measure the ohm resistance in the K10 coil between A1 and A2. The resistance should be approx. 150 ohms. - Check to make sure cable 40 is intact between the contactor K10: A1 and battery minus. 2. If input 601 receives the correct voltage and the error remains, then replace the A5 electronic card.
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Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
107
Description
Main contactor K10 does not close after key start and emergency switch is deactivated
Error mode
Critical error
Error cause
Defective contactor K10 Defective electronic card A5
Comments
Main connector, K10, contactor tips
1. Inspect the voltage at terminal 808. It should stay at battery plus, i.e. nominal +48 VDC, when the key switch (S17) has been switched on. - If there is no voltage, inspect fuse F62 (10 A). - If the fuse is OK, then check to make sure cable 23 is intact. - If cable 23 is OK, then inspect the K10 contactor tips. - If the contactor tips are OK, then check to make sure cable 1 is intact. 2. If a voltage of +48 VDC is available at terminal 808 on the card and the error remains, then replace the A5 electronic card.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
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Electrical System — 5000.1 Codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
108
Description
Main contactor K10 does not close after key start and emergency switch is deactivated
Error mode
Critical error
Error cause
Defective contactor K10 Defective electronic card A5
Comments
Main connector, K10, contactor tips
1. Inspect the voltage at terminal 808. It should stay at 0 VDC when the key switch (S17) has been switched off. - If the voltage is correct, then check to make sure the K10 contactor tips have not been welded together. - If the contactor tips are OK, check to make sure cables 23 and 8 are not short-circuited with any live parts. 2. If the voltage remains at 0 VDC at terminal 808 on the card and the error remains, then replace the A5 electronic card
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Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
111
Description
Potentiometer R2 for brake pedal supplies incorrect voltage (4.6 V)
Error mode
Critical error
Error cause
Defective potentiometer/wiring Defective electronic card A5
Comments
Potentiometer R2, brake control
1. Check to make sure that R2 is correctly seated in its mount. - Check to make sure the voltage across R2 (1 and 2) is 7-7.5 VDC. - The voltage at input 502 should be 1.7 VDC when R2 is set to the neutral position and 4.1 VDC when the brake pedal is fully depressed. - If the voltage is < 0.4 VDC, then the voltage of 7-7.5 V is missing; if the voltage is > 4.6 VDC then 0 V is missing. If the cables are intact, replace the potentiometer R2. 2. If input 505 receives the correct voltage and the error remains, then replace the A5 electronic card.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
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Electrical System — 5000.1 Codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Code
112
Description
Error at test of brake input
Error mode
Critical error
Error cause
Defective electronic card A5
Order number 244989-040
Comments
Code
114 (VR only)
Description
Too fast regenerative lowering of the forks.
Error mode
Critical error
Error cause
1. Battery fully charged
Comments
2. Defective lift controller A2
Description 1. If the battery has been newly charged and a heavy load is lowered, the battery is unable to receive the additional charge. In this case, the charging voltage from the lift controller will increase, while the lowering speed also increases. An error code is generated if the lowering speed is too high. Drive the truck for a couple of minutes to allow the battery to discharge somewhat. Following this, the error should not reoccur. 2. In spite of the above action, if the error reappears, replace the A2 lift controller.
Code
120
Description
Memory cell for steering set point value, incorrect value
Error mode
Steering error
Error cause
Displaced A5 electronics card Defective electronic card A5
Comments
Restart can reset error
1. Temporary interference may have affected the card. Try to restart the truck.
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Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
121
Description
Safety relay deactivated because of incorrect voltage at drive stage or communications error with master processor
Error mode
Steering error
Error cause
Displaced A5 electronics card Defective electronic card A5
Comments
Restart can reset error
1. Temporary interference may have affected the card. Try to restart the truck.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
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Electrical System — 5000.1 Codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
122
Description
Warning temperature in steering servo
Error mode
Steering error
Error cause
High ambient temperature Steering binds Defective steering motor Defective wiring to steering motor Defective electronic card A5
Comments
Steering motor, M6
1. Check the ventilation around the A5 electronic card. 2. Lift the truck. - Check to make sure the steering has no mechanical seizure. - Inspect the current level during steering. It should be approx. 5 A. 3. Inspect cables 60 and 61 as well as terminals 903 and 904. 4. Inspect the steering motor. - Brushes and brush mounts. See MSM 1730. - Armature windings 5. If the error remains, replace the A5 electronic card.
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Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
123
Description
Output voltage to steering motor does not correspond to requested steering
Error mode
Steering error
Error cause
Defective steering motor Defective wiring to steering motor Defective electronic card A5
Comments
Steering motor, M6
1. Inspect cables 60 and 61 as well as terminals 903 and 904. 2. Inspect the steering motor. - Brushes and brush mounts. See the S1730 tab: "Electric steering motor". - Armature windings. 3. If the error remains, replace the A5 electronic card.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
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Electrical System — 5000.1 Codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
125
Description
Steering generator error at test
Error mode
Steering error
Error cause
Defective generator/carbon brushes Defective wiring Defective electronic card A5
Comments
Steering generator, U1
1. Inspect cables 62 and 129. 2. Inspect the steering generator. - Brushes and commutator. See the S 4100 tab: "Mechanical steering system". - Armature windings 3. If the error remains, replace the A5 electronic card.
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Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
126
Description
Steering motor error at test
Error mode
Steering error
Error cause
Fault F61 fuse Defective steering motor/carbon brushes Defective wiring Defective electronic card A5
Comments
Steering motor, M6
1. Inspect fuse F61, 30 A, the cables 1 and 25 as well as terminal 901. 2. Inspect cables 60 and 61 as well as terminals 903 and 904. 3. Inspect the steering motor. - Brushes and brush mounts. See MSM 1730. - Armature windings. 4. If the error remains, replace the A5 electronic card.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
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Electrical System — 5000.1 Codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
127
Description
Communications error between steering processor and master processor
Error mode
Steering error
Error cause
External interference (static electricity) Defective electronic card A5
Comments
Restart can reset error
1. Temporary interference may have affected the card. Try to restart the truck.
Code
128
Description
Memory cell for steering set point value contains incorrect value
Error mode
Critical error
Error cause
External interference (static electricity) Defective electronic card A5
Comments
Restart can reset error
1. Temporary interference may have affected the card. Try to restart the truck.
Code
130
Description
Communications error between I/O processor and master processor
Error mode
Critical error
Error cause
External interference (static electricity) Defective electronic card A5
Comments
Restart can reset error
1. Temporary interference may have affected the card. Try to restart the truck.
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Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
131
Description
Error at test of safety relay (steering) at start-up
Error mode
Steering error
Error cause
Fault F61 fuse Defective wiring to F61 Defective electronic card A5
Comments
Fuse F61, 30 A
1. Inspect fuse F61, 30 A. 2. Inspect the cables 1 and 25 as well as terminal 901. 3. If the error remains, replace the A5 electronic card.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
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Electrical System — 5000.1 Codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
133
Description
Error at test of safety relay (steering) at start-up
Error mode
Steering error
Error cause
Defective electronic card A5
Comments 1. Temporary interference may have affected the card. Try to restart the truck. 2. If the error remains in spite of several start attempts, replace the A5 electronic card.
Code
134
Description
Safety relay (steering) has opened
Error mode
Steering error
Error cause
Electronics card A5 displaced/jarred Defective electronic card A5
Comments 1. The relay could have opened if the truck has been driven on bumpy surfaces or has bumped forcefully into something. Try to restart the truck. 2. If the error remains in spite of several start attempts, replace the A5 electronic card.
Code
135
Description
Error at test of safety relay (main circuit) at start-up
Error mode
Critical error
Error cause
Defective electronic card A5
Comments 1. Temporary interference may have affected the card. Try to restart the truck. 2. If the error remains in spite of several start attempts, replace the A5 electronic card.
Code
136
Description
Error at test of safety relay (main circuit) at start-up
Error mode
Critical error
Error cause
Defective electronic card A5
Comments 1. Temporary interference may have affected the card. 17- 196
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Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Try to restart the truck. 2. If the error remains in spite of several start attempts, replace the A5 electronic card.
Code
137
Description
Safety relay (main circuit) has opened
Error mode
Critical error
Error cause
Electronics card A5 displaced/jarred Defective electronic card A5
Comments
Restart can reset error
1. The relay could have opened if the truck has been driven on bumpy surfaces or has bumped forcefully into something. Try to restart the truck. 2. If the error remains in spite of several start attempts, replace the A5 electronic card.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
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Electrical System — 5000.1 Codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
140
Description
Defective check-sum in parameter memory at start-up
Error mode
Critical error
Error cause
Displaced A5 electronics card Defective electronic card A5
Comments
Restart can reset error Reset a parameter and restart Download new program
1. Temporary interference may have affected the card. - Try to restart the truck. - Change a parameter and restart the truck. - Download new firmware. 2. If the error remains, replace the A5 electronic card.
Code
141
Description
Defective check-sum for applicable program
Error mode
Critical error
Error cause
Defective download of program from PC Defective electronic card A5
Comments
Download new program via CAN Change program memory
1. Temporary interference may have affected the card. Download new firmware. 2. If the error remains, replace the A5 electronic card.
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Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
150
Description
No communication with frequency inverter at startup
Error mode
Drive regulator error and lift regulator error
Error cause
Defective CAN wiring/resistance 15 (V) Fault frequency converter Defective electronic card A5
Comments
CAN communication
1. Check to make sure the cables 117, 118, 119 and 120 are not shortcircuited or interrupted. Also check the resistors R100 and R101. 2. Check to make sure output 401 on the A5 card has +15 VDC. 3. Try with a new A1 traction controller . 4. Try with a new A2 lift controller. 5. Try with a new A5 electronic card.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
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Electrical System — 5000.1 Codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
151
Description
No communication with drive motor’s frequency inverter at start-up
Error mode
Drive regulator error
Error cause
Defective CAN wiring/resistance Faulty frequency inverter
Comments
CAN communication between A5 and A1
1. Check to make sure the cables 117, 118, 119 and 120 are not shortcircuited or interrupted. Also check the R101 resistor. 2. Try with a new A1 traction controller.
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Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
152
Description
No communication with drive motor’s frequency inverter during operation
Error mode
Drive regulator error
Error cause
Defective CAN wiring/resistance Faulty frequency inverter
Comments
CAN communication between A5 and A1
1. Check to make sure the cables 117, 118, 119 and 120 are not shortcircuited or interrupted. Also check the R101 resistor. 2. Try with a new A1 traction controller.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
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Electrical System — 5000.1 Codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
153
Description
No communication with pump motor’s frequency inverter at start-up
Error mode
Lift regulator error
Error cause
Defective CAN wiring/resistance Faulty frequency inverter
Comments
CAN communication between A5 and A2
1. Check to make sure the cables 117, 118, 119 and 120 are not shortcircuited or interrupted. Also check the R101 resistor. 2. Try with a new A2 lift controller.
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Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
154
Description
No communication with pump motor’s frequency inverter during operation
Error mode
Lift regulator error
Error cause
Defective CAN wiring/resistance Faulty frequency inverter
Comments
CAN communication between A5 and A2
1. Check to make sure the cables 117, 118, 119 and 120 are not shortcircuited or interrupted. Also check the R101 resistor. 2. Try with a new A2 lift controller.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
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Electrical System — 5000.1 Codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
155 - 163
Description
General communications error
Error mode
Drive regulator error
Error cause
Defective CAN wiring/resistance External CAN unit incorrectly connected Displaced A5 electronics card Defective electronic card A5
Comments
CAN communication
1. Check to make sure the cables 117, 118, 119 and 120 are not shortcircuited or interrupted. Also check the R100 and R101 resistors. 2. Check whether the CAN bus has been correctly connected to all other units. 3. Temporary interference may have affected the card. Try to restart the truck. 4. If the error remains in spite of several start attempts, replace the A5 electronic card.
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Code
170 - 177
Description
Wire guidance related fault
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Error mode
Loop steering error
Error cause
Error type presented on A3’s display See the loop steering description for interpretation of error messages
Comments
See instructions for wire guidance, C-code 4500
Code
175
Description
Sensor for aisle centre activated outside of narrow aisle (sensor for narrow aisle not activated)
Error mode
General error
Error cause
Sensor S4 or S9 has received mechanical impact Defective sensor S4 or S9 Defective wiring to S4 or S9 Defective electronic card A5
Comments
Sensors S4 and S9
1. One or both magnetic sensors have triggered. LED 11 lights. Reset the magnetic sensors by sweeping a magnet across the sensors. 2. If the error remains, inspect the cabling from the sensors. 3. If the cabling is intact, replace the sensor.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
17- 205
Electrical System — 5000.1 Codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
203
Description
CPU or memory error at drive motor’s frequency inverter
Error mode
Drive regulator error
Error cause
Faulty frequency inverter
Comments 1. Replace the A1 traction controller.
Code
205
Description
Overheated drive motor
Error mode
Drive regulator error
Error cause
Motor overload Defective thermoelectric sensor/wiring
Comments
Restart possible
Temperature sensor B1 in the drive motor M1
1. Check whether the ventilation is OK, especially the M10 fan in the motor compartment. 2. Inspect B1. - Disconnect terminal X26. Measure the ohm resistance at B1 in X26. It should be approx. 570 ohms at 20oC. - Check whether cable 11 is intact between X26 and terminal 4 on A1. - Check whether cable 14 is intact between X26 and terminal 7 on A1. - Check to make sure that the contact pins in the connectors are 17- 206
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Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
not loose or oxidized.
Code
206 - 207
Description
Overheated drive motor frequency inverter
Error mode
Drive regulator error
Error cause
Defective cooling fan Defective motor Faulty frequency inverter
Comments
Restart possible
1. Inspect the M12 fan next to the frequency convertors. 2. Inspect the drive motor and its cabling. 3. If everything else is OK, replace A1.
Code
208
Description
Excessive current at drive motor frequency inverter
Error mode
Drive regulator error
Error cause
Motor cables incorrectly connected Faulty frequency inverter
Comments
Drive motor circuit
1. Check to make sure the motor cables are intact and correctly connected. 2. Replace the A1 traction controller.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
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Electrical System — 5000.1 Codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
209 - 210
Description
Excessive voltage at drive motor frequency inverter
Error mode
Drive regulator error
Error cause
Defective battery Defective motor Faulty frequency inverter
Comments 1. Check whether the battery is intact, sufficiently charged and of the correct type. 2. Check whether the travel motor is OK. 3. If everything else is OK, replace A1.
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Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
211 - 212
Description
Voltage too low at drive motor’s frequency inverter
Error mode
Drive regulator error
Error cause
Defective wiring/fuse F62 External current load incorrectly connected Defective electronic card A5 Faulty frequency inverter
Comments
Main contactor, K10
1. An error code is generated if the truck is not switched off prior to disconnecting the charging connector. 2. Check to make sure that no optional equipment is overloading the electrical system. 3. Check whether input 808, cable 23 has 48 VDC when K10 is engaged. If not, inspect fuse F62 (10 A), the K10 contactor tips and cables 1, 8 and 23. 4. If this does not correct the error, replace A1. 5. Replace A5.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
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Electrical System — 5000.1 Codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
213 - 214
Description
CAN error at drive motor’s frequency inverter
Error mode
Drive regulator error
Error cause
Faulty frequency inverter
Comments
Code
223
Description
CPU or memory error at pump motor’s frequency inverter
Error mode
Lift regulator error
Error cause
Faulty frequency inverter
Comments
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Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
225
Description
Overheated pump motor
Error mode
Lift regulator error
Error cause
Motor overload Defective thermoelectric sensor/wiring
Comments
Restart possible
Temperature sensor B2 in the pump motor
1. Check whether the ventilation is OK, especially the M10 fan in the motor compartment. 2. Inspect B2. - Disconnect the cable to B2. Measure the ohm resistance at B2. It should be approx. 570 ohms at 20oC. - Check whether cable 16 is intact between B2 and terminals 4 and 8 on A1. - Check whether cable 19 is intact between B2 and terminal 7 on A1. - Check to make sure that the contact pins in the connectors are not loose or oxidized.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
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Electrical System — 5000.1 Codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
226 - 227
Description
Overheated pump motor frequency inverter
Error mode
Lift regulator error
Error cause
Defective cooling fan Defective motor Faulty frequency inverter
Comments
Restart possible
Pump motor circuit
1. Inspect the M12 fan next to the controllers. 2. Inspect the motor cables 5, 6 and 7 and the M3 pump motor. 3. If everything is OK, replace A2.
17- 212
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
228
Description
Excessive current at pump motor’s frequency inverter
Error mode
Lift regulator error
Error cause
Motor cables incorrectly connected Faulty frequency inverter
Comments
Pump motor, M3
1. Check to make sure the motor cables 5, 6 and 7 are intact and correctly connected. 2. If the cabling is OK, replace A2.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
17- 213
Electrical System — 5000.1 Codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
229 - 230
Description
Excessive voltage at pump motor’s frequency inverter
Error mode
Lift regulator error
Error cause
Defective battery Poor contact at K10’s contact points Faulty frequency inverter
Comments
Battery circuit
1. Check whether the battery is intact, sufficiently charged and of the correct type. 2. Inspect the K10 contactor tips. 3. If everything is OK, replace A2.
17- 214
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
231 - 232
Description
Voltage too low at pump motor’s frequency inverter
Error mode
Lift regulator error
Error cause
Defective wiring/fuse F62 External current load incorrectly connected Defective electronic card A5 Faulty frequency inverter
Comments
Main contactor, K10
1. An error code is generated if the truck is not switched off prior to disconnecting the charging connector. 2. Check to make sure that no optional equipment is overloading the electrical system. 3. Check whether input 808, cable 23 has 48 VDC when K10 is engaged. If not, inspect fuse F62 (10 A), the K10 contactor tips and cables 1, 8 and 23. 4. If this does not correct the error, replace A2. 5. Replace A5
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
17- 215
Electrical System — 5000.1 Codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
233 - 234
Description
CAN error at pump motor’s frequency inverter
Error mode
Lift regulator error
Error cause
Defective CAN wiring/resistance Faulty frequency inverter
Comments
CAN communication between A5 and A2
1. Check to make sure the cables 117, 118, 119 and 120 are not shortcircuited or interrupted. Also check the R101 resistor. 2. Try with a new A2 lift controller.
17- 216
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical System — 5000.1 Codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
This page is intentionally left blank
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
17- 217
Electrical System — 5000.1 Codes T-code 485, 487
17- 218
Valid from serial number 6004330-
Service Manual
Date 2013-03-04
Order number 244989-040
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical system – 5000.2 General Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
18- Electrical system – 5000.2 18.1 General The electrical system in the AC powered VRE150/VRE125SF comprises a number of electronic units, A1-A5 as well as A16, A20 and A23, which communicate with each other over a CAN (Controller Area Network). While the truck is switched on, communication is always in progress. The truck's main board, A5, also communicates with the display on the instrument panel, the height indicator display, the height pre-set and the length indication display, A6-A9, via a RS485 serial port. Input signals for the various truck functions to the electronic units can be digital (switches and sensors) and analogue (potentiometers and tachometer). The output signals from the electronic units to the function components are also both digital (valves, drive wheel brake, etc.) and analogue (support arm brakes). The accompanying picture shows a schematic overview of the wiring between the different electronic units as well as between separate units and the functional components.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
18- 1
Electrical system – 5000.2 General T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
VRE125SF Display, A6
Main contactor
Height preselection, A7
Height indication, A8
RS 485
Motor
Brakes
AC drive freq. Inverter, A1
Aisle functions Accelerate pedal Brake pedal
Logic card A5
AC pump freq. Inverter, A2
Joysticks On/Off valves
Lower
Batt. Meas.
Steering Motor
CAN-Bus
Personal protection
Valve traverse
Wire guidance, A3 Service key
Pulse counter traverse
Fork unit card A4
S D16 Shock sensor Pinkods-login
18- 2
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical system – 5000.2 General Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
VRE150 Display, A6
Main contactor
Height preselection, A7
Height indication, A8
RS 485
Motor
Brakes
AC drive freq. Inverter, A1
Aisle functions Accelerate pedal Brake pedal
Logic card A5
AC pump freq. Inverter, A2
Joysticks On/Off valves
Lower
Batt. Meas.
Steering
CAN-Bus
Personal protection Prop. Valve traverse Prop. Valve rotation Pulse counter traverse
Wire guidance, A3 Service key
Fork unit card A4 Rotation pot.
S D16 Shock sensor
Extra functions
© BT Europe AB
Motor
Service Manual
Pinkods-login
Veflex VR, VR SF, VRE150, VRE125SF
18- 3
Electrical system – 5000.2 Logic card, drive controller A1 and lift controller A2 T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
18.2 Logic card, drive controller A1 and lift controller A2 18.2.1 General The controller has a green OK status LED. The controller stores basic firmware for controlling the drive motor and pump motor. The controller also has built-in monitoring of CAN communication, DC voltage level, internal controller temperature and motor temperature. Possible malfunction is detected by the controller, and corresponding information is sent over the CAN to the A5 main logic card where the error code is recorded and displayed on the instrument panel display. The controller can be reprogrammed via the CAN.
18- 4
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical system – 5000.2 Logic card, drive controller A1 and lift controller A2 Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
18.2.2 Connection terminal and terminal pillars I = Input, O = Output
Conn.
Cable A1/A2
Description
Active
Input/ output
1
22
Key start/stop
+48 VDC
I
2
NC
3
10/15
Sensor, + voltage
+12 VDC, 50 mA
O
4
11/16
Sensor, -
0V
O
5
12/17
Pulse transducer, phase 1
+12 V, 1 kohm
I
6
13/18
Pulse transducer, phase 2
+12 V, 1 kohm
I
7
14/19
Motor temperature
8
-/16
CAN ID0 (Not connected when used as A1)
9
NC
10
119
CAN H
0-5 V
I/O
11
120
CAN L
0-5 V
I/O
12
117
CAN + voltage, external
+15 VDC
I
13
118
CAN -, external
0V
I
B+
8
Battery +
+48 VDC
I
B-
40
Battery -
0V
I
O
2/5
Motor winding U
0-33 V
O
V
3/6
Motor winding V
0-33 V
O
W
4/7
Motor winding W
0-33 V
O
© BT Europe AB
I 1: Open 0: Sensor, -
I
I
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
18- 5
Electrical system – 5000.2 Logic card, drive controller A1 and lift controller A2 T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
18.2.3 Technical data Parameter
Setting
Unit
Description
Operating voltage
48
V
Max. operating voltage
65
V
Overvoltage limit
Min. operating voltage
30
V
Undervoltage limit
Frequency
8/13
kHz
Contactor voltage
48
V
Ambient operating temperature
-35 - +55
oC
Current limit, downregulated in case of excess temperature of cooling body
85
o
C
0 A at 125o C
Current limit, downregulated in case of too low temperature of cooling body
-20
o
C
50% current limit at start-up
Current limit
350
A
2 minutes.
Speed
100
%
Modulation
18.2.4 Installing a new logic card in the truck The logic card can be supplied in different states: 1. Pre-programmed at completion number = P/N for frequency converter, including program. 2. Not programmed for the part number. = only P/N for regulator. When installing a new logic card in the truck, some parameters must be reprogrammed to ensure safe operation of the truck. On the A5 card, adjust the R1 potentiometer according to C code 6000.
18.2.5 Programming Use the TruckCom application to download new firmware to the logic card. For details, see the TruckCom user guide.
18- 6
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical system – 5000.2 Logic card, fork unit, A4 Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
18.3 Logic card, fork unit, A4 18.3.1 General The truck's programmable parameters for the fork unit are stored in the A4 logic card. The A4 card monitors the truck's hydraulic functions for the fork unit as well as CAN communication. Malfunctions are detected by the A4 card and the corresponding information is sent via the CAN to the A5 main card. Warning codes from A4 are displayed as original codes on the instrument panel display. Error codes are recorded by the A5 card, however a reference code C034 for fork unit error appears on the instrument panel display. To see the actual error code, check the A5 error code log. The A4 card can be reprogrammed via the CAN.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
18- 7
Electrical system – 5000.2 Logic card, fork unit, A4 T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
18.3.2 Connector plug I = Input, O = Output
18- 8
Conn.
Cable
Description
Active
Input/ output
001
22
Voltage supply from battery
+48 VDC
I
002
NC
+10 V
O
003
NC
0-24 V
O
004
95
+48 V
O
005
NC
+48 V
O
006
NC
+48 V
O
007
NC
0-10 V
I
008
52
Pulse transducer for traversing, phase 1
+15 V
I
009
53
Pulse transducer for traversing, phase 2
+15 V
I
010
103
Traversing, reference sensor
+15 V
I
011
56
Pulse generator for height measurement free lift, phase 1
+15 V
I
012
55
Pulse generator for height measurement free lift, phase 2
+15 V
I
013
104
Height measurement for free lift, reference sensor
+15 V
I
014
NC
Spare
(0-10 V or 0-48 V)
I
015
40
Battery -
0V
I
016
NC
0-24 V
O
017
94
+48 V
O
018
NC
+48 V
O
019
NC
+48 V
O
020
150
Switch signal, for dual camera systems
021
NC
Spare
022
NC
Spare
I
023
NC
Spare
I
024
NC
Spare
I
025
NC
Spare
I
Directional valve, traversing right
Directional valve, traversing left
Service Manual
O (0-20 V)
I
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical system – 5000.2 Logic card, fork unit, A4 Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Conn.
Cable
Description
Active
Input/ output
026
NC
Spare
(+48 V)
I
027
119
CAN H
0-5 V
I/O
028
20
Voltage supply for sensor
+15 V
O
029
40
Battery -
0V
I
030
NC
Spare
031
NC
032
NC
Spare
O
033
NC
Spare
O
034
NC
Spare
O
035
NC
Spare
(0-20 V)
I
036
NC
Spare
(0-20 V)
I
037
NC
Spare
I
038
NC
Spare
I
039
NC
Spare
I
040
NC
Spare
(+48 V)
I
041
20
Relay position (connected to terminal 28
+15 V
I
042
120
CAN L
0-5 V
I/O
© BT Europe AB
O (0-24 V)
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
O
18- 9
Electrical system – 5000.2 Logic card, fork unit, A4 T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Status of inputs and outputs If calibration parameter 38 is set to 4, the status on each input/output of the A4 logic card is shown on the display at next start-up. The picture shows the display segment for each input/output.
18- 10
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical system – 5000.2 Logic card, main card, A5 Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
18.4 Logic card, main card, A5
18.4.1 General The A5 logic card has green LEDs on inputs from microswitches and sensors, red LEDs on outputs to contactors and valves, and yellow LEDs for voltages. The truck's programmable parameters for steering (incl. wire guidance), travel speeds, deceleration and lift height limits are stored in the logic card. The A5 card monitors the steering and drive functions as well as the hydraulic functions for lifting and lowering together with CAN communication. Any errors with regard to these functions are recorded and the corresponding error codes are shown on the instrument panel display. The A5 card handles recording and display of error codes, either the actual code or a reference code, generated by the other electronic units in the truck. Information about these are sent via CAN. The A5 card can be reprogrammed via the CAN.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
18- 11
Electrical system – 5000.2 Logic card, main card, A5 T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
18.4.2 Connection terminals and voltages on A5 The connection terminal LEDs are listed in the table below: I=Input, green light emitting diode (LED) O= Output, red light emitting diode (LED) Other= Yellow light emitting diode (LED)
10X
18- 12
Conn.
Cable
Description
Active (V)
LED
101
NC
Spare
102
NC
Spare
103
NC
Spare
104
45
Selection of direction of travel for fork direction at creep speed
+48
I
105
46
Selection of direction of travel for steering wheel direction at creep speed
+48
I
106
41
In narrow aisles, front switch
+48
I
107
42
In narrow aisles, rear switch
+48
I
108
NC
Spare
I
109
NC
Spare
I
110
43
Safety pedal (left foot switch)
+48
I
111
44
In aisle centre (at aisle-end brake)
+48
I
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical system – 5000.2 Logic card, main card, A5 Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
20X Conn.
Cable
Description
Active (V)
LED
201
22
Personal safety equipment, strapped as standard
202
-
Indication signal for lifting (See parameter 28)
+48
O
203
49
Seat switch
+48
I
204
81
Weight indicator
+48
I
205
100
Lift height limitation, bypass
+48
I
206
-
Speed reduction, driving
+48
I
207
22
Personal safety equipment, strapped as standard
+48
I
208
-
Indication signal for truck travel (See parameter 28)
+48
O
209
57
Steering wheel sensor, 180°
+48
I
210
58
Steering wheel sensor, channel A
+15
I
211
59
Steering wheel sensor, channel B
+15
I
I
30X Conn.
Cable
Description
Active (V)
LED
301
98
Height sensor, channel A
0 -(+)15
I
302
99
Height sensor, channel B
0 -(+)15
I
303
NC
Spare
304
66
Wire guidance not requested
+48
I
305
91
Half pallet handling, selected
+48
I
306
92
Indication, half pallet handling selected
+48
307
107
Electronics fan
+32/48
© BT Europe AB
Service Manual
I
Veflex VR, VR SF, VRE150, VRE125SF
18- 13
Electrical system – 5000.2 Logic card, main card, A5 T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
40X Conn.
Cable
Description
Active (V)
401
117
CAN - Series (+)
+15
402
118
CAN - Series (-)
0
403
119
CANH
0-5
404
120
CANL
0-5
405
121
RS485 - Series (+)
406
122
RS485 - Series (-)
407
125
RS485 - TX (+), transmits data
408
126
RS485 - TX (-), transmits data
409
127
RS485 - RX (+), receives data
410
127
RS485 - RX (-), receives data
411
NC
Reserve, analogue input
LED
(0-10 V or 050 V)
50X Conn .
Cable
Description
Active (V)
501
50
Potentiometer, driving, set point
+3.7-1.7
502
51
Potentiometer, brake, set point
+1.7-4.1
503
82
Potentiometer, lifting movement, set point
+0.66-3.7-6.6
504
83
Potentiometer, traversing movement, set point
+0.77-3.7-6.6
505a
84
Potentiometer, fork rotation, set point
+0.66-3.7-6.6
5061
85
Potentiometer, auto rotation/extra (1) hydraulic function, set point
+0.66-3.7-6.6
507
27
Potentiometer feed
+7.0 - +7.5
508
28
Minus to 501-506, 510
0
509
62
Steering tachometer (+)
Max. ±3
5101
86
Potentiometer, extra (2) hydraulic function, set point
+0.66-3.7-6.6
511
129
Steering tachometer (-)
0
LED
a.Only used on the VRE150.
18- 14
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical system – 5000.2 Logic card, main card, A5 Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
60X Conn.
Cable
Description
Active (V)
601
70
Battery guard, voltage measurement (+)
+48
602
71
Battery guard, voltage/current measurement (-)
0
603
72
Battery guard, current measurement (+)
604
NC
Spare
605
NC
Reserve, analogue input
LED
(0-10 V or 050 V)
70X Conn.
Cable
Description
Active (V)
LED
701
89
Valve, fork lifting
+0.5-48
O
702
88
Valve, fork lowering
+0.5-48
O
703
90
Valve, fork movement selection
+0.5-48
O
704
NC
Spare
(+0,5-48)
O
705
32
Indication, forks in home position
+48
O
706
33
Indication, in narrow aisle mode
+48
O
707
38
Truck travel alarm
+48
O
708
37
Warning lamp H2
+48
O
709
108
Length indication lamp (in narrow aisles) H96
+48
O
710
101
Valve, cab tilting up (cold store version only)
+0.5-48
O
711
102
Valve, cab tilting down (cold store version only)
+0.5-48
O
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
18- 15
Electrical system – 5000.2 Logic card, main card, A5 T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
80X Conn.
Cable
Description
Active (V)
LED
801
63
Support arm brake 1, active
0.2 -(+)48
O
802
64
Motor brake, released
1,5-(+)48
O
803
68
Support arm brake 2, active
0,2-(+)48
O
804
31
Main contactor
+48
O
805
21
Battery voltage, (+) 48 V
+48
+48 V
806
NC
807
24
Battery voltage, (+) 48 V after key
+48
808
23
Battery voltage, (+) 48 V after main contactor
+48
809
22
Battery voltage, (+) 48 V after emergency stop
+48
810
29
Voltage meter feed sensor, (+) 15 V
+15
811
30
Minus feed sensor
0
0 +48 V KEY
+48 V ESO
90X
18- 16
Conn.
Cable
Description
Active (V)
901
25
Battery voltage, (+) 48 V
+48
902
40
Battery voltage, minus
0
903
60
Steering motor, (+)
+48
904
61
Steering motor, (-)
+48
Service Manual
LED
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical system – 5000.2 Logic card, main card, A5 Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
LED
Colour
Function
+ 48 V STEER
Yellow
Voltage present at steering electronics
+ 48V_SR
Yellow
Steering OK
STEER PWR
Yellow
Steering OK
POWER OK
Yellow
Indicates all voltages present on the logic card
Potentiometer
Function
RV 1
Not used. (Trimming of proportional valve opening position)
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
18- 17
Electrical system – 5000.2 Electric system, overview T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
18.5 Electric system, overview VRE125SF 8
1 1
G1 48V
X1
SHUNT WIRE
X1
+ -
40 22 F63
MEASURING WIRES
26 40
1 ID
45 46
40 119
X3:7 GND
S89
1 40 22
49 27
X3:4 CAN H
120 X3:3 CAN L
50
R1
27
28
28 29
X3:5 OPERATION MODE PIN 1
30
X3:9 OPERATION MODE PIN 2 S66
58 C4
59 S65
47 nF
57
110
INP LEFT FOOT SWITCH
809
INP +48VDC SUPPLY OUTPUTS
104
INP DRIVE FORK DIR CREEP
105
INP STEER WHEEL DIR CREEP
203
INP SEAT SWITCH
507
POT FEED 7-7,5VDC
501
SPEED REFERENCE VALUE
508
72
71
31
70 INP BATT IND + 601
43 22
S26
40 25 M6
60 61
U1
62
29 30
125
OV 4
PRE SELECTION HEIGHT UNIT A7 0V 6
3 RX- +48VDC 4 1 TX+ 5 TX-
RX+ HEIGHT UNIT 409 RX- HEIGHT UNIT 410 SERIE + 405 SERIE - 406
RS 485
TX + 407
127 128 121
1 SERIE +
122
2 SERIE -
125
3 RX +
126
4 RX -
DISPLAY A6
POT GND
810
+15VDC
811
GND
210
INP STEER WHEEL ANGLE A
211
INP STEER WHEEL ANGLE B
209
INP STEER WHEEL REF 180 DEG
OUT CAN +15VDC OUT CAN GND OUT/INP CAN H OUT/INP CAN L
902
GND
901
+48VDC STEER SERVO
903
OUT + STEER MOTOR
904
GND FOR STEER MOTOR
401 402 403 404
INP STEERING WHEEL TACHO +
INP HEIGHT COUNTER > FREELIFT PULSE A
301
GND FOR TACHO
INP HEIGHT COUNTER > FREELIFT PULSE B
302
802
OUT PARKING BRAKE
502
INP BRAKE REFERENCE VALUE
63
801
OUT SUPPORT ARM BRAKE 1
INP WIRE GUIDANCE OFF
304
68
803
OUT SUPPORT ARM BRAKE 2
51
126
7 RX+
511
64
Y5:1
LIFT HEIGHT INDICATOR A8
2 RX-
509
129
R2
E3
5 RX+ +48VDC 3
TX - 408
S131 Y1
192 E4
ELECTRONIC CARD A5
806 F61
191
40
RX- 2
LENGTH INDICATOR A9
INP BATT IND CURRENT (+) 603
S21
24
INP KEY
INP BATT IND - CURRENT (-) 602
S17
+ 48VDC
807
804
23 S23
X3:2 X3:1
805
INP MAIN CONTACTOR 808
21 24
OUT MAIN CONTACTOR
21 21
S99
26
4 OV
22
F60
2
3 +48VDC RX+ 5
F62
8
ELECTRONIC CARD A16
1
2
X42 X42 EXTERNAL EQUIPMENT
MAIN CONTACTOR K10
40
1
117 118 119 120
U10
98
29 30
99
66 30
40 22 27 28
Y6:1
Y5:2
29 WITHOUT WIRE GUIDANCE
Y6:2
OUT CABIN LOWER 711
S120
Y21
102
OUT CABIN LIFT
OUT TRAVEL ALARM
R32
H18
H95
H96
Y20
H3
710 101
OUT WARNING LAMP MOTION
OUT LENGTH INDICATION LAMP (IN AISLE) 709
707 38
OUT FORKS IN HOME POSITION (L, R OR MIDDLE)
R31
108
708 37
H2
OUT HALF PALLET HANDLING IND LAMP
OUT IN AISLE IND LAMP 706
705
INP HALF PALLET HANDLING MODE
R34 S90 S9
S7
S178
S156
S5 Y11
33
306
305
INP IN AISLE MIDDLE S4
703
111 44
89
Y24
Y10
88
702
M10
701
E10
OUT FORK LIFT
OUT FORK LOWER
54
H1
32
OUT POWER FAN ELECTRIC PANEL
R30
INP SPEED REDUCTION
307
INP IN AISLE SIGNAL2
206
91
INP OVERRIDE
92
INP WEIGHT
205
90
S18
107
INP PERSONAL PROTECTION 2
204
107
162 M12
OUT DATA COLLECT DRIVE
207
42
100
OUT DATA COLLECT LIFT
208
S8
S33
INP PERSONAL PROTECTION 1
202
INP IN AISLE SIGNAL1
81
S61
201
S6
161
INP JOYSTICK TRAVERSE
OUT FORK SELECT MOVE
160
40
504
106
83
R4
22
503 INP JOYSTICK FORK
41
82
R6
18- 18
30
30
29 22
29 22
40
40
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical system – 5000.2 Electric system, overview Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
20
40 22
ELECTRONIC CARD TURRET HEAD A4 U9
55
40
56 22 40 20
012 INP HEIGHT COUNTER < FREELIFT PULSE A 011 INP HEIGHT COUNTER < FREELIFT PULSE B 001 INP +48VDC SUPPLY OUT TRAVERSE LEFT 017
029 GND 028 OUT +15VDC SUPPLY
OUT TRAVERSE RIGHT 004
041 INP STEER SAFETY RELAY
20 40 U13
52 53 103
OUT SWITCH SIGNAL 020 015 GND INP. 15 VDC
009 INP TRAVERSE COUNTER PULSE A
030
Y8
94
Y9
95
150 20
008 INP TRAVERSE COUNTER PULSE B
20 22 40 8
010 INP FORKS HOME POS INDICATOR
S50
120 119
042 OUT/INP CAN L
INP HEIGHT REFERENCE 013
S93
104
R109
027 OUT/INP CAN H
SERVICE KEY INTERFACE X41 117 118 119 120
1 2
FREQUENCY INVERTER PUMP A2
3
PUMP MOTOR M3 U
4
R100
5
V
6
W
7 117 118 119 120
300A F3
U
B+ B-
V W
7 12 4
13
3
10 11
5
1
119
120 JP2:3 OUT ON WIRE JP1:21 OUT +5VDC
JP1:7 INP ENCODER PULSE A
OUT +12VDC JP2:21
JP1:8 INP ENCODER PULSE B
INP STEER WHEEL IN HOME POS JP2:9
17
U12
18 22
3 4
160A F1
U
W
7
12
4
13
3
10 11
5
22
6
40
1
111 112 113
B+ B-
V
S85
8 40
14 B1
11 10 12
U11
22 40
13 22
22 40
JPW2:13 SHIELD
JPW2:15 OUT +12VDC
JPW2:8 OUT T3
JPW2:7 OUT T2
JPW2:6 OUT T1
JPW2:5 OUT T0
JPW2:3 INP LEFT COIL
JPW2:2 INP NEAR WIRE COIL
JPW2:1 INP RIGHT COIL
JPW2:14 GND VIOLET
J1T:14
BLUE
J1T:8
GREEN
J1T:7
J1T:6
YELLOW
ORANGE
J1T:5
RED
J1T:3
BROWN
BLACK
J1T:1
J1T:2
JPW1:13 SHIELD J1L:13
JPW1:14 GND
JPW1:8 OUT T3
JPW1:7 OUT T2
JPW1:6 OUT T1
JPW1:5 OUT T0
JPW1:3 INP LEFT COIL
JPW1:2 INP NEAR WIRE COIL
JPW1:1 INP RIGHT COIL
JPW1:15 OUT +12VDC GREY
VIOLET
J1L:14
J1L:15
J1L:8
BLUE
GREEN
J1L:7
ORANGE
YELLOW
J1L:6
J1L:3
J1L:5
RED
BROWN
BLACK
J1L:1
J1L:2
GND JP2:23
2
117 118 119 120
JP3:4
GND JP2:24
ANTENNA 1 W1
W
JP3:2
U15
© BT Europe AB
JP3:1
INP +48VDC SUPPLY JP2:11
132 133
V
WIRE GUIDANCE A3
JP1:12 GND
130
15
J1T:3
67 131
B2
16
GREY
R35
DRIVE MOTOR M1 U
J1T:15
40
S120
19
FREQUENCY INVERTER DRIVE A1
OUT/INP CAN L JP4:5 OUT/INP CAN H JP4:6
WITHOUT WIRE GUIDANCE
40
ID 8
6
22
8
ANTENNA 2 W2
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
18- 19
Electrical system – 5000.2 Electric system, overview T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
VRE150 8
1 G1 48V
X1
1
SHUNT WIRE
X1
+ -
40 22 F63
MEASURING WIRES
26 40
1
2
2
S99
26
191
1 ID
5 RX+ +48VDC 3
RX- 2
2 RX-
LENGTH INDICATOR A9
72
71
70
31
23 22 S26
45 46
40 119
1 1
X3:7 GND
S89
40 22
27
X3:4 CAN H
50
R1
120 X3:3 CAN L
49
27
28
28 29
X3:5 OPERATION MODE PIN 1
30
X3:9 OPERATION MODE PIN 2
S66
58 C4
59 S65
47 nF
57
807
INP KEY
110
INP LEFT FOOT SWITCH
809
INP +48VDC SUPPLY OUTPUTS
104
INP DRIVE FORK DIR CREEP
105
INP STEER WHEEL DIR CREEP
203
INP SEAT SWITCH
507
POT FEED 7-7,5VDC
501
126
125
PRE SELECTION HEIGHT UNIT A7
804
ELECTRONIC CARD A5
40 25 M6
60 61
U1
62 129
RX+ HEIGHT UNIT 409 RX- HEIGHT UNIT 410 SERIE + 405
64
R2 Y5:1
29 30
51
SERIE - 406
RS 485
TX + 407 TX - 408
127 128 121
1 SERIE +
122
2 SERIE -
125
3 RX +
126
4 RX -
DISPLAY A6
POT GND
810
+15VDC GND
210
INP STEER WHEEL ANGLE A
211
INP STEER WHEEL ANGLE B
209
INP STEER WHEEL REF 180 DEG
OUT CAN +15VDC OUT CAN GND OUT/INP CAN H OUT/INP CAN L
902
GND
901
+48VDC STEER SERVO
401 402 403 404
903
OUT + STEER MOTOR
904
GND FOR STEER MOTOR
509
INP STEERING WHEEL TACHO +
INP HEIGHT COUNTER > FREELIFT PULSE A
301
511
GND FOR TACHO
INP HEIGHT COUNTER > FREELIFT PULSE B
302
802
OUT PARKING BRAKE
INP WIRE GUIDANCE OFF
304
S131 Y1
1 TX+ 5 TX-
806 F61
0V 6
3 RX- +48VDC 4
SPEED REFERENCE VALUE
508
811
INP BATT IND CURRENT (+) 603
43
INP BATT IND - CURRENT (-) 602
S21
24
INP BATT IND + 601
S23 S17
X3:2 X3:1
+ 48VDC
INP MAIN CONTACTOR 808
805 24
OUT MAIN CONTACTOR
F60
21 21
OV 4
4 OV
7 RX+
ELECTRONIC CARD A16
E3
LIFT HEIGHT INDICATOR A8
3 +48VDC RX+ 5
F62
8
192 E4
40
X42 X42 EXTERNAL EQUIPMENT
MAIN CONTACTOR K10
40
1
502
INP BRAKE REFERENCE VALUE
63
801
OUT SUPPORT ARM BRAKE 1
68
803
OUT SUPPORT ARM BRAKE 2
117 118 119 120
U10
98
29
99
30
66 30
40 22 27 28
Y6:1
Y5:2
29 WITHOUT WIRE GUIDANCE
Y6:2
OUT CABIN LIFT
OUT CABIN LOWER 711
710
102
101
S120
Y21
OUT WARNING LAMP MOTION
OUT TRAVEL ALARM
H18
H95
H96
Y20
OUT IN AISLE IND LAMP
OUT FORKS IN HOME POSITION (L, R OR MIDDLE)
OUT LENGTH INDICATION LAMP (IN AISLE) 709 R32
108
38
707
708
705
706
37
33 R31
H3
R34 S90
S4 S9
S7
S178
S5
S156
Y11
H2
305
INP IN AISLE MIDDLE
OUT FORK LIFT
OUT FORK LOWER
89
Y24
Y10
88
702
M10
703
E10
701
H1
INP HALF PALLET HANDLING MODE
OUT POWER FAN ELECTRIC PANEL
OUT HALF PALLET HANDLING IND LAMP
307
54
306
INP SPEED REDUCTION
32
INP OVERRIDE
206
R30
INP WEIGHT
205
91
INP PERSONAL PROTECTION 2
204
92
207
111
107
INP PERSONAL PROTECTION 1 OUT DATA COLLECT LIFT OUT DATA COLLECT DRIVE
90
S18
INP JOYSTICK SPARE2
44
M12
100
510
201 202 208
INP IN AISLE SIGNAL2
S33
INP JOYSTICK SPARE1/ AUTO ROTATE
107
81
S61
INP JOYSTICK ROTATE
506
42
86 160
R15
505
S8
85
R14
40
INP JOYSTICK TRAVERSE
INP IN AISLE SIGNAL1
R5
504
106
84
503 INP JOYSTICK FORK
41
83
R4
22
S6
R6
OUT FORK SELECT MOVE
82
18- 20
30
30
29 22
29 22
40
40
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical system – 5000.2 Electric system, overview Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
20
40 22
ELECTRONIC CARD TURRET HEAD A4 U9
55
40
56 22 40 20
012 INP HEIGHT COUNTER < FREELIFT PULSE A 011 INP HEIGHT COUNTER < FREELIFT PULSE B OUT PROPORTIONAL VALVE TRAVERSE 016
001 INP +48VDC SUPPLY
OUT TRAVERSE LEFT 017
029 GND 028 OUT +15VDC SUPPLY
OUT TRAVERSE RIGHT 004 OUT PROPORTIONAL VALVE ROTATE 003
041 INP STEER SAFETY RELAY
20 40 U13
52 53 103
OUT ROTATE COUNTER CLOCKWISE 006
015 GND
OUT ROTATE CLOCKWISE 005
Y25
93 Y8
94
Y9
95 Y26
73
Y27
74 Y28
75
009 INP TRAVERSE COUNTER PULSE A 008 INP TRAVERSE COUNTER PULSE B
20 22 40 8
010 INP FORKS HOME POS INDICATOR
S50
OUT SPARE 1A 018 OUT SPARE 1B 019 120 119
042 OUT/INP CAN L
INP HEIGHT REFERENCE 013 R109
OUT POT FEED +10VDC 002
027 OUT/INP CAN H
INP ROTATION ANGLE 007
Y16
76 Y17
77
S93
104 39 65
R8
SERVICE KEY INTERFACE X41 117 118 119 120
1 2
FREQUENCY INVERTER PUMP A2
3
PUMP MOTOR M3 U
4
R100
5
V
6
W
7 117 118 119 120
300A F3
U
B+ B-
V
7 12 4
13 10
3
11
5
1
119
120 67 131
JP2:3 OUT ON WIRE
JP3:1
JP1:12 GND
INP +48VDC SUPPLY JP2:11
JP1:21 OUT +5VDC
132
JP1:7 INP ENCODER PULSE A
OUT +12VDC JP2:21
133
JP1:8 INP ENCODER PULSE B
INP STEER WHEEL IN HOME POS JP2:9
GND JP2:24
15 17
U12
18 22
4
160A F1
U
W
7
12
4
13
3
10 11
5
22
6
40
1
111 112 113
B+ B-
V
S85
8 40
14 B1
11 10 12
U11
22 40
13 22
22 40
JPW2:13 SHIELD
JPW2:15 OUT +12VDC
JPW2:14 GND
JPW2:8 OUT T3
JPW2:7 OUT T2
JPW2:6 OUT T1
JPW2:5 OUT T0
JPW2:3 INP LEFT COIL
JPW2:2 INP NEAR WIRE COIL
3
J1T:3
J1T:14
VIOLET
BLUE
J1T:8
GREEN
J1T:7
J1T:6
J1T:5
YELLOW
ORANGE
RED
JPW2:1 INP RIGHT COIL
Service Manual
J1T:3
BROWN
BLACK
J1T:1
J1T:2
JPW1:15 OUT +12VDC
JPW1:14 GND
JPW1:8 OUT T3
JPW1:7 OUT T2
JPW1:6 OUT T1
JPW1:5 OUT T0
JPW1:3 INP LEFT COIL
JPW1:2 INP NEAR WIRE COIL
JPW1:1 INP RIGHT COIL
JPW1:13 SHIELD J1L:13
J1L:15
GREY
VIOLET
J1L:14
BLUE
J1L:8
GREEN
J1L:7
J1L:6
YELLOW
ORANGE
J1L:5
RED
BROWN
BLACK
J1L:1
J1L:2
ANTENNA 1 W1
GND JP2:23
2
117 118 119 120
JP3:4
130
J1L:3
W
JP3:2
U15
© BT Europe AB
B2
16
GREY
R35
V
WIRE GUIDANCE A3
J1T:15
40
S120
19
FREQUENCY INVERTER DRIVE A1 DRIVE MOTOR M1 U
OUT/INP CAN L JP4:5 OUT/INP CAN H JP4:6
WITHOUT WIRE GUIDANCE
40
ID 8 W
6
22
8
ANTENNA 2 W2
Veflex VR, VR SF, VRE150, VRE125SF
18- 21
Electrical system – 5000.2 Symbol list and wiring diagrams T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
18.6 Symbol list and wiring diagrams 18.6.1 List of symbols Symbol
Description
Symbol
Description
Battery
18- 22
Brake coil, normally released
Brake coil, normally applied
Switch normally open
Switch normally closed
Push-button switch, normally open
Push-button switch, normally closed
Momentary switch, normally open
Momentary switch, normally closed
Push-button switch, latching, normally open
Emergency switch off
Key switch normally open
Push-button switch, latching and momentary
Electro-magnetic switch, normally open
Electro-magnetic switch, normally closed
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical system – 5000.2 Symbol list and wiring diagrams Order number 244989-040
Symbol
Date 2013-03-04
Valid from serial number 6004330-
Description
Symbol
T-code 485, 487
Description
Pressure-sensitive switch, normally open
Pressure-sensitive switch, normally closed
Capacitive switch, normally open
Capacitive switch, normally closed
Inductive sensor, normally open
Inductive sensor, normally closed
Pulse transducer
Seat heater with thermostat
Temperature sensor
Motor, general
Series motor, armature coils, DC
Series motor, DC
Motor, permanent magnet
Three-phase motor, AC
© BT Europe AB
Series winding
Shunt winding
Converter, AC/DC
Converter, DC/DC
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
18- 23
Electrical system – 5000.2 Symbol list and wiring diagrams T-code 485, 487
Symbol
18- 24
Valid from serial number 6004330-
Description
Date 2013-03-04
Symbol
Order number 244989-040
Description
Variable resistor (potentiometer)
Fixed resistor
Contactor
Horn
Lamp
Valve
Fuse
Diode
Zener diode
Light emitting diode (LED)
Connector
Multi-pin connect
Capacitor
Measuring cable
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
© BT Europe AB
Service Manual
2
1
MAIN CONTACTOR K10 A1 A2
X1
MEASURING WIRES
G1 48 V + X1
10A F62
SHUNT WIRE
23
31
70
71
72
808
804
601
602
603
INP. MAIN CONTACTOR
OUT. MAIN CONTACTOR
INP. BATT. INDI. +
249735 1/25
INP. BATT. INDI. -, CURRENT -(-)
INP. BATT. INDI. CURRENT -(+)
ELECTRONIC CARD A5
40
Sh. 2
Date 2013-03-04
8
40
1
Order number 244989-040
Sh. 2
Sh. 3
Electrical system – 5000.2 Symbol list and wiring diagrams
Valid from serial number 6004330T-code 485, 487
18.6.2 Electric wiring diagrams VRE125SF
Veflex VR, VR SF, VRE150, VRE125SF
18- 25
18- 26
22
40
Service Manual
X30
105
B1
Bk
-
+
Red
11
14
4
7
Wh
13
12
1
6
5
+
118/BLUE 119/RED 120/WHITE
2 3 4
X31 X31 X31 X31
X45 X45 X45 X45
4
3
2
120
119
118
117
404
403
402
401
INP./OUT. CAN L
INP./OUT. CAN H
OUT. CAN GND
OUT. CAN +15VDC
ELECTRONIC CARD A5
M
3~A
DRIVE MOTOR M1 U V M W
Sh. 3
Sh. 3
Sh. 7
Sh. 7
249735 2/25
120/WHITE
119/RED
118/BLUE
117
Date 2013-03-04
R100
117
1
11
10
13
12
W
V
U
Valid from serial number 6004330-
SERVICE KEY INTERFACE X41
A
B
Bl
10 3 SPEED MEASURING IN M1 U11
THERMO ELECTRICAL SENSOR IN M1
-
B-
+
B
160A F1
T-code 485, 487
Sh. 3
Sh. 1 3
Sh. 1 7
8
FREQUENCY INVERTER, DRIVE A1
Electrical system – 5000.2
Symbol list and wiring diagrams Order number 244989-040
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
© BT Europe AB
Service Manual
120
119
40
21
21
CAN L
OPERATION MODE PIN1
OPERATION MODE PIN 2
X3:5
X3:9
CAN H
GND
+48VDC SUPPLY
X3:3
X3:4
X3:7
X3:1
X3:2
ELECTRONIC CARD A16
X3:6
24 1
S21 2
X30
EMERGENCY SWITCH OFF
X25
X32
1
S89
2
3
S26
1
1
3
S23
X30
3
X25
X32
X32
49
46
45
22
43
24
21
203
105
104
809
110
807
805
INP. SEAT SWITCH
249735 3/25
INP. DRIVE, STEER WHEEL DIRECTION, CREEP
INP. DRIVE, FORK DIRECTION, CREEP
+ 48VDC SUPPLY OUTPUTS
INP. LEFT FOOT SWITCH
INP. KEY
+ 48VDC
Date 2013-03-04
22
10A F60
Order number 244989-040
Sh. 2 4
Sh. 1 5
1
ELECTRONIC CARD A5
Electrical system – 5000.2 Symbol list and wiring diagrams
Valid from serial number 6004330T-code 485, 487
Veflex VR, VR SF, VRE150, VRE125SF
18- 27
Service Manual
Sh. 3 5
Sh. 6
22
28
27
X30
X25
M
1 X25
4
M
M12
S18
Bl -
3 54 3
HORN H1
X32
R1
+R
X32
107
28
50
27
307
508
501
507
40
249735 4/25
OUT. POWER, FAN ELECTRIC PANEL
POT. GND
INP. SPEED REFERENCE VALUE
POT. FEED 7-7,5VDC
Sh. 3 5
Date 2013-03-04
IN
FAN PUMPMOTOR M10 X35 X35
SEAT HEATER E10
+
18- 28 Valid from serial number 6004330-
-
Sh. 6
T-code 485, 487
2
ELECTRONIC CARD A5
Electrical system – 5000.2
Symbol list and wiring diagrams Order number 244989-040
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
© BT Europe AB
Service Manual
Sh. 3 10
C4
X30
Br
Bk
1
40
22
30A F61
Red
X32
Br
S65 Bk
M
U1
M
M6
Red
X34
Veflex VR, VR SF, VRE150, VRE125SF
129
62
61
60
25
40
57
59
58
511
509
904
903
901
902
806
209
211
210
811
810
GND, TACHO
249735 5/25
INP. STEERING WHEEL TACHO +
GND, STEER MOTOR
OUT. + , STEER MOTOR
+ 48VDC STEER SERVO
GND
INP. STEER WHEEL REFERENCE 180 DEG.
INP. STEER WHEEL ANGLE B
INP. STEER WHEEL ANGLE A
GND
+ 15VDC
Valid from serial number 6004330-
Bk
Bk
Wh
30
30 S66
29
29
Date 2013-03-04
Sh. 4 6
Sh. 4 6
Sh. 11
Sh. 11
Bl
Order number 244989-040
Bl
ELECTRONIC CARD A5
Electrical system – 5000.2 Symbol list and wiring diagrams T-code 485, 487
18- 29
18- 30
Service Manual
Sh. 4 8
Sh. 4 8
Sh. 5 7
28
27
40
22
X38
DISPLAY A6
2
3
4
RX +
RX -
1
SERIE -
SERIE +
S131 2
RIGHT ARM, OUTER Y6:2
RIGHT ARM, INNER Y5:2
Y1
X46
X46
X46
X46
R2
X38
X38
68
63
51
126
125
122
121
64
803
801
502
408
407
406
405
802
RS 485
OUT. SUPPORT ARMBRAKE 2
OUT. SUPPORT ARMBRAKE 1
INP. BRAKE REFERENCE VALUE
TX-
TX+
SERIE -
SERIE +
OUT. PARKING BRAKE
ELECTRONIC CARD A5
249735 6/25
Sh. 10
Sh. 10
Date 2013-03-04
125
126
Valid from serial number 6004330-
LEFT ARM, OUTER Y6:1
LEFT ARM, INNER Y5:1
1
EMERGENCY MODE
1
T-code 485, 487
2
Sh. 5 7
X30
Electrical system – 5000.2
Symbol list and wiring diagrams Order number 244989-040
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB 3
© BT Europe AB
Service Manual
Sh. 6 8
22
X30
155
-
A
B
Wh
Bl
18
17
15
16
19
Veflex VR, VR SF, VRE150, VRE125SF 1
6
5
3
4
7
11
10
13
12
7
6
5
M
3~A
M
PUMP MOTOR M3 U V W
249735 7/25
120/WHITE
119/RED
118/BLUE
117
Sh. 3 12
Sh. 3 12
Sh. 2
Sh. 2
Valid from serial number 6004330-
Bk
+
Red
SPEED MEASURING IN M3 U12
B2
THERMO ELECTRICAL SENSOR IN M3
W
8 ID
U
V
+
-
B-
+
Date 2013-03-04
40
B
300A F3
Order number 244989-040
Sh. 6 8
Sh. 2
8
FREQUENCY INVERTER, PUMP A2
Electrical system – 5000.2 Symbol list and wiring diagrams T-code 485, 487
18- 31
Service Manual
40
X14 X16 X49
X30
R4
2
1
X30
X32 5
S33 1
Y9
Y8
X33
X31
X75
S61
X45 5
NOT ON COLD STORECABIN
NOT ON COLD STORECABIN
X33
X33
INP. OVERRIDE
INP. WEIGHT
004
017
OUT. TRAVERSE RIGHT
OUT. TRAVERSE LEFT
249735 8/25
INP. PERS. PROT. 2 (NOT ACTIVE) (WHEN USED, SEE PAGE 21)
ELECTRONIC CARD A4
205
204
207
INP. PERS. PROT. 1 (NOT ACTIVE) (WHEN USED, SEE PAGE 21)
OUT. DATA COLLECT, DRIVE
208
201
OUT. DATA COLLECT, LIFT
INP. SPEED REDUCTION
INP. JOYSTICK TRAVERSE
INP. JOYSTICK FORK
202
206
504
503
Date 2013-03-04
95
94
100
81
22
22
83
82
Valid from serial number 6004330-
Sh. 7 9
22
28
X32
R6
ELECTRONIC CARD A5
T-code 485, 487
Sh. 7 9
Sh. 6
Sh. 6
X32
1
3
1
3
18- 32 2
27
Electrical system – 5000.2
Symbol list and wiring diagrams Order number 244989-040
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
© BT Europe AB
Sh. 8 10
Sh. 8 10
22
40
X30
Service Manual
X69
X14
S5 Bl
STEER WHEEL DIR. RIGHT S156 Br Bk
Br
FORK DIRECTION 1
Y11
S7 Bl
Br
S9 Bl
Y24
S6 Bl
S8 Bl
Veflex VR, VR SF, VRE150, VRE125SF Br
S4
Bl
STEER WHEEL DIRECTION
Br
STEER WHEEL DIRECTION 2
Br
STEER WHEEL DIRECTION 1
FORK DIR. LEFT S178 Br Bk
FORK DIRECTION
Br
FORK DIRECTION 2
X47
Y10
X15
X69
X15
X15
X47
X47
X47
44
42
41
90
89
88
111
107
106
703
701
702
INP. IN AISLE, MIDDLE
INP. IN AISLE, SIGNAL 2
INP. IN AISLE, SIGNAL 1
249735 9/25
OUT. SELECT FORK MOVE
OUT. FORK LIFT
OUT. FORK LOWER
Valid from serial number 6004330-
X69
X14
X14
X47
X47
Date 2013-03-04
Bl
Order number 244989-040
Bl
ELECTRONIC CARD A5
Electrical system – 5000.2 Symbol list and wiring diagrams T-code 485, 487
18- 33
18- 34
1
40
22
X45
Service Manual
10A F63
X37
X30
X45
40
Y20
-
+
+
9
5
330
920
-
Y21
H96
R31
+
-
2
1
+
-
109
H95
H2
ID 0V
1 4
2
1
+48V
3
R30
R32
47ohm/50W
+
320
RX-
RX+
2
5
40
26
NOT 680ohm/2W
X45
X45
LENGTH INDICATOR A9
680ohm/2W
R34
680ohm/2W
EXTERNAL EQUIPMENT X42 X42
H3
H18
H90
S90
1
S99
X23
X23
5
X75
191
X37
X36
X30
X31
X30
ON COLDSTORE CABIN X75 X30
X31
X31
E4
X45
X45
102
101
108
38
37
33
32
92
91
X46
X46
192
E3
OUT. CABIN LOWER
OUT. CABIN LIFT
249735 10/25
126
125
Sh. 6 11
Sh. 6 11
OUT. LENGTH INDICATION LAMP (IN AISLE)
OUT. TRAVEL ALARM
OUT. WARNING LAMP (MOTION)
OUT. IN AISLE INDICATION LAMP
OUT. FORKS IN HOME POSITION
OUT. HALF PALLET HANDLING INDI. LAMP
INP. HALF PALLET HANDLING MODE
WORKING LIGHT
711
710
709
707
708
706
705
306
305
Date 2013-03-04
26
X45
X45
X23
X23
X36
-
10
1
Valid from serial number 6004330-
X31
X31
X31
X31
X31
NOT ON COLDSTORE CABIN X31 X45
X31
X45
T-code 485, 487
Sh. 5 13
Sh. 9 11
Sh. 9 11
ELECTRONIC CARD A5
Electrical system – 5000.2
Symbol list and wiring diagrams Order number 244989-040
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
© BT Europe AB
Service Manual
Sh. 12
X17
X17
X32
X32
X14 X16 X49
X15
X15
X31
X45
2
4
6
+48V
0V
-
Bk
-
+
Red
Bk
+
Red
U9
U10
3
1
5
TX+
TX-
7
RX-
RX+
PRE SELECTION HEIGHT A7
RX-
0V
4
5
B
A
B
A
Bl
Wh
Bl
Wh
Br
X34
X34
X34
X34
S93 Bl
X45
X45
X17
X17
X46
X46
X15
X15
104
56
55
99
98
128
127
013
011
012
Sh. 10
Sh. 10
INP. HEIGHT COUNTER > FREELIFT PULSE B
INP. HEIGHT COUNTER > FREELIFT PULSE A
RX- HEIGHT UNIT
RX+ HEIGHT UNIT
Veflex VR, VR SF, VRE150, VRE125SF
249735 11/25
INP. FORKS < REFERENCE HEIGHT
INP. HEIGHT COUNTER < FREELIFT PULSE B
INP. HEIGHT COUNTER < FREELIFT PULSE A
ELECTRONIC CARD, TURRET UNIT A4
302
301
410
409
ELECTRONIC CARD A5
126
125
Valid from serial number 6004330-
20
30
X30
RX+
+48V
3
Date 2013-03-04
Sh. 5
Sh. 5
29
40
22
LIFTING HEIGHT INDICATOR A8
Order number 244989-040
Sh. 10 12
Sh. 10 12
X45
Electrical system – 5000.2 Symbol list and wiring diagrams T-code 485, 487
18- 35
18- 36
Service Manual
20
120/WHITE
119/RED
40
22
X30
X15
X15
X14
X14
X16
X16
X16
X16
X49
X49
X49
X49
-
B
A
Wh
Bl
Br
S50 Bk
103
53
52
010
008
249735 12/25
INP. FORKS IN HOME POS. INDICATOR
INP. TRAVERSE COUNTER PULSE B
INP. TRAVERSE COUNTER PULSE A
INP. STEER SAFETY RELAY 041
009
OUT. + 15VDC SUPPLY
INP./OUT. CAN L
120ohm / 1W
028
042
R109
INP./OUT. CAN H
GND 015
027
GND
INP. + 48VDC SUPPLY
029
001
Date 2013-03-04
Bk
+
Red
U13
20
120
119
40
22
Valid from serial number 6004330-
Sh. 11 18
Sh. 7 14
Sh. 7 14
Sh. 11 13
Sh. 11 13
T-code 485, 487
Bl
ELECTRONIC CARD, TURRET UNIT A4
Electrical system – 5000.2
Symbol list and wiring diagrams Order number 244989-040
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
© BT Europe AB
Service Manual
Sh. 12 14
Sh. 12 14
Sh. 10 22
X45
X44
1
S97
5
X57
X45
0/1/2/3
(Bk) S70
(Ye)
(Gn)
(Or)
DEFROST START (1500W)
(Gn)
(Bl)
S68 COMFORT HEATER (1500W) FAN SPEED / MASTER ON/OFF S69 (Ye) (Wh)
(Red)
COLD STORE CABIN
FAN
M
Y1
TIMER
THERMOSTAT 2 4
15
5A
30A
30A
30A
30A
18
750W
750W
750W
HEATER IN COLD STORE CABIN
249735 13/25
750W
Valid from serial number 6004330-
Veflex VR, VR SF, VRE150, VRE125SF
40
X31
E2
E1
157
COURTESY LIGHTS IN CABIN
22
1
E98
Date 2013-03-04
A1
Order number 244989-040
A2
OPTION
Electrical system – 5000.2 Symbol list and wiring diagrams T-code 485, 487
18- 37
Service Manual
120/WHITE
119/RED
40
22
X30
X48
X48
X48
X48
Br
S85 Bk
120
119
113
112
111
40
22
JP3:4
INP./OUT. CAN L
INP./OUT. CAN H
GND
249735 14/25
INP. STEER WHEEL IN HOME POS.
OUT. + 12VDC
GND
INP. + 48VDC SUPPLY
Date 2013-03-04
JP3:2
JP3:1
JP4:5
JP4:6
JP2:23
JP2:9
JP2:21
JP2:24
JP2:11
Valid from serial number 6004330-
Sh. 12 25
Sh. 12 25
Sh. 13 18
Sh. 13 15
WIRE GUIDANCE A3
T-code 485, 487
Bl
18- 38 WIRE GUIDANCE, PAGE 14 TO 17.
OPTION
Electrical system – 5000.2
Symbol list and wiring diagrams Order number 244989-040
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
© BT Europe AB
Service Manual
Sh. 14 19
22
X30
X32
-
5
S120
7
H120 10 9
B
A
Ye
Gr
670
R35
680 ohm/2W
X32
X32
X48
66
67
133
132
OUT. ON WIRE
INP. ENCODER PULSE B
INP. ENCODER PULSE A
304
Veflex VR, VR SF, VRE150, VRE125SF
249735 15/25
INP. WIRE GUIDANCE OFF
ELECTRONIC CARD A5
JP2:3
JP1:8
JP1:7
OUT. + 5VDC
GND
Valid from serial number 6004330-
VRSF WITHOUT WIRE GUIDANCE
X32
Wh
+
Br
ENCODER U15
JP1:21
JP1:12
Date 2013-03-04
130
131
WIRE GUIDANCE A3
Order number 244989-040
WIRE GUIDANCE, PAGE 14 TO 17.
OPTION
Electrical system – 5000.2 Symbol list and wiring diagrams T-code 485, 487
18- 39
ANTENNA 1 W1
18- 40
Service Manual GREY
VIOLET
JPW1:13
JPW1:15
JPW1:14
T3
T2
T1
SHIELD
OUT. + 12VDC
GND
JPW1:8 OUT.
JPW1:7 OUT.
JPW1:6 OUT.
T0
LEFT COIL
JPW1:5 OUT.
JPW1:3 INP.
NEAR WIRE COIL
RIGHT COIL
249735 16/25
Date 2013-03-04
J1L:13
J1L:15
J1L:14
BLUE
GREEN
YELLOW
ORANGE
RED
JPW1:2 INP.
JPW1:1 INP.
Valid from serial number 6004330-
J1L:8
J1L:7
J1L:6
J1L:5
J1L:3
BROWN
BLACK
WIRE GUIDANCE A3
T-code 485, 487
J1L:2
J1L:1
WIRE GUIDANCE, PAGE 14 TO 17.
OPTION
Electrical system – 5000.2
Symbol list and wiring diagrams Order number 244989-040
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
ANTENNA 2 W2
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
J1T:13
J1T:15
GREY
VIOLET
BLUE
GREEN
YELLOW
ORANGE
JPW2:13
JPW2:15
JPW2:14
T3
T2
T1
SHIELD
OUT. + 12VDC
GND
JPW2:8 OUT.
JPW2:7 OUT.
JPW2:6 OUT.
T0
LEFT COIL
NEAR WIRE COIL
RIGHT COIL
JPW2:5 OUT.
JPW2:3 INP.
JPW2:2 INP.
JPW2:1 INP.
2497354 17/25
Valid from serial number 6004330-
J1T:14
J1T:8
J1T:7
J1T:6
J1T:5
RED
BROWN
BLACK
Date 2013-03-04
J1T:3
J1T:2
J1T:1
WIRE GUIDANCE A3
Order number 244989-040
WIRE GUIDANCE, PAGE 14 TO 17.
OPTION
Electrical system – 5000.2 Symbol list and wiring diagrams T-code 485, 487
18- 41
18- 42
Service Manual
Sh. 23
Sh. 23
114
115
OUT:4
OUT:3
256
115 X60
X60
X60
X151
X151
X151
X151
X52
X52
WHEN STEREO/CD
X61
X61
X61
X60
156
115
114
110
X55
X55
X55
X55
156
115
114
110
20
150
INP. 15 VDC
OUT. SWITCH SIGNAL
A:2
B:2
B:1
A:1
SHIELD
GND
+ 12VDC
VIDEO SIGNAL
TV-MONITOR A49
030
020
249735 18/25
Date 2013-03-04
40
20
SHIELD
GND
114
X61
PAGE 18 AND 20.
ELECTRONIC CARD, TURRET UNIT A4
Valid from serial number 6004330-
Sh. 14 19
Sh. 12 19
OUT
OUT:2
X14
PAGE 19
+ 12VDC
X16
PAGE 19
210
40
X49
OUT:1
SET:2
150
PAGE 19
VIDEO SIGNAL
GND
SET:1
CAMERA ON FORKS, BT-BRAND EXCLUDING COLDSTORE CABIN
OPTION
T-code 485, 487
PAGE 19
SET
INP. SWITCH SIGNAL
CAMERA SELECTOR A54
Electrical system – 5000.2
Symbol list and wiring diagrams Order number 244989-040
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
© BT Europe AB
Service Manual
40
22
20
X30
X30
SHIELD
OUT:4
256
115
114
210
X61
X61
X61
X61
X60
X60
X60
X60 120ohm/0,6W
R49
X:A50
X:A50
X:A50
X:A50
Veflex VR, VR SF, VRE150, VRE125SF
114
115
40
22
256
115
114
210
20
150
INP. 15 VDC
OUT. SWITCH SIGNAL
SHIELD
GND
+ 12VDC
VIDEO SIGNAL
+
-
-
+
OUT. + 12VDC
OUT. GND
INP. GND
INP. + 48VDC
VOLTAGE CONVERTER A14
A:2
B:2
B:1
A:1
TV-MONITOR A50
030
020
249735 19/25
Valid from serial number 6004330-
Sh. 18 21
Sh. 15 21
Sh. 18
PAGE 19
OUT:3
OUT:2
+ 12VDC
GND
OUT:1
VIDEO SIGNAL
X14
CAMERA ON FORKS, PAGE 19 AND 20.
ELECTRONIC CARD, TURRET UNIT A4
Date 2013-03-04
OUT
PAGE 19
X16
40
X49
SET:2
150
PAGE 19
GND
SET:1
OPTION CAMERA ON FORKS, COLDSTORE CABIN AND TOYOTA BRAND.
Order number 244989-040
PAGE 19
SET
INP. SWITCH SIGNAL
CAMERA SELECTOR A54
Electrical system – 5000.2 Symbol list and wiring diagrams T-code 485, 487
18- 43
18- 44
Service Manual 102
103
104
+ 12VDC
GND
SHIELD
101
102
103
104
+ 12VDC
GND
SHIELD
114
115
256
114
115
256
IN1:4
IN1:3
IN1:2
IN1:1
SHIELD
GND
+ 12VDC
VIDEO SIGNAL 1
410
114
115
256
410
114
115
256
IN2:4
SHIELD
PAGE 18
GND
+ 12VDC
VIDEO SIGNAL 2
249735 20/25
IN 2
PAGE 18
PAGE 18
IN 1
Date 2013-03-04
IN2:3
IN2:2
IN2:1
PAGE 18 VIDEO SIGNAL
310
310
CAMERA SELECTOR A54
Valid from serial number 6004330-
VIDEO SIGNAL
CAMERA ON FORKS, RIGHT A52
101
CAMERAS ON FORKS
T-code 485, 487
VIDEO SIGNAL
CAMERA ON FORKS, LEFT A51
OPTION
Electrical system – 5000.2
Symbol list and wiring diagrams Order number 244989-040
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
X2:4
X2:5
X2:6
INP. 0VDC SUPPLY
INP. DRIVE, STEER WHEEL DIRECTION
INP. 0VDC SUPPLY
40
X2:3
X34
X33
X32
INP. DRIVE, FORK DIRECTION
PERSONAL PROTECTION SYSTEM TBM GM-107ECO
166
165
X30
X150
X150
X150
4
3
S33
8
2
7
1
164
163
100
33
202
208
205
706
OUT. DRIVE, STEER WHEEL DIRECTION
OUT. DRIVE, FORK DIRECTION
INP. OVERRIDE
OUT. IN AISLE INDICATION LAMP
249735 21/25
NOTE! OUTPUT FOR AUDIBLE AND VISIBLE ALARM FROM TBM GM-107ECO EQUIPMENT NOT SHOWED.
X33
OVERRIDE EMERGENCY MODE / OVERRIDE LIFT HEIGHT
X30
Valid from serial number 6004330-
Sh. 19 22
Sh. 22
Sh. 22
22
33
Date 2013-03-04
Sh. 19 23
Sh. 22
ELECTRONIC CARD A5
Order number 244989-040
PERSONAL PROTECTION SYSTEM, PAGE 21 AND 22.
OPTION
Electrical system – 5000.2 Symbol list and wiring diagrams T-code 485, 487
18- 45
18- 46
Service Manual
166
162
X150
X150
X150
X150
X150
X150
X150
X150
X150
X150
X150
X1:13
249735 22/25
INP. OVERRIDE EMERGENCY MODE
OUT. +24VDC
INP. 0 VDC SUPPLY X2:12
X1:12
INP. IN AISLE
OUT. WARNING RELAY
INP. WARNING RELAY
OUT. EMERGENCY RELAY
INP. EMERGENCY RELAY
OUT. EMERGENCY RELAY
INP. EMERGENCY RELAY
0 VDC SUPPLY
INP. +48VDC SUPPLY
X2:10
X1:7
X1:6
X1:5
X1:4
X1:3
X1:1
X9:2
X9:1
8A F
Date 2013-03-04
Sh. 21
165
206
INP. SPEED REDUCTION
161
160
9
Valid from serial number 6004330-
Sh. 21
33
207
201
INP. PERSONAL PROTECTION 2
INP. PERSONAL PROTECTION 1
ELECTRONIC CARD A5
40
7,5A F64
PERSONAL PROTECTION SYSTEM GM-107ECO
T-code 485, 487
Sh. 21
Sh. 21 23
Sh. 13
1
OPTION PERSONAL PROTECTION SYSTEM, PAGE 21 AND 22.
Electrical system – 5000.2
Symbol list and wiring diagrams Order number 244989-040
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
© BT Europe AB
W5
LEFT +
X56
X51
Service Manual H5
RIGHT -
RIGHT +
X56
X56
OUT. +12V
B:4
B:3
B:6
B:5
A:8
A:4
A:7
OUT. RIGHT (-)
OUT. RIGHT (+)
OUT. LEFT (-)
OUT. LEFT (+)
INP.GND
INP. +12V KEY
INP. +12VDC
STEREO/CD A11
1
249735 23/25
OUT. GND (GALV SEPARATED)
OUT. GND (GALV. SEPARATED)
OUT. +12V
INP. GND
INP. +48V
Valid from serial number 6004330-
X56
340
312
312
312
2
5
4
3
6
Date 2013-03-04
LEFT -
X51
340
115
40
22
115
H4
STEREO/CD
114
X44
X44
114
40
22
DC/DC CONVERTER A10
Order number 244989-040
Sh. 18
Sh. 18
Sh. 22 24
Sh. 21 24
OPTION
Electrical system – 5000.2 Symbol list and wiring diagrams T-code 485, 487
Veflex VR, VR SF, VRE150, VRE125SF
18- 47
18- 48
Sh. 23 25
Sh. 23 25
40
22
W5
X:A9
X:A9
Service Manual 340
312
312
312
340
40
22
OUT. +12V
OUT. GND
INP. GND
INP. +48V
OUT. RIGHT (+)
OUT. (-) B:4
OUT. LEFT (-) B:6
B:3
OUT. LEFT (+)
INP. GND
INP. KEY +12V
INP. +12V
249735 24/25
Valid from serial number 6004330-
B:5
A:8
A:4
A:7
STEREO/CD A11
+
-
-
+
DC/DC CONVERTER A10
T-code 485, 487
H5
H4
STEREO/CD ON COLDSTORE CABIN
OPTION
Electrical system – 5000.2
Symbol list and wiring diagrams Date 2013-03-04 Order number 244989-040
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
TRUCK LOG SYSTEM
OPTION
© BT Europe AB W7
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
40
INP. CAN L
INP. CAN H
INP. CAN L
INP. CAN H
INP. GND
INP. +48VDC (LOGGED IN)
X3:9
OPERATION MODE PIN 2
ELECTRONIC CARD, KEYPAD A16
4
3
2
1
249735 25/25
Valid from serial number 6004330-
WHITE
RED
40
22
4
3
INP. GND
INP. +48VDC
Date 2013-03-04
TRUCK LOG SYSTEM, SHOCK SENSOR A23
WHITE
RED
2
1
Order number 244989-040
40
21
TRUCK LOG SYSTEM, CONTROL UNIT A20
Electrical system – 5000.2 Symbol list and wiring diagrams T-code 485, 487
18- 49
18- 50
Service Manual
8
40
1
2
1
MAIN CONTACTOR K10 A1 A2
X1
MEASURING WIRES
G1 48 V + X1
10A F62
SHUNT WIRE
23
31
70
71
72
808
804
601
602
603
INP. MAIN CONTACTOR
OUT. MAIN CONTACTOR
INP. BATT. INDI. +
246883 1/22
INP. BATT. INDI. -, CURRENT -(-)
INP. BATT. INDI. CURRENT -(+)
ELECTRONIC CARD A5
40 Sh. 2
T-code 485, 487
Sh. 2
Sh. 3
Electrical system – 5000.2
Symbol list and wiring diagrams Valid from serial number 6004330Date 2013-03-04 Order number 244989-040
18.6.3 Electric wiring diagrams VRE150
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
© BT Europe AB
22
40
X30
B1
Service Manual
-
4
7
Wh
13
12
1
6
5
BLUE RED WHITE
2 3 4
X31 X31 X31 X31
X45 X45 X45 X45
11
10
13
12
W
V
U
4
3
2
120/WHITE
119/RED
118/BLUE
117
404
403
402
401
M
INP./OUT. CAN L
INP./OUT. CAN H
OUT. CAN GND
OUT. CAN +15VDC
ELECTRONIC CARD A5
M
3~A
DRIVE MOTOR M1
U V W
Veflex VR, VR SF, VRE150, VRE125SF
246883 2/22
120/WHITE
119/RED
118/BLUE
117
Sh. 3
Sh. 3
Sh. 7
Sh. 7
Valid from serial number 6004330-
R100
117
1
SERVICE KEY INTERFACE X41
A
B
Bl
+ Date 2013-03-04
Bk
+
Red
11
14
10 3 SPEED MEASURING IN M1 U11
THERMO ELECTRICAL SENSOR IN M1
-
B-
+
B
160A F1
Order number 244989-040
Sh. 3
Sh. 1 3
Sh. 1 7
8
FREQUENCY INVERTER, DRIVE A1
Electrical system – 5000.2 Symbol list and wiring diagrams T-code 485, 487
18- 51
18- 52
Service Manual
22
1
X30
10A F60
WHITE
CAN L
OPERATION MODE PIN 1
OPERATION MODE PIN 2
X3:5
X3:9
CAN H
GND
+48VDC SUPPLY
X3:3
X3:4
X3:7
X3:1
X3:2
X3:6
24
1
S21 2
X30
EMERGENCY SWITCH OFF
X25
X32
1
2
S89
3
1
3
S23
S26
1
3
X30
X25
X32
X32
49
46
45
22
43
24
203
105
104
809
110
807
805
246883 3/22
INP. SEAT SWITCH
INP. DRIVE, STEER WHEEL DIRECTION, CREEP
INP. DRIVE, FORK DIRECTION, CREEP
+ 48VDC SUPPLY OUTPUTS
INP. LEFT FOOT SWITCH
INP. KEY
+ 48VDC
Valid from serial number 6004330-
RED
40
21
21
ELECTRONIC CARD A16
21
T-code 485, 487
Sh. 2 4
Sh. 1 5
ELECTRONIC CARD A5
Electrical system – 5000.2
Symbol list and wiring diagrams Date 2013-03-04 Order number 244989-040
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Service Manual
Sh. 3 5
Sh. 6
22
28
27
X30
X25
IN
Veflex VR, VR SF, VRE150, VRE125SF
M
1 X25
4
M
M12
S18
Bl -
3 54 3
HORN H1
X32
R1
+R
X32
107
28
50
27
307
508
501
507
40
Sh. 3 5
246883 4/22
OUT. POWER, FAN ELECTRIC PANEL
POT. GND
INP. SPEED REFERENCE VALUE
POT. FEED 7-7,5VDC
Valid from serial number 6004330-
FAN PUMPMOTOR M10 X35 X35
SEAT HEATER E10
+
© BT Europe AB Date 2013-03-04
-
Sh. 6
Order number 244989-040
2
ELECTRONIC CARD A5
Electrical system – 5000.2 Symbol list and wiring diagrams T-code 485, 487
18- 53
18- 54
Service Manual
C4
X30
S66 Bk
1
40
22
30A F61
Red
X32
Br
S65 Bk
M
U1
M
M6
Red
X34
129
62
61
60
25
40
57
59
511
509
904
903
901
902
806
209
211
210
811
810
GND, TACHO
246883 5/22
INP. STEERING WHEEL TACHO +
GND, STEER MOTOR
OUT. + , STEER MOTOR
+ 48VDC STEER SERVO
GND
INP. STEER WHEEL REFERENCE 180 DEG.
INP. STEER WHEEL ANGLE B
INP. STEER WHEEL ANGLE A
GND
+ 15VDC
Date 2013-03-04
Bk
Bk
Wh
58
30
30
Br
29
29
Valid from serial number 6004330-
Sh. 3 10
Sh. 4 6
Sh. 4 6
Sh. 11
Sh. 11
Bl
T-code 485, 487
Bl
ELECTRONIC CARD A5
Electrical system – 5000.2
Symbol list and wiring diagrams Order number 244989-040
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
© BT Europe AB
Service Manual
Sh. 4 8
Sh. 4 8
Sh. 5 7
28
27
40
22
X38
DISPLAY A6
3
4
RX -
2
SERIE -
RX +
1
SERIE +
S131 2
LEFT ARM, OUTER Y6:1
LEFT ARM, INNER Y5:1
1
EMERGENCY MODE
RIGHT ARM, OUTER Y6:2
RIGHT ARM, INNER Y5:2
Y1
X46
X46
X46
X46
R2
X38
X38
68
63
51
126
125
122
121
64
803
801
502
408
407
406
405
802
RS 485
Veflex VR, VR SF, VRE150, VRE125SF
125
126
Sh. 10
Sh. 10
Valid from serial number 6004330-
246883 6/22
OUT. SUPPORT ARMBRAKE 2
OUT. SUPPORT ARMBRAKE 1
INP. BRAKE REFERENCE VALUE
TX-
TX+
SERIE -
SERIE +
OUT. PARKING BRAKE
ELECTRONIC CARD A5
Date 2013-03-04
1
Order number 244989-040
2
Sh. 5 7
X30
Electrical system – 5000.2 Symbol list and wiring diagrams T-code 485, 487
18- 55
3
18- 56
Service Manual
Sh. 6 8
22
40
X30
Bk
-
+
Red
A
B
Wh
Bl
18
17
15
16
19
11
10
13
7
6
5
M
3~A
PUMP MOTOR M3 U V M W
Sh. 3 12
Sh. 3 12
Sh. 2
Sh. 2
246883 7/22
120/WHITE
119/RED
118/BLUE
117
Date 2013-03-04
1
6
5
3
4 12
W
8 ID
7
V
U
-
+
Valid from serial number 6004330-
SPEED MEASURING IN M3 U12
B2
THERMO ELECTRICAL SENSOR IN M3
+
B-
B
300A F3
T-code 485, 487
Sh. 6 9
Sh. 2
8
FREQUENCY INVERTER, PUMP A2
Electrical system – 5000.2
Symbol list and wiring diagrams Order number 244989-040
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Sh. 7 9
Sh. 6
22
28
X32
X32
X30
X30
X32
5
R6
1
3
27
R4
R5
R14
Service Manual
S61
R15
1
2 2 2
1
3
1
3
1
3
1
5
S33 1
X75
100
81
86
85
84
83
82
INP. PERS. PROT. 2 (NOT ACTIVE) (WHEN USED SEE PAGE 20) 207
205
INP. OVERRIDE
246883 8/22
INP. PERS.PROT. 1 (NOT ACTIVE) (WHEN USED SEE PAGE 20) 201
INP. WEIGHT
OUT. DATA COLLECT, DRIVE 208
204
OUT. DATA COLLECT, LIFT
INP. SPEED REDUCTION
INP. JOYSTICK SPARE 2
INP. JOYSTICK SPARE 1/AUTO ROTATE
INP. JOYSTICK ROTATE
INP. JOYSTICK TRAVERSE
INP. JOYSTICK FORK
202
206
510
506
505
504
503
Valid from serial number 6004330-
X33
X31
X33
X33
X33
X33
X33
ELECTRONIC CARD A5
Date 2013-03-04
3
© BT Europe AB 2
Order number 244989-040
2
Sh. 6
Electrical system – 5000.2 Symbol list and wiring diagrams T-code 485, 487
Veflex VR, VR SF, VRE150, VRE125SF
18- 57
18- 58
Service Manual
Sh. 8 10
Sh. 7 10
22
40
X30 Bl
S7 Bl
FORK DIR., LEFT S178 Br Bk
Br
FORK DIRECTION 2
Br
S9 Bl
FORK DIRECTION
X69
X47
S6 Bl
S8 Bl
Br
S4
Bl
STEER WHEEL DIRECTION
Br
STEER WHEEL DIRECTION 2
Br
STEER WHEEL DIRECTION 1
Y24
Y10
X15
X15
X15
X47
X47
X47
44
42
41
90
89
88
111
107
106
703
701
702
246883 9/22
INP. IN AISLE, MIDDLE
INP. IN AISLE, SIGNAL 2
INP. IN AISLE, SIGNAL 1
OUT. SELECT FORK MOVE
OUT. FORK LIFT
OUT. FORK LOWER
Date 2013-03-04
X14
X69
S5
STEER WHEEL DIR., RIGHT S156 Br Bk
Br
FORK DIRECTION 1
Y11
X47
Valid from serial number 6004330-
X69
X14
X14
X47
Bl
T-code 485, 487
Bl
ELECTRONIC CARD A5
Electrical system – 5000.2
Symbol list and wiring diagrams Order number 244989-040
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
© BT Europe AB
1
40
22
Service Manual
10A F63
X30
40
26
X45
Y20
-
+
+
9
5
330
920
-
Y21
H96
R31
+
2
1
109
-
-
H2
H95
R32
320
47ohm/50W
+
+
X45
X45
ID 0V
1 4
2
1
+48V
3
RX- 2
RX+ 5
LENGTH INDICATOR A9
680ohm/2W
R34
680ohm/2W
EXTERNAL EQUIPMENT X42 X42
H3
H18
H90
S90
40
26
R30
1
S99
X23
X23
680ohm/2W
5
X75
X75
191
X37
X36
X30
X30
X31
X31
X31
X30
E4
X45
X45
102
101
108
38
37
33
32
92
91
X46
X46
192
E3
OUT. CABIN LOWER
OUT. CABIN LIFT
246883 10/22
126
125
Sh. 6 11
Sh. 6 11
OUT. LENGTH INDICATION LAMP (IN AISLE)
OUT. TRAVEL ALARM
OUT. WARNING LAMP (MOTION)
OUT. IN AISLE INDICATION LAMP
OUT. FORKS IN HOME POSITION (L,R OR CENTER)
OUT. HALF PALLET HANDLING INDI. LAMP
INP. HALF PALLET HANDLING MODE
WORKING LIGHT
711
710
709
707
708
706
705
306
305
Valid from serial number 6004330-
X31
X31
X45
X23
X23
X36
-
10
1
Date 2013-03-04
X31
X37
X45
X31
X31
X45
X45
X31
X31
X45
Order number 244989-040
Sh. 5 21
Sh. 9 11
Sh. 9 11
ELECTRONIC CARD A5
Electrical system – 5000.2 Symbol list and wiring diagrams T-code 485, 487
Veflex VR, VR SF, VRE150, VRE125SF
18- 59
18- 60
Service Manual
20
30
X30
X14
X15
X15
X31
X45
X16
X17
X17
X32
X32
X49
RX-
0V
4
2
5
4
6
+48V
0V
-
Bk
-
+
Red
Bk
+
Red
U9
U10
3
1
5
TX+
TX-
7
RX-
RX+
PRE SELECTION HEIGHT A7
RX+
+48V
3
B
A
B
A
Bl
Wh
Bl
Wh
Br
X34
X34
X34
X34
S93 Bl
X45
X45
X17
X17
X46
X46
X15
X15
INP. HEIGHT COUNTER > FREELIFT PULSE B
INP. HEIGHT COUNTER > FREELIFT PULSE A
RX- HEIGHT UNIT
RX+ HEIGHT UNIT
013
011
012
246883 11/22
INP. FORKS < REFERENCE HEIGHT
INP. HEIGHT COUNTER < FREELIFT PULSE B
INP. HEIGHT COUNTER < FREELIFT PULSE A
ELECTRONIC CARD, TURRET UNIT A4
302
301
410
409
Sh. 10
Sh. 10
Date 2013-03-04
104
56
55
99
98
128
127
ELECTRONIC CARD A5
126
125
Valid from serial number 6004330-
Sh. 12
Sh. 5
29
40
22
LIFTING HEIGHT INDICATOR A8
T-code 485, 487
Sh. 5
Sh. 10 12
Sh. 10 12
X45
Electrical system – 5000.2
Symbol list and wiring diagrams Order number 244989-040
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
© BT Europe AB
Service Manual
Sh. 11
Sh. 7 14
Sh. 7 14
20
120/WHITE
119/RED
40
22
X15
X15
X14
X30
X16
X16
X16
X14
X49
X49
X49
X16
X49
-
B
A
Wh
Bl
Br
S50 Bk
103
53
52
Veflex VR, VR SF, VRE150, VRE125SF
010
008
246883 12/22
INP. FORKS IN HOME POS. INDICATOR
INP. TRAVERSE COUNTER PULSE B
INP. TRAVERSE COUNTER PULSE A
INP. STEER SAFETY RELAY 041
009
OUT. + 15VDC SUPPLY
INP./OUT. CAN L
120ohm / 1W
028
042
R109
INP./OUT. CAN H
GND 015
027
GND
INP. + 48VDC SUPPLY
029
001
Valid from serial number 6004330-
Bk
+
Red
U13
20
WHITE
RED
40
22
Date 2013-03-04
Sh. 11 13
Sh. 11 14
Order number 244989-040
Bl
ELECTRONIC CARD, TURRET UNIT A4
Electrical system – 5000.2 Symbol list and wiring diagrams T-code 485, 487
18- 61
Sh. 12 14
40
X14 X16 X49
18- 62
Service Manual
X62
X64
Y16
Y27
Y9
R8
Y17
Y28
Y26
Y8
X64
65
39
77
76
75
74
73
95
94
93
007
002
019
018
005
006
003
004
017
016
INP. ROTATION ANGLE
OUT. POT. FEED + 10VDC
OUT. SPARE 1B
OUT. SPARE 1A
OUT. ROTATE, CLOCKWISE
246883 13/22
OUT. ROTATE, COUNTER CLOCKWISE
OUT. PROPORTIONAL VALVE ROTATE
OUT. TRAVERSE RIGHT
OUT. TRAVERSE LEFT
OUT. PROPORTIONAL VALVE TRAVERSE
Date 2013-03-04
X64
X63
X63
X63
X63
X63
X63
X63
X63
Valid from serial number 6004330-
X62
X62
X62
X62
X62
Y25
T-code 485, 487
X62
X62
ELECTRONIC CARD A4
Electrical system – 5000.2
Symbol list and wiring diagrams Order number 244989-040
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
© BT Europe AB
Service Manual
Sh. 12 22
Sh. 12 22
Sh. 13 19
Sh. 12 15
120/WHITE
119/RED
40
22
X30
X48
X48
X48
X48
Br
S85 Bk
120
119
113
112
111
40
22
JP3:4
JP3:2
246883 14/22
INP./OUT. CAN L
INP./OUT. CAN H
GND
INP. STEER WHEEL IN HOME POS.
OUT. + 12VDC
GND
INP. + 48VDC SUPPLY
Valid from serial number 6004330-
JP3:1
JP4:5
JP4:6
JP2:23
JP2:9
JP2:21
JP2:24
JP2:11
WIRE GUIDANCE A3
Date 2013-03-04
Bl
Order number 244989-040
WIRE GUIDANCE, PAGE 14-17
OPTION
Electrical system – 5000.2 Symbol list and wiring diagrams T-code 485, 487
Veflex VR, VR SF, VRE150, VRE125SF
18- 63
18- 64
Service Manual
Sh. 14 19
22
X30
X32
-
S120 7
Ye
Gr
670
R35
680 ohm/2W
X32
X32
X48
66
67
133
132
OUT. ON WIRE
INP. ENCODER PULSE B
INP. ENCODER PULSE A
304
246883 15/22
INP. WIRE GUIDANCE OFF
ELECTRONIC CARD A5
JP2:3
JP1:8
JP1:7
OUT. + 5VDC
GND
Date 2013-03-04
5
H120 10 9
B
A
JP1:21
JP1:12
Valid from serial number 6004330-
VR WITHOUT WIRE GUIDANCE
X32
Wh
+
Br
ENCODER U15
130
131
WIRE GUIDANCE A3
T-code 485, 487
WIRE GUIDANCE, PAGE 14-17
OPTION
Electrical system – 5000.2
Symbol list and wiring diagrams Order number 244989-040
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
LOAD ANTENNA W1
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
J1L:13
J1L:15
GREY
VIOLET
BLUE
GREEN
YELLOW
ORANGE
RED
OUT. + 12VDC
GND
T3
T2
T1
JPW1:13 SHIELD
JPW1:15
JPW1:14
JPW1:8 OUT.
JPW1:7 OUT.
JPW1:6 OUT.
T0
LEFT COIL
NEAR WIRE COIL
RIGHT COIL
JPW1:5 OUT.
JPW1:3 INP.
JPW1:2 INP.
JPW1:1 INP.
246883 16/22
Valid from serial number 6004330-
J1L:14
J1L:8
J1L:7
J1L:6
J1L:5
J1L:3
BROWN
BLACK
Date 2013-03-04
J1L:2
J1L:1
WIRE GUIDANCE A3
Order number 244989-040
WIRE GUIDANCE, PAGE 14-17
OPTION
Electrical system – 5000.2 Symbol list and wiring diagrams T-code 485, 487
18- 65
TRACTOR ANTENNA W2
18- 66
Service Manual
J1T:13
GREY
VIOLET
BLUE
JPW2:13
JPW2:15
JPW2:14
T3
T2
T1
SHIELD
OUT. + 12VDC
GND
JPW2:8 OUT.
JPW2:7 OUT.
JPW2:6 OUT.
T0
LEFT COIL
JPW2:5 OUT.
JPW2:3 INP.
246883 17/22
NEAR WIRE COIL
RIGHT COIL
Date 2013-03-04
J1T:15
J1T:14
J1T:8
GREEN
YELLOW
ORANGE
RED
JPW2:2 INP.
JPW2:1 INP.
Valid from serial number 6004330-
J1T:7
J1T:6
J1T:5
J1T:3
BROWN
BLACK
WIRE GUIDANCE A3
T-code 485, 487
J1T:2
J1T:1
WIRE GUIDANCE, PAGE 14-17
OPTION
Electrical system – 5000.2
Symbol list and wiring diagrams Order number 244989-040
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
© BT Europe AB
103
104
+12VDC
GND
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF X52
X61
X61
X61
X61
X60
X60
X60
X60
X55
X55
X55
X55
115
114
156
110
B:2
B:1
A:2
A:1
GND
+12VDC
SCREEN
VIDEO SIGNAL
246883 18/22
Valid from serial number 6004330-
X52
WHEN STEREO/CD
X67
X67
X67
X67
Date 2013-03-04
115
114
102
101
SCREEN
VIDEO SIGNAL
TV-MONITOR A50
Order number 244989-040
Sh. 19
Sh. 19
CAMERA A51
CAMERA ON FORKS.
OPTION
Electrical system – 5000.2 Symbol list and wiring diagrams T-code 485, 487
18- 67
18- 68
Sh. 18
Sh. 18
Sh. 14 20
Sh. 15 20
Service Manual
W5
H4 X56
H5
B:4
B:3
B:6
B:5
A:8
A:4
A:7
OUT. RIGHT (-)
OUT. RIGHT (+)
OUT. LEFT (-)
OUT. LEFT (+)
INP. GND
INP. +12V KEY
INP. +12VDC
246883 19/22
Date 2013-03-04
X56
X56
OUT. +12VDC
STEREO/CD A11
1
OUT. GND (GALV. SEPARATED)
OUT. GND (GALV. SEPARATED)
OUT. +12VDC
INP. GND
INP. +48VDC
Valid from serial number 6004330-
X56
340
312
312
312
2
5
4
3
6
DC/DC CONVERTER A10
T-code 485, 487
340
115
40
22
115
STEREO/CD
114
X44
X44
114
40
22
OPTION
Electrical system – 5000.2
Symbol list and wiring diagrams Order number 244989-040
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
X2:4
X2:5
X2:6
INP. 0VDC SUPPLY
INP. DRIVE, STEER WHEEL DIRECTION
INP. 0VDC SUPPLY
40
X2:3
X34
X33
X32
INP. DRIVE, FORK DIRECTION
PERSONAL PROTECTION SYSTEM TBM GM-107ECO
166
165
X30
X150
X150
X150
4
3
S33
8
2
7
1
164
163
100
202
208
205
706
OUT. DRIVE, STEER WHEEL DIRECTION
OUT. DRIVE, FORK DIRECTION
INP. OVERRIDE
OUT. IN AISLE INDICATION LAMP
246883 20/22
NOTE! OUTPUT FOR AUDIBLE AND VISIBLE ALARM FROM TBM GM-107ECO EQUIPMENT NOT SHOWED.
X33
33
Valid from serial number 6004330-
Sh. 19 21
Sh. 21
Sh. 21
22
OVERRIDE EMERGENCY MODE / OVERRIDE HEIGHT
X30
Date 2013-03-04
Sh. 19 22
Sh. 21
33
ELECTRONIC CARD A5
Order number 244989-040
PERSONAL PROTECTION SYSTEM, PAGE 20 AND 21.
OPTION
Electrical system – 5000.2 Symbol list and wiring diagrams T-code 485, 487
18- 69
18- 70
Service Manual
Sh. 20
166
162
X150
X150
X150
X150
X150
X150
X150
X150
X150
X150
X150
X1:13
246883 21/22
INP. OVERRIDE EMERGENCY MODE
OUT. +24VDC
INP. 0 VDC SUPPLY X2:12
X1:12
INP. IN AISLE
OUT. WARNING RELAY
INP. WARNING RELAY
OUT. EMERGENCY RELAY
INP. EMERGENCY RELAY
OUT. EMERGENCY RELAY
INP. EMERGENCY RELAY
0 VDC SUPPLY
INP. +48VDC SUPPLY
X2:10
X1:7
X1:6
X1:5
X1:4
X1:3
X1:1
X9:2
X9:1
8A F
Date 2013-03-04
165
206
INP. SPEED REDUCTION
161
160
9
Valid from serial number 6004330-
Sh. 20
33
207
201
INP. PERSONAL PROTECTION 2
INP. PERSONAL PROTECTION 1
ELECTRONIC CARD A5
40
7,5A F64
PERSONAL PROTECTION SYSTEM GM-107ECO
T-code 485, 487
Sh. 20
Sh. 20 22
Sh. 10
1
PERSONAL PROTECTION SYSTEM, PAGE 20 AND 21.
OPTION
Electrical system – 5000.2
Symbol list and wiring diagrams Order number 244989-040
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
© BT Europe AB W7
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
40
INP. CAN L
INP. CAN H
INP. CAN L
INP. CAN H
INP. GND
INP. +48VDC (LOGGED IN)
X3:9
OPERATION MODE PIN 2
ELECTRONIC CARD, KEYPAD A16
4
3
2
1
246883 22/22
Valid from serial number 6004330-
WHITE
RED
40
22
4
3
INP. GND
INP. +48VDC
Date 2013-03-04
TRUCK LO SYSTEM, SHOCK SENSOR A23
WHITE
RED
2
1
Order number 244989-040
40
21
TRUCK LOG SYSTEM, CONTROL UNIT A20
Electrical system – 5000.2 Symbol list and wiring diagrams T-code 485, 487
18- 71
Sh. 7 9
Sh. 6
Sh. 6
22
28
X32
X32
X30
X30
X32
5
R6
1
3
R4
1
3
R5
1
3
R14
1
3
1
5
S33 1
100
81
86
85
84
83
82
INP. PERS.PROT. 1 (NOT ACTIVE) (WHEN USED SEE PAGE 22) INP. PERS. PROT. 2 (NOT ACTIVE) (WHEN USED SEE PAGE 22)
201
207
205
INP. OVERRIDE
247602_8
OUT. DATA COLLECT, DRIVE 208
INP. WEIGHT
OUT. DATA COLLECT, LIFT 202
204
INP. SPEED REDUCTION
INP. JOYSTICK SPARE 2
INP. JOYSTICK SPARE 1/AUTO ROTATE
INP. JOYSTICK ROTATE
INP. JOYSTICK TRAVERSE
INP. JOYSTICK FORK
206
510
506
505
504
503
Date 2013-03-04
X33
X31
X33
X33
X33
X33
X33
ELECTRONIC CARD A5
Valid from serial number 6004330-
S61
R15
1
Service Manual
3
2 2 2
18- 72 2
T-code 485, 487
2
27
Electrical system – 5000.2
Symbol list and wiring diagrams Order number 244989-040
18.6.4 Electric wiring diagrams, cold store cabins VRE150
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
© BT Europe AB
Sh. 5 14
1
40
22
Service Manual
10A F63
X37
X30
Veflex VR, VR SF, VRE150, VRE125SF
40
26
X45
X45
X23
X23
X36
+
+
9
5
330
920
-
Y21
H96
R31
+
680~E/2W
R34
680~E/2W
2
1
109
-
-
H2
H95
R32
320
47~E/50W
+
+
X45
X45
ID 0V
1 4
2
1
+48V
3
RX-
RX+
LENGTH INDICATOR A9
EXTERNAL EQUIPMENT X42 X42
H3
H18
H90
Y20
-
-
10
S90
2
5
40
26
R30
1
S99
X23
X23
680~E/2W
5
191
X37
X36
X30
X30
X31
X31
X31
X30
E4
X45
X45
102
101
108
38
37
33
32
92
91
X46
X46
192
247602_10
E3
OUT. CABIN LOWER
OUT. CABIN LIFT
126
125
Sh. 6 11
Sh. 6 11
OUT. LENGTH INDICATION LAMP (IN AISLE)
OUT. TRAVEL ALARM
OUT. WARNING LAMP (MOTION)
OUT. IN AISLE INDICATION LAMP
OUT. FORKS IN HOME POSITION (L,R OR CENTER)
OUT. HALF PALLET HANDLING INDI. LAMP
INP. HALF PALLET HANDLING MODE
WORKING LIGHT
711
710
709
707
708
706
705
306
305
Valid from serial number 6004330-
X31
X31
X31
X45
1
Date 2013-03-04
X31
X31
X31
X31
X45
Order number 244989-040
Sh. 9 11
Sh. 9 11
ELECTRONIC CARD A5
Electrical system – 5000.2 Symbol list and wiring diagrams T-code 485, 487
18- 73
18- 74
Service Manual
Sh. 13 15
Sh. 12 15
Sh. 10 22
X45
1
S97
5
X45
0/1/2/3
(Bk) S70
(Gn)
(Bl)
FAN
M
Y1
TIMER
THERMOSTAT 2 4
15
5A
30A
30A
30A
30A
18
750W
750W
750W
247602_14
750W
Date 2013-03-04
(Ye)
(Gn)
(Or)
DEFROST START (1500W)
S68 COMFORT HEATER (1500W) FAN SPEED / MASTER ON/OFF S69 (Wh) (Ye)
(Red)
COLD STORE CABIN
HEATER IN COLD STORE CABIN
Valid from serial number 6004330-
40
X31
E2
E1
157
COURTESY LIGHTS IN CABIN
22
1
E98
A1
T-code 485, 487
A2
OPTION
Electrical system – 5000.2
Symbol list and wiring diagrams Order number 244989-040
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical system – 5000.2 Symbol list and wiring diagrams Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
18.6.5 Component list, standard truck Symbol
Designation/function
Component picture
A1
Frequency converter, M1
4
A2
Frequency converter, M3
4
A3
Logic card, wire guidance
A4
Logic card, fork unit
6
A5
Electronic circuit board
4
A6
Display, instrument panel
1
A7
Height preselector
2
A8
Height indication display
7
A9
Length indication display
7
A10
Voltage converter, 48/12 V
A11
Stereo/CD
A14
Voltage converter, 48/12 V
A16
Key Pad
A20
Truck Log System
A23
Shocksensor
A49
TV monitor, arm-mounted cameras
A50
TV monitor
7
A51
TV camera
7
A52
TV camera, arm-mounted, left
A53
TV camera, arm-mounted, right
A54
Camera switching unit
B1
Temperature sensor, M1
4
B2
Temperature sensor, M3
4
E3, E4
Work spotlights
7
E10
Seat heater
3
E98
Cab heater
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
18- 75
Electrical system – 5000.2 Symbol list and wiring diagrams T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Symbol
Designation/function
Component picture
F1
Travel motor fuse, 160 A
4
F3
Pump motor fuse, 300 A
4
F60
Operating fuse for A5 card, 10 A
4
F61
Steering motor fuse, 30 A
4
F62
Operating fuse for K10, 10 A
4
F63
Operating fuse for extra equipment, 10/16 A
4
G1
Battery 48 V
7
H1
Horn
4
H2
Warning lamp
7
H3
Travel alarm
H4
Left speaker
H5
Right speaker
H18
Indication lamp, in narrow aisle mode
H90
Indicator light, half pallet handling
H95
Indicator light, forks in home position
H96
Length indication lamp
H120
Indicator light, wire guidance
K10
Main contactor
4
M1
Drive motor
4
M3
Pump motor
4
M6
Steering motor
4
M10
Pump motor fan
4
M12
Electric panel fan
4
R1
Potentiometer, truck travel
4
18- 76
Service Manual
7
7
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical system – 5000.2 Symbol list and wiring diagrams Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Symbol
Designation/function
Component picture
R2
Potentiometer, brake
4
R4
Potentiometer, traversing
2
R5 (VRE150 only)
Potentiometer, rotation
2
R6
Potentiometer, fork lifting/fork lowering
2
R8 (VRE150 only)
Potentiometer, rotation angle
6
R14 (VRE150 only)
Potentiometer, extra hydraulic function/auto rotation
2
R15 (VRE150 only)
Potentiometer, extra hydraulic function
2
R30
Series resistor, H95
R31
Series resistor, H18
R32
Series resistor, H96
R34
Series resistor, H90
R35
Series resistor, H120
R49 (VRE125SF)
Damping resistor, camera
R100
Resistor, service key
7
R102
Resistor, emergency lowering of forks
4
R109
CAN bus termination resistor
S1
Microswitch, operator number/programming
1
S2
Microswitch, operator number/increase
1
S3
Micro-switch, operator number/decrease
1
S4
Magneto switch, aisle centre, steering wheel direction
5
S5
Magnetic switch, aisle indication 1, fork direction
5
S6
Magnetic switch, aisle indication 1, steering wheel direction
5
S7
Magnetic switch, aisle indication 2, fork direction
5
S8
Magnetic switch, aisle indication 2, steering wheel direction
5
S9
Magneto switch, aisle centre, fork direction
5
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
18- 77
Electrical system – 5000.2 Symbol list and wiring diagrams T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Symbol
Designation/function
Component picture
S17
Key switch
1
S18
Microswitch, horn
2
S21
Emergency switch off
1
S23
Safety switch, left foot pedal
4
S26
Micro-switch, travel direction selector with creep speed
2
S27
Micro-switch, travel direction, fork direction, foot
8
S29
Micro-switch, travel direction, steering wheel direction, foot
8
S33
Microswitch, max. lift height bypass
2
S50
Inductive sensor, forks in home position, traversing
6
S61
Weight indicator
7
S65
Pulse transducer, steering wheel centre
4
S66
Pulse transducer, steering wheel direction
4
S68
Micro-switch, fan speed
S69
Micro-switch, main heater
S70
Micro-switch, auxiliary heater
S85
Pulse transducer, steering wheel home position
See C-code 4500
S89
Microswitch, seat
3
S90
Micro-switch, half pallet handling
7
S93
Magneto switch, reference height
6
S97
Micro-switch, cab illumination
S99
Microswitch, work spotlights
7
S120
Micro-switch, wire guidance requested
2
S131
Microswitch, parking brake release
4
S156
Photo cell, aisle indication 1
S178
Photo cell, aisle indication 2
U1
Tachometer, steering
2
U9
Pulse transducer, height measurement in free lift range
6
18- 78
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical system – 5000.2 Symbol list and wiring diagrams Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Symbol
Designation/function
Component picture
U10
Pulse transducer, height measurement above free lift range
7
U11
Pulse transducer, drive motor
4
U12
Pulse transducer, pump motor
4
U13
Pulse transducer, traversing movement
7
U15
Pulse transducer, wire guidance steering angle
See C-code 4500
W1
Wire guidance antenna, fork direction
W2
Wire guidance antenna, steering wheel direction
W5
Radio antenna
X1
Terminal, battery connector
7
X14
Terminal, at tank, to mast
4
X15
Terminal, at tank, to mast
4
X16
Terminal, at mast
5
X17
Terminal, at mast
5
X23
Connector
X25
Terminal, seat
3
X30
Terminal, at electric panel
4
X31
Terminal, at electric panel
4
X32
Terminal, at electric panel
4
X33
Terminal, at electric panel
4
X34
Terminal, at electric panel
4
X35
Terminal, at fan in motor compartment
4
X36
Terminal, warning lamp
X37
Terminal, panel alarm
X38
Terminal, at tank for support arm brake
X39
Terminal, support arm brake Y5:1, Y5:2
X40
Terminal, support arm brake Y6:1, Y6:2
X41
Terminal, CAN terminal in ceiling
© BT Europe AB
Service Manual
7
Veflex VR, VR SF, VRE150, VRE125SF
18- 79
Electrical system – 5000.2 Symbol list and wiring diagrams T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Symbol
Designation/function
Component picture
X42
Terminal, Aux at electric panel
4
X44
Terminal, at tiller arm bracket
X45
Terminal, roof pillar
1
X46
Terminal, at electric panel
4
X47
Terminal, at tank for pump valve block
4
X48
Terminal, at tank for wire guidance
4
X49
Terminal, at A4
6
X51
Connector from DC/DC converter to radio receiver
X52
Connector splice used when both a radio receiver and camera are installed
X55
Connector between machine housing up to camera monitor
X56
Terminal to speaker box in ceiling
X60
Terminal, at mast
6
X61
Terminal, for camera at A4
6
X62 (VRE150 only)
Terminal, fork unit valve block
6
X63 (VRE150 only)
Terminal, fork unit valve block
6
X64 (VRE150 only)
Terminal, for rotary potentiometer
6
X65 (VRE150 only)
Terminal, for traversing pulse transducer
6
X67 (VRE150 only)
Terminal, for camera, on fork unit
6
X69
Connector to photocell
X75
Connector splice between roof harness and instrument harness
X150
Terminal for PPS
X151 (VRE125SF)
Connector between monitor and camera switch
Y1
Magnet, parking brake
18- 80
Service Manual
4
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical system – 5000.2 Symbol list and wiring diagrams Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Symbol
Designation/function
Component picture
Y5:1
Magnet, support arm brake
7
Y6:1
Magnet, support arm brake
7
Y5:2
Magnet, support arm brake
7
Y6:2
Magnet, support arm brake
7
Y8
Solenoid valve, traversing left
6
Y9
Solenoid valve, traversing right
6
Y10
Solenoid valve, lowering
4
Y11
Solenoid valve, lifting
4
Y16 (VRE150 only)
Solenoid valve, extra hydraulic function 1A
Y17 (VRE150 only)
Solenoid valve, extra hydraulic function 1B
Y20
Valve, cabin lifting
Y21
Valve, cabin lowering
Y24
Solenoid valve, fork movement
4
Y25 (VRE150 only)
Proportional valve, traversing
6
Y26 (VRE150 only)
Proportional valve, rotation
6
Y27 (VRE150 only)
Solenoid valve, counter-clockwise rotation
6
Y28 (VRE150 only)
Solenoid valve, clockwise rotation
6
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
18- 81
Electrical system – 5000.2 Symbol list and wiring diagrams T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
18.6.6 Component location Picture 1 A16
A6
X45
S21
Picture 2 A7
U1
S18
R12 R13 R11
S120
R14
S33
R15
S26
X11
18- 82
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical system – 5000.2 Symbol list and wiring diagrams Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Picture 3
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
18- 83
Electrical system – 5000.2 Symbol list and wiring diagrams T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Picture 4 M6 X23 S66 S65
X38 X48
S131 X32
X14
S 66
X33
X34
X 660
X47
X15
Y1
X46
X31 X30
F63 F62
X42
A5
F60 M12
F1
A1
F3
F61
A2
K10 R1 H1
R2 S23
M10 X35 S66
18- 84
S65
M6
Service Manual
M1 B1 U11
Y1
M3 B2 U12
Y10 Y11 Y24
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical system – 5000.2 Symbol list and wiring diagrams Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Picture 5 (VRE125SF)
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
18- 85
Electrical system – 5000.2 Symbol list and wiring diagrams T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Picture 5 (VRE150)
18- 86
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical system – 5000.2 Symbol list and wiring diagrams Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Picture 6 (VRE125SF)
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
18- 87
Electrical system – 5000.2 Symbol list and wiring diagrams T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Picture 6 (VRE150)
18- 88
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical system – 5000.2 Symbol list and wiring diagrams Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Picture 7 (VRE125SF)
U10 X41 R100
S61
S90
A50
H18, H95, S99 H2
A8
E3
E4
A9
G1
X1
A51
Y5:1 Y5:2
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
Y6:1 Y6:2
18- 89
Electrical system – 5000.2 Symbol list and wiring diagrams T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Picture 7 (VRE150)
U10
X41 R100
S61
S90
H2
E3
E4
H18, H95, S99
A50 A8
A9
A51 G1 Y5:1 Y5:2
Y6:1 Y6:2
X1
18- 90
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical system – 5000.2 Symbol list and wiring diagrams Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Picture 8 S27 S23
© BT Europe AB
Service Manual
S29
Veflex VR, VR SF, VRE150, VRE125SF
18- 91
Electrical system – 5000.2 Function description T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
18.7 Function description The A5 logic card for the VRE150/VR125SF AC contains microprocessors that detect switch settings, control voltages, etc. and provides instructions for external electronic components, relays, valves, etc. To ensure that all pre-set information remains intact in the electronic module when the battery is disconnected, the module is powered by an internal battery. Any errors registered by the microprocessor are shown on the display. The error codes are described in connection with the electronic card. The inputs and outputs of the electronic card are marked with connection numbers and can be easily connected/ disconnected using the contacts. Inputs and outputs with two fixed positions have LED indicators: green for input, red for output and others in yellow.
18- 92
Designation
Diode number
Designation of the input/output on the card as it appears in the wiring diagram
The diode number/name that shows the active input/output on the card
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical system – 5000.2 Function description Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
18.7.1 Truck not switched on When the battery is connected to the truck using the battery connector, a voltage of +48 V is applied on A5/805 and A5/901 on the logic card and the LEDs are lit according to the table. A voltage of 15 V is supplied from A5/810 to the sensors S66 and U10. LEDs 210, 211, 301 and 302 are lit depending on whether the sensor is actuated or not. A voltage of +7.35 V is supplied from A5/507 to the potentiometer R1 in the speed control, the brake control R2 and the hydraulic controls R4R6, R14-R15.
Designation
Diode number
STEER WHEEL ANGLE
210, 211
HEIGHT COUNTER
301, 302
+48 VDC
+48 V
+48 VDC STEER SERVO
+48 V STEER STEER PWR POWER OK
18.7.2 Truck started up The truck is powered up when the operator logs in with his PIN code and depresses the green I key on the keypad. In order for travel direction selection and the hydraulics to operate, the operator must sit in the seat so that switch S89 is closed. The voltage travels over the operating fuse F60, the log-in unit A16 and emergency stop switch S21 to the logic card A5/807 and 809, via S89 to A5/203, the frequency converters A1 and A2, the height electronics A7 and A8 as well as the fan M10, which subsequently starts. The A5 logic card then verifies that the internal safety function is operating, and it closes the main contactor K10, output A5/804, to supply power to the drive and pump motors. The A5 logic card starts communication with the height electronics A7 and A8, the length indication A9 and supplies a voltage of +32 V to the fan M12, which starts to rotate at half speed. A5 checks that the voltage from the potentiometers is +3.65 V and also sends a control pulse to the tachometer U1 and the steering motor M6. If the truck has a heater, a voltage of +48 V is also supplied to the thermostat and the seat heater E10.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
18- 93
Electrical system – 5000.2 Function description T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
The display lights and shows the firmware version number, after which it reverts to the normal display: time of day, operating hours, battery status and any error codes. The duration during which the truck is operated is measured and stored in the electronics module. The LEDs indicated in the table below light up: Nos. 706–711 light up if the valves are not installed on the truck. The LEDs on the frequency converters A1 and A2 are lit. .
Designation
Diode number
LEFT FOOT SWITCH
110
SEAT SWITCH
203
WIRE GUIDANCE OFF
304
CABIN LIFT
710
CABIN LOWER
711
SUPPORT ARM BRAKE
801 (dimly lit)
FORK LOWER
803 (dimly lit)
MAIN CONTACTOR
804
KEY
+48 V KEY
+48 VDC SUPPLY OUTPUTS
+48 V ESO +48 V_SR
18.7.3 Travel direction selection When the S26 control is depressed, a voltage is supplied from the switch to A5/104 or 105. If the control is kept depressed for at least three seconds, the truck will travel at creep speed, but only if the mechanical brake has been released.
Designation
Diode number
DRIVE, FORK DIR CREEP
104
DRIVE, STEERING WHEEL DIR CREEP
105
The display shows the travel direction.
18- 94
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical system – 5000.2 Function description Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
18.7.4 Driving When the speed control R1 is actuated, the drive motor brake will be released. If the safety switch S23 has not been actuated, +48 V on A5/ 110, when the parking brake is released, a buzzer in the display starts sounding. If the operator depresses the accelerator pedal while at the same time depressing the green key I, the pedal must return to the neutral position before the truck can be driven. When the accelerator pedal is pressed down, the potentiometer R1 is actuated, and as the accelerator pedal is pressed down further, the voltage received from R1 to A5/501 gradually decreases. The voltage will fall from 3.7 to 1.7 V to give 0–100% speed. A1 controls drive motor speed using information from A5 via CAN. Power is fed through fuse F1 of A1, and is converted to 3-phase AC that is supplied to M1. The drive motor speed is measured using the sensor U11. If the travel direction selector on the steering console is kept pressed for at least three seconds, the truck will travel at creep speed. If the operator stands up from his seat for more than three seconds, A5 will cut the power to Y1, output 802, causing the parking brake to be applied. The drive motor operating time is measured and stored in the electronic module.
© BT Europe AB
Designation
Diode number
PARKING BRAKE
802
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
18- 95
Electrical system – 5000.2 Function description T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
18.7.5 Travel speeds Outside narrow aisles and with forks in the "home position" - Fork height 1.2 m but 10o = speed is reduced to max 2.5 km/h (0.7 m/s). - Fork height >3.0 m = speed reduced to max 2.5 km/h (0.7 m/s). - Forks not in the "home position" = speed always reduced to max 2.5 km/h (0.7 m/s).
Rail-guided truck Truck with support arm brakes: - Driving in the direction of the drive wheel, fork height 0 = connected In increments of 0.05 If the truck is equipped with height measurement, two different max. lift heights can be set with this parameter. The second max. height value must be equal to or larger than the first height value. The height that was last active is usually used as max. height before the mast reaches the top.
18
Lift height limiter level 2, m
0-13.5
13.5
0 = not connected > 0 = connected In increments of 0.05 Set greater or equal to Lift height limitation 1. If the truck is equipped with height measurement, two different max. lift heights can be set with this parameter. The second max. height value must be equal to or larger than the first height value. The height that was last active is usually used as max. height before the mast reaches the top.
19
Fork free-lift height, m
0-4.5
See the table below
Top side of fork to floor when inner guide is at top. In increments of 0.01
20
Time display
1-5
2
1 = ignition time (A) 2 = total movement time (b) 3 = drive motor time (c) 4 = pump motor time (d) 5 = service time (S)
21
Battery size
1-20
12
Selection of size/type of battery, increased parameter values result in deeper discharge of battery See table below.
22
Support arm brake
0-1
0
0 = Truck without support arm brakes 1 = Truck with support arm brakes
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Service Manual
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Electrical system – 5000.2 Setting all parameters T-code 485, 487
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Date 2013-03-04
Order number 244989-040
No.
Type of parameter
Min.max.
Std. value
Remarks
23
Travel alert; truck moving
0-3
0
0: No alert 1: Warning in steering wheel-direction 2: Warning in fork-direction 3: Warning in both directions 4: Alert in drive wheel direction outside narrow aisle 5: Alert in fork direction outside narrow aisle 6: Alert in both directions outside narrow aisle
24
Left foot switch
0-1
0
0 = Activates buzzer 1 = Also cuts drive motor When this parameter is set to 1, it is possible to stop the truck using the drive motor but impossible to continue driving unless the safety pedal is depressed.
25
Service interval, h
0-2000
0
This parameter sets the service interval for the truck. The buzzer sounds and C029 is shown on the display when the service counter reaches zero. The counter shows the time that has passed since the last service intervention should have been made. 0 = No service counter In increments of 50h
26
Cab tilting
0/1
0
0 = No 1 = Yes
27
Lift priority
0/1
1
0 = Fork lift prioritised 1 = Fork lift not prioritised When this parameter is set too 1, fork lifting priority is cancelled. The hydraulic function that is in use will continue even if fork lifting is activated.
28
Data collection
0/1
0
0:202 Hydraulics 0:208 Driving 1:202 Travel in drive wheel direction 1:208 Travel in fork direction 2.208 Buzzer to shock sensor
29
Max. lift height, m
0-13.5
30
I/O Box
2-1
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In increments of 0.05 Electric stop at max. lift height 0
0: Not connected 1: Output 1 hydraulics Output 2 Driving 2: Output 1 Driving in drive wheel direction Output 2 Driving in fork direction Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical system – 5000.2 Setting all parameters Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
No.
Type of parameter
Min.max.
Std. value
Remarks
33
Wire guidance warning
0-29
23
Buzzer alert and deceleration/stop when wire is detected but wire guidance is not activated. 0:Buzzer alert for 2.2 seconds. 1-9: Constant buzzer alert, deceleration to stop after 1-9 seconds 10-19: Constant buzzer alert, Deceleration to 1.3 km/h after 0-9 s. 20-29: Constant buzzer alert, Deceleration to 2.5 km/h after 0-9 seconds.
34
Steering
0-5
3
Adjusts the sensitivity for the wire when the trucks travels on the wire
35
Bottom offset, mm
0-500
0
In increments of 10 Earlier slowdown of the lowering movement close to the bottom position.
36
Wire guidance
0-4
0
0: No wire guidance 1: Wire guidance 2: Not used 3: WG learning offset mode 4: WG learning frequency mode Parameter value >=2 resets automatically to 1 when key is turned after initiating learning mode.
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Electrical system – 5000.2 Setting all parameters T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
No.
Type of parameter
Min.max.
Std. value
Remarks
37
Calibration weight for weight measurement, kg
1005000
1000
• Set this parameter to the weight with which the truck will be calibrated. • Terminate the programming in the normal way. • Keep the weight measurement button pressed while turning the start key. 0000 will be shown in the hour counter window. • Perform lifting with empty forks in the free-lift range until the weight set with the parameter is displayed in the hour counter. • Lift the calibration weight with the forks and lift the forks approx. 100 mm. • Press the weighing switch and lift until the hour counter is displayed again. • This completes the calibration of weight measurement. In increments of 10
38
Calibration
1-4
0
1) Calibration of neutral position for accelerometer and brake. Set the parameter. The parameter is set at next start-up. 2) Fork calibration. Set the parameter. At next start-up, the forks can be calibrated according to the fork calibration instructions (see below). Confirm the completed calibration by keeping the fork direction selector pressed for two seconds. The parameter returns to 0 automatically. 3) For factory testing. The parameter returns to 0 automatically. 4) When set to 4, the I/O status of the fork unit is displayed. The status is displayed during next start-up. The parameter returns to 0 automatically.
39
Operator access, key
1-4
3
1 = Ignition, open 2 = Ignition, locked 3 = Keyboard, open 4 = Keyboard, locked
40
Time, year
0-99
In increments of 1
41
Time, day
1-31
In increments of 1
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Electrical system – 5000.2 Setting all parameters Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
No.
Type of parameter
Min.max.
42
Time, month
1-12
43
Fork unit type
0-1
0
Specify the fork unit type in use: 0 = Rotating fork apparatus 1 = Telescoping fork apparatus Note: Factory parameter! No change permitted!
44
Travel length, traversing movement, mm
10002500
Set to current
Factory parameter (pre-set at factory) In increments of 2 Note: If the fork unit is changed to another one with a different travel length, this parameter should be adjusted.
45
Travel length, half pallet handling, mm
5002500
900
Factory parameter (pre-set at factory) In increments of 2
46
Speed reduction, traversing movement
0-1
1
Speed reduction dependent on current lift height. Limit height = 5.0, 7.0 and 9.0 m 0: Not engaged 1: Active
47 (VRE150)
Pump motor speed, rotation
0-90
34
This parameter adjusts the pump motor speed during fork rotation. In increments of 2
48 (VRE150)
Pump motor speed, traversing and combined movement
0-90
46
This parameter adjusts the pump motor speed during traversing movement and during combined fork movement. The higher the parameter value, the higher the pump motor speed. In increments of 2
49 (VRE125 SF)
Max. pump motor speed, shuttle fork unit
0-90
24
This parameter adjusts the pump motor max. speed during traversing movement. The higher the parameter value, the higher the pump motor speed. In increments of 2
50 (VRE125 SF)
Braking ramp, traversing movement
0-4
4
This parameter adjust the distance between the braking point and the end stop or centre position during traversing movement. The lower the parameter value, the longer the braking distance. Braking ramp at end stop and centre position In increments of 1
50 (VRE150)
Braking length, traversing movement end stop
0-4
4
Distance control, end position-end position In increments of 1
© BT Europe AB
Service Manual
Std. value
T-code 485, 487
Remarks In increments of 1
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Electrical system – 5000.2 Setting all parameters T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
No.
Type of parameter
Min.max.
Std. value
Remarks
51 (VRE150)
Braking length, rotation movement end stop
0-4
4
This parameter adjusts the distance between the rotation movement end stop and the braking point during the rotation movement. The lower the parameter value, the longer the braking distance. See parameter 58. Distance control, end position-end position In increments of 1
52
Not used
53 (VRE150)
Rotation angle symmetry, angle centring for parameter 59
0-20
0
This parameter calibrates the symmetry for the rotation angle, left/right position, selected with parameter 59. Procedure: - Forks parked in home position, traversing in left home position. - Parameter 59 set to 20°. - Start auto rotation and check the rotation angle when traversing starts. - Move the unit to the right home position - Start auto rotation and check the rotation angle when traversing starts. - If the starting angle at the left position is smaller than in the right position, reduce the parameter value. If it is bigger, increase the parameter value. - Adjust the parameter value until the start angles are the same. In increments of 1
54
Reference height free-lift, mm
400-800
500
The calibration height for height measurement in the free-lift range - This parameter is used to calibrate the position for the free-lift reference switch, S93. - Lift the fork unit until the reference switch is centred with the magnet. - Measure the fork height above the floor from the top of the forks. - Set the height measurement as the parameter value. In increments of 2
55
Max. speed, traversing movement, %
60-100
100
As a percentage of max. travel speed In increments of 5
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Electrical system – 5000.2 Setting all parameters Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
No.
Type of parameter
Min.max.
Std. value
Remarks
56 (VRE150)
Max. speed, rotation movement, %
60-100
100
As a percentage of max. travel speed In increments of 5
57
Braking ramp
0-4
0
This parameter sets the ramp/time for braking the traversing movement when stopping midway during movement or when changing direction of movement. The lower the parameter value, the shorter the time and the harder the braking. In increments of 1
58 (VRE150)
Braking ramp, rotation movement
0-4
0
Time for switch-off of the proportional valve. In increments of 1
59 (VRE150)
Start of traversing movement during auto rotation, ° (degrees)
0-50
0
This parameter determines the rotation angle at which starting of traversing movement is permitted when auto rotation is active. 0: Auto-rotation not connected >0: Angle at which traversing may start In increments of 2
60 (VRE150)
Max. permitted lift height for auto rotation, m
1-12
2
In increments of 1
61 (VRE150)
Auto rotation to straight ahead position
0-10
0
0: Auto-rotation to middle, not connected >0: 0 = Auto-rotation to middle, connected Select parameter value for correction of angle deviation Use this parameter to activate or deactivate auto rotation to the straight ahead position. Parameter value >0. Select a parameter value to adjust the angle deviation from 90o rotation. - Select a value for the parameter; five is a suitable starting value. - Drive the unit from the left home position, fork tips to left. - Check the fork deviation from 90°. - Increase the parameter value if the forks have turned more than 90°, decrease the value if rotation is less. - Test the function again and verify the result. Repeat this procedure until the rotation angle becomes 90°.
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Service Manual
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Electrical system – 5000.2 Setting all parameters T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
No.
Type of parameter
Min.max.
Std. value
Remarks
62 (VRE150)
Extra hydraulic function 1, pump motor speed, %
10-100
10
Max. pump motor speed extra hydraulic function, pot 1 In increments of 5
63 (VRE150)
Extra hydraulic function 2, pump motor speed, %
10-100
20
Max. pump motor speed extra hydraulic function, pot 2 In increments of 2
64 (VRE150)
Extra hydraulic function 1, pump motor torque, %
0-100
0
Max. pump motor torque, extra hydraulic function, pot 1 0: No extra function In increments of 5
65 (VRE150)
Extra hydraulic function 2, pump motor torque, %
0-100
0
Max. pump motor torque, extra hydraulic function, pot 2 0: No extra function In increments of 5
66 (VRE150)
Auto rotation start
0-255
50
Start speed for rotation in auto rotation mode A higher parameter value provides a higher rotation speed until traversing movement starts. In increments of 1
67
Camera switching unit
0-255
0
0: Not fitted >0: Fitted In increments of 1
68-70
Not used
18.9.1 Parameter 19
18- 124
Lifting height
Coarse setting Free lift height
4300
1.57
4900
1.77
5500
1.97
6100
2.17
7000
2.605
7600
2.805
8200
3.005
8800
3.205
9400
3.54
Service Manual
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Electrical system – 5000.2 Setting all parameters Order number 244989-040
© BT Europe AB
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Lifting height
Coarse setting Free lift height
10000
3.74
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Electrical system – 5000.2 Setting all parameters T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
18.9.2 Parameter 21 Use this parameter to indicate which kind of battery has been installed in the truck. This parameter can also be used to compensate for different driving styles. When setting the battery guard break point, perform measurement as follows: 1. Specific gravity with fully charged battery. Use to inspect the battery quality. 2. When the battery indicator shows 80% discharge (minimum specific gravity 1.14). The specific gravity may vary depending on the type of battery used.
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Electrical system – 5000.2 Setting all parameters Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
Value
T-code 485, 487
Function
Battery (Ah)
Less discharged
900
1 2 3 4 5 6 7 8 9 10
11 12 13
730, 700, 580 CSM More discharged
600
14
15
480, 450
16 17
360
18 19 20 WARNING! Correct parameter setting. Battery may be destroyed. If parameters are set higher than recommended, this will cause overdischarge of the batteries, resulting in battery destruction.
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Electrical system – 5000.2 Setting all parameters T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
18.9.3 Parameter 38 Following completed calibration, this parameter is automatically reset to zero.
Calibration of travel speed and brake potentiometers • Set the parameter to 1. • Restart the truck. Now follows the calibration of the travel speed and brake potentiometers. Note: Calibration of gas and brake takes place during restart. Does not affect the controls when calibration starts.
Calibration of fork movements (VRE150) Fork rotation • Rotate the forks to an end stop. • Set the parameter to 2. • The lamp that indicates forks in home position blinks during the calibration procedure. After completed calibration, the lamp stops blinking. • Turn the ignition key on and off once. • Perform 180° rotation to the other end stop. Please note that the movement starts very slowly and then the speed increases. The rotation speed is reduced before the end stop is reached. • Keep the travel direction/fork direction selector depressed for two seconds Note: If the traversing lever is actuated during calibration of rotation movement, calibration must be performed of the proportional valves for traversing.
Proportional valves, traversing • Drive the fork unit to an end stop. • Set the parameter to 2. • The lamp that indicates forks in home position blinks during the calibration procedure. After completed calibration, the lamp stops blinking. • Move the lever to its extreme position to traverse the fork unit to the other end position. The movement starts at very slow speed and then increases to full speed. Later, the movement again changes to very slow speed. Continue at very slow speed until the end stop. 18- 128
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Electrical system – 5000.2 Setting all parameters Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
• Keep the travel direction/fork direction selector depressed for two seconds
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Electrical system – 5000.2 Warning codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
18.10 Warning codes Character
Error Warning
When an error occurs, a buzzer sounds and a code is displayed in the right-hand section of the display (D) for 10 seconds. The error is also displayed in the text box (G). If the error is still present after one minute, the buzzer will sound again and the warning will reappear for two seconds. This process continues until the fault is rectified, however, the truck can still be driven with all functions according to the table. From the beginning, the log only contains the number 255 which signifies “no error”. WARNING! Ignoring error indication. This could jeopardise truck safety. Always inspect all truck functions prior to starting up the truck.
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Electrical system – 5000.2 Error codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
18.11 Error codes The 50 latest errors are recorded in the error log together with the date and time.
18.11.1 Error mode Error mode
Description/measures
Start-up error
The truck does not start the travel and hydraulic functions
Critical error
The steering safety relay is triggered. The main contactor opens. The parking brake is applied
General error
Current function stops
Height error
Fork lifting at low speed.
Emergency switch off activated
The main contactor opens. Parking brakes are activated.
Steering error
The steering safety relay is triggered. The drive motor reverses to standstill.
Driving regulator error
The main contactor opens. Lift transistor regulator error Steering is possible. The parking brake is applied during braking
Lift transistor regulator error
Hydraulics are stopped. Valves are closed.
Warning codes 3-99 give a warning signal of 2 Hz. Error codes 100- give a warning signal of 4 Hz.
18.11.2 Safety logics In case of the following functions, this will occur. X = Action -- = Function disabled
Action: Function
K10 opens
Y1 is activate d
Reversing with M1
Emergency switch off
X
X
--
Key
X
X
--
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Service Manual
Steering not possible
Function on A5 stops --
X
--
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Electrical system – 5000.2 Error codes T-code 485, 487
Action: Function
Valid from serial number 6004330-
K10 opens
Y1 is activate d
Steering error Error in A1
X
Date 2013-03-04
Reversing with M1
Steering not possible
X
X
--
18- 132
Function on A5 stops
--
Error in A2 Error in A5
Order number 244989-040
X (+ solenoid valves off) X
X
--
Service Manual
X
--
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical system – 5000.2 Error codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
18.11.3 Warning code without recording Code
3
Description
Shock sensor activated by TLS
Error mode
Travel speed reduced to crawl speed
Error cause
1. Truck collision 2. 3. 4.
Remarks
Enter the reset code (11111) using the keypad
Code
4
Description
Truck has been immobilised via programming of the TLS
Error mode
Travel speed reduced to crawl speed
Error cause
1. Stop code entered in the TLS. 2. 3. 4.
Remarks
Enter the reset code via the TLS or the service code
Code
5
Description
No communication with the I/O unit
Error mode
No action
Error cause
1. Defective I/O unit 2. Defective CAN cable 3. 4.
Remarks
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Electrical system – 5000.2 Error codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
11
Description
High temperature on electronic card cooling plate
Error mode
Max. current to steering motor reduced
Error cause
Steering/gear jamming Steering bearings jamming Defective steering motor Defective electronic card A5
Remarks
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Service Manual
Cool and check motor/gear
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical system – 5000.2 Error codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
12
Description
Error in steering angle measurement detected
Error mode
No action
Error cause
Steering angle pulse transducer has lost pulses Incorrectly adjusted pulse transducer Transducer is affected by external interference
Remarks
Will be reset when the steering reference sensors has been passed
Steering angle sensor, S66.
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Electrical system – 5000.2 Error codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
13
Description
No or too few pulses from the height measurement during fork lifting or fork lowering
Error mode
No action
Error cause
Defective reference switch Defective sensor/wiring harness Incorrect oil quality Defective A4 logic card Defective A5 logic card
Remarks
Current lift height will be set to 13 m. Max. travel speed, creep speed
Height sensor U9/U10 and reference sensor S93.
1. Check whether +15V is applied on A4 input 013 when S93 is closed. If not, inspect S93 and its cabling. 2. Check whether the LEDs LD301 and LD302 on A5 blink when the forks are lifted and lowered. The flashing is irregular because the pulses have a 90 degree phase displacement. If this is OK, proceed to step 3. h: If LD301 and LD302 always are off, check that there is a voltage of +15 V on U10. The red cable is plus and the black cable is 0 18- 136
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Electrical system – 5000.2 Error codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
V. If there is no voltage, check that the cables are intact and that the contact pins in the contacts X15 and X17 are not loose or oxidised. i: If flashing is sporadic, check that the wire is not slipping on the height sensor roller. j: If mechanical operation is OK, check that the cables from U10, white cable 98 to input 301 and blue cable 99 to input 302, are intact. Check that the pins in terminals X17 and X15 are not loose or oxidised. k: If the wiring harness and contacts are intact, replace the height sensor U10. l: Measure the inputs A4/ 011 and 012 and check whether pulses are present when lifting and lowering the forks. (Approx. 15 V) If this is OK, proceed to step 4. m: If inputs A4/011 and 012 remain 0 V continuously, check whether a voltage of +15 V is applied on U9. The red cable is plus and the black cable is 0 V. If there is no voltage, check that the cables are intact and that the contact pins in the contacts X49, X16 and X14 are not loose or oxidised. n: If the cabling and terminals are intact, replace the height sensor U9. 3. If the oil is too thick, standard oil in cold store trucks, the fork lowering movement especially will be too slow. 4. If nothing else can rectify the problem, replace the A4 logic card.
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Electrical system – 5000.2 Error codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
14
Description
Seat switch actuated for more than 20 min. without operating the truck
Error mode
No action
Error cause
Jumpered switch Defective switch/wiring harness Defective A5 logic card
Remarks
Seat switch S89
1. If LD203 is lit continuously. - Verify that the seat switch is not jumpered. - Disconnect cable 49 at switch S89, terminal 3. If LD203 goes out, check the function of S89. 2. If LD203 does not go out, inspect the cable by disconnecting it also at contact 203. 3. If LD203 does not go out, replace the A5 electronic card
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Electrical system – 5000.2 Error codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
15
Description
Safety switch actuated for more than 20 min. without operating the truck
Error mode
No action
Error cause
Jumpered switch Defective switch/wiring harness Defective A5 logic card
Remarks
Safety switch (left foot switch), S23
1. If LD110 is lit continuously. - Verify that the safety switch is not jumpered. - Disconnect cable 43 at switch S23, terminal 3. If LD110 goes out, check the function of S23. 2. If LD110 does not go out, inspect the cable by disconnecting it also at contact 110. 3. If LD110 does not go out, replace the A5 electronic card
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Electrical system – 5000.2 Error codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
16
Description
Voltage from accelerator potentiometer R1 is outside the calibrated value at start-up. (+/-0.2V).
Error mode
Start-up error
Error cause
Pedal actuated during start-up Defective potentiometer/bracket/wiring harness Incorrect calibration Defective A5 logic card
Remarks
Return to neutral position
Speed control, R1
1. Verify that the speed control is not stuck in the depressed position. Check whether any object blocks the pedal/links. Check the locking nuts on the link between the potentiometer and pedal. 2. Inspect R1 for correct mounting in the bracket. Check that the contact pin in contact X19 is not loose or oxidised. The voltage on input 501 must be ~3.7 +/- 0.2 VDC when R1 is correctly adjusted mechanically. 3. For calibration of the speed control, see the section “Parameter setting” in this manual. Check that both the speed and brake control as well as the joystick control for the hydraulic functions are in the neutral position. (Unactivated position). 4. If the voltage on input 501 is correct and calibration does not rectify the problem, then replace electronic card A5.
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Electrical system – 5000.2 Error codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
17
Description
Voltage from the brake pedal potentiometer R2 outside the calibrated value at start-up (+/-0.2 V).
Error mode
Start-up error
Error cause
Pedal actuated during start-up Defective potentiometer/bracket/wiring harness Incorrect calibration Defective A5 logic card
Remarks
Return to neutral position
Brake control, R2
1. Check that the brake pedal is not stuck in the depressed position. 2. Inspect R2 for correct mounting in the bracket. Check that the pins in contact X36 are not loose or oxidised. The voltage applied on input 502 should be ~1.7 +/- 0.2 VDC when R2 has been correctly adjusted mechanically. 3. For calibration of the brake control, see the section “Parameter setting” in this manual. Check that both the speed and brake control as well as the joystick control for the hydraulic functions are in the neutral position. © BT Europe AB
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Electrical system – 5000.2 Error codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
(Unactivated position) 4. If the voltage on input 502 is correct and calibration does not rectify the problem, replace the A5 logic card.
Code
18
Description
The battery in the electronic card A5 has reached the lowest voltage level
Error mode
The internal clock stops
Error cause
Battery voltage is too low
Remarks
Code
19
Description
Programmed parameter values have been lost
Error mode
The default values have been loaded
Error cause
Overmodulated A5 electronic card
Remarks
Reprogram the A5 electronic card
1. See section 11 “Parameter setting” in this manual.
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Electrical system – 5000.2 Error codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
21
Description
Potentiometer R6 used for fork lifting/lowering supplies incorrect voltage at start-up (+/-0.6V).
Error mode
Start-up error
Error cause
Joystick actuated during start-up Defective potentiometer/bracket/wiring harness Defective A5 logic card
Remarks
Return to neutral position
Fork control, joystick R6 Pg. 6
27
ELECTRONIC CARD A5
X32 1
R6 Pg. 6
28
X32
X33
82
2
503
INP. JOYSTICK FORK
504
INP. JOYSTICK TRAVERSE
505
INP. JOYSTICK ROTATE
3
83
84
1. Check that the joystick for fork operation is not stuck in the actuated position. 2. Inspect R6 for correct mounting in the bracket. The voltage applied on input 503 should be 3.7 +/- 0.6 VDC when R6 has been correctly adjusted. 3. Calibrate the fork control. - Check that the joystick is not actuated and that it is in the neutral position. - Turn the key switch on and off once. The joystick will now be calibrated. 4. If the voltage applied on input 503 is correct and calibration does not rectify the problem, replace the A5 logic card.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
18- 143
Electrical system – 5000.2 Error codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
22
Description
Potentiometer R4 used for traversing movement supplies incorrect voltage at key start-up (+/-0.6V).
Error mode
Start-up error
Error cause
Joystick actuated during start-up Defective potentiometer/bracket/wiring harness Defective A5 logic card
Remarks
Traversing, joystick R4 Pg. 6
ELECTRONIC CARD A5
X32
27
82 Pg. 6
28
503
INP. JOYSTICK FORK
504
INP. JOYSTICK TRAVERSE
505
INP. JOYSTICK ROTATE
X32
1 X33
R4
83
2 3
84
1. Check that the joystick for the traversing function has not seized in the actuated position. 2. Inspect R4 for correct mounting in the bracket. The voltage applied on input 504 should be 3.7 +/- 0.6 VDC when R4 has been correctly adjusted. 3. Calibrate the traversing control. - Check that the joystick is not actuated and that it is in the neutral position. - Turn the key switch on and off once. The joystick will now be calibrated. 4. If the voltage applied on input 504 is correct and calibration does not rectify the problem, replace the A5 logic card.
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Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical system – 5000.2 Error codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
23 (VRE150 only)
Description
Potentiometer R5 for rotation movement supplies incorrect voltage at key start-up. (+/-0.6V)
Error mode
Start-up error
Error cause
1. Joystick not in neutral position during start-up 2. Defective potentiometer/bracket/wiring harness 3. Defective A5 logic card
Remarks
Mast rotation control, joystick R5 Pg. 6
27
ELECTRONIC CARD A5
X32
82 Pg. 6
28
503
INP. JOYSTICK FORK
504
INP. JOYSTICK TRAVERSE
505
INP. JOYSTICK ROTATE
X32
83
1 X33
R5
2
84
3
1. Check that the joystick for the fork rotation movement has not seized in the actuated position. 2. Inspect R5 for correct mounting in the bracket. The voltage applied on input 505 should be 3.7 +/- 0.6 VDC when R12 has been correctly adjusted. 3. Calibrate the rotation control. - Check that the joystick is not actuated and that it is in the neutral position. - Turn the key switch on and off once. The joystick will now be calibrated. 4. If the voltage applied on input 505 is correct and calibration does not rectify the problem, replace the A5 logic card.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
18- 145
Electrical system – 5000.2 Error codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
24 (VRE150 only)
Description
Potentiometer R14 or R15 for the extra function “auto rotation” and “2” supplies incorrect voltage at key start-up. (+/-0.6V)
Error mode
Start-up error
Error cause
1. Joystick not in neutral position during start-up 2. Defective potentiometer/bracket/wiring harness 3. Incorrect calibration. 4. Defective A5 logic card
Remarks
Return to neutral position
Extra hydraulic function, joystick R14 and joystick R15 Pg. 6
27
ELECTRONIC CARD A5
X32
82 Pg. 6
28
503
INP. JOYSTICK FORK
504
INP. JOYSTICK TRAVERSE
505
INP. JOYSTICK ROTATE
X32
83
84
1
R14
X33
85
X33
86
506
INP. JOYSTICK SPARE 1/AUTO ROTATE
2 3
1
R15
2
510
3 206 X
INP. SPEED REDUCTION
1. Check that both joysticks used for the extra hydraulic function are not stuck in the actuated position. 2. Inspect R14 and R15 for correct mounting in the brackets. The voltage applied on inputs 506 and 510 should be 3.7 +/- 0.6 VDC when R14 and R15 have been correctly adjusted. 3. Calibration of the control for the extra hydraulic functions. - Check that both joysticks are not actuated and that they are in the neutral positions. - Turn the key switch off and on once. The joystick will now be 18- 146
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical system – 5000.2 Error codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
calibrated. 4. If the voltage on inputs 506 and 510 is correct and calibration does not rectify the problem, replace the A5 logic card.
Code
25
Description
Output stage error
Error mode
General error
Error cause
See codes 50-62 for more information
Remarks 1. Inspect S133, which is situated under the armrest panel. 2. To view the registers with recorded warning codes, see the section “Display and programming”: The number of the address register is displayed on the left side, while the value is displayed on the right side.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
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Electrical system – 5000.2 Error codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
26
Description
Output stage error
Error mode
General error
Error cause
See codes 90-94 for more information
Remarks 1. Proceed as follows to view the registers with recorded warning codes. See the section “Display and programming” The address register’s number will be displayed on the left side and the value on the right side.
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Electrical system – 5000.2 Error codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
27
Description
Incorrect battery measurement
Error mode
Battery display flashes
Error cause
Poor contact in the battery measurement cables Defective A5 logic card Defective battery
Remarks
Measuring the battery
1. Verify the voltage (+48 VDC) shown on the battery indicator, wire 70 supplies positive voltage to terminal 601, while cable 71 supplies terminal 602 with negative voltage. 2. Check that cable 72 and its connectors are intact and have good contact from the shunt to terminal 603. Check that cable 71 has good contact with the shunt. 3. If no problem is detected in steps 1 and 2, try with a new A5 electronic card. 4. Contact the battery manufacturer for assistance with testing the battery.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
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Electrical system – 5000.2 Error codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
28
Description
Emergency stop switch off is activated
Error mode
Emergency switch-off connector has triggered
Error cause
Operator action Defective switch/wiring harness Defective A5 logic card
Remarks
Reset S21 and switch S17 off/on
Emergency stop switch, S21 ELECTRONIC CARD A5 10A Pg. 1 5
1
F60
Pg. 14
21
X30
24
A16 21
X30
24
EMERGENCY SWITCH OFF S21
Pg. 2 4
X30 1
21
805 X
+ 48VDC
807 X
INP. KEY
110 X
INP. LEFT FOOT SWITCH
22
809 X
+ 48VDC SUPPLY OUTPUTS
45
104 X
INP. DRIVE, FORK DIR, CREEP
46
105 X
INP. DRIVE, STEER WHEEL DIR, CREEP
24
43
2
22
49
203 X
INP. SEAT SWITCH
1. Check that S21 has not been activated. 2. If LED 809 is not lit, there is an interruption in the circuit. If LED 809 is lit, the error code could be caused by poor connection in the circuit. Inspect cable 22 by disconnecting it from contact 809 and perform Ohm measurement to terminal 2 on S21. Also check that the terminal pins are not loose or oxidised. If the cable is intact, continue with Ohm measurement through S21 to terminal 1. If S21 has not been depressed, there should be no interruption. If everything is OK, check whether the connection between S17 and S21 is intact. 3. If S21 and the connecting cables are OK, replace the A5 electronic card.
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Electrical system – 5000.2 Error codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
29
Description
Service time (S) is zero
Error mode
No action
Error cause Remarks
Can be reset with the parameter
1. Resetting parameter 25: - See the section “Programming” in this document. - The service intervals can be checked in the section Preventive maintenance.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
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Electrical system – 5000.2 Error codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
31
Description
Phase error, pulse counter for traversing movement
Error mode
No action
Error cause
Wiring fault Sensor error Defective A4 logic card
Remarks
Only creep speed permitted for fork movement
Pulse transducer, U13
1. Measure the inputs A4/ 008 and 009 and check whether pulses are present when lifting and lowering the forks. (Approx. 15 V) If this is OK, proceed to step 2. - If inputs A4/008 and 009 remain 0 V continuously, check whether a voltage of +15 V is applied on U13. The red cable is plus and the black cable is 0 V. If there is no voltage, check that the cables are intact and that the contact pins in the contacts X49, X16 and X14 are not loose or oxidised. 2. If the cabling and terminals are intact, replace the height sensor U13. 18- 152
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Electrical system – 5000.2 Error codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
3. If nothing else can rectify the problem, replace the A4 logic card.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
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Electrical system – 5000.2 Error codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
33
Description
Programmed parameter values have been lost
Error mode
The default values have been loaded
Error cause
Interference in logic card A
Remarks
Reprogram the A4 logic card. Only creep speed permitted for fork movement
Code
34
Description
Input stage error
Error mode
General error
Error cause
See codes 63-81 for more information
Remarks
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Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical system – 5000.2 Error codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
35
Description
Incorrect signal from one of the two aisle transmitters
Error mode
No action
Error cause
One of the sensors is in the wrong position
Remarks
Check LED 106/107 on A5 to determine which input has received an incorrect signal. Reset the aisle transmitters by moving a magnet past the sensors.
Aisle indicator switches S5, S6, S7 and S8
1. Check LED 106/107 on A5 to determine which input has received an incorrect signal. Reset the aisle transmitters by moving a magnet past the sensors. 2. If the error remains, inspect the cabling from the sensors. If it is intact, replace the sensor.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
18- 155
Electrical system – 5000.2 Error codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
36
Description
Wire guidance learning did not succeed
Error mode
No action
Error cause Remarks
Perform wire guidance “learning” once again
Code
37
Description
Wire guidance limit values exceeded
Error mode
General error
Error cause
The truck has drifted beyond the set angle or lateral signal limit
Remarks
The speed is reduced to 4.0 km/h. The warning code disappears when the truck returns to within the limit value.
Code
38
Description
Wire guidance requested, but wire guidance not defined in the parameter settings
Error mode
No action
Error cause
Parameter 36 has not been set for active wire guidance
Remarks
Code
39
Description
The inputs for personal safety system have been dead for more than 20 s. Inputs 202 and 207.
Error mode
Critical error
Error cause
Cable break Defective personnel protection system
Remarks
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Service Manual
The emergency brakes are applied
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical system – 5000.2 Error codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
40
Description
Warning temperature for travel motor
Error mode
Maximum current is reduced
Error cause
High temperature in the travel motor Defective temperature sensor/wiring harness Defective frequency converter Defective A5 logic card
Remarks
Temperature sensor B1 in drive motor M1
1. Check that the ventilation is OK, especially the fan M10 in the motor compartment 2. Inspect B1. - Disconnect the connector. Measure the resistance in B1, approx. 570 ohms at 20oC. - Check whether cable 11 is intact between B1 and terminal 4 on A1. - Check whether cable 14 is intact between B1 and terminal 7 on A1. - Check that the contact pins in the connections are not loose or oxidised. 3. If B1 and its cables are OK, replace A1.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
18- 157
Electrical system – 5000.2 Error codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
41
Description
Warning temperature in the drive motor frequency converter
Error mode
Maximum current is reduced
Error cause
High temperature in the frequency converter Defective fan Defective temperature sensor/wiring harness Defective frequency converter Defective A5 logic card
Remarks 1. Check that the ventilation is OK. 2. Inspect the fan M12 at the controllers. 3. If the ventilation is OK, replace A1.
Code
42
Description
Current calibration error in the drive motor frequency converter
Error mode
No action
Error cause
Defective frequency converter
Remarks 1. Replace the drive controller A1.
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Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical system – 5000.2 Error codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
45
Description
Warning temperature for the lifting motor
Error mode
Maximum current is reduced
Error cause
High temperature in the lifting motor Defective temperature sensor/wiring harness Defective frequency converter Defective A5 logic card
Remarks
Temperature sensor B2 in the pump motor M3
1. Check that the ventilation is OK, especially the fan M10 in the motor compartment 2. Inspect B2. - Disconnect terminals 4, 7 and 8 on A2. Measure the resistance at B2 between the two cables 16 and cable 19. The resistance in B1 should be approx. 570 ohms at 20oC. - Check whether cable 16 is intact between X12 and terminal 4 on A1. 3. If B2 and its cables are OK, replace A2.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
18- 159
Electrical system – 5000.2 Error codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
46
Description
Warning temperature in the pump motor frequency converter
Error mode
Maximum current is reduced
Error cause
High temperature in the frequency converter Defective fan Defective temperature sensor/wiring harness Defective frequency converter Defective A5 logic card
Remarks 1. Check that the ventilation is OK. 2. Inspect the fan M12 at the motor controllers. 3. If the ventilation is OK, replace A2.
Code
47
Description
Current calibration error in the pump motor frequency converter
Error mode
No action
Error cause
Defective frequency converter
Remarks 1. Replace the lift transistor regulator A2.
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Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical system – 5000.2 Error codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
18.11.4 Warning codes with registration When a warning code is displayed, the code is automatically recorded in the log. Recording is made at the first available position from the 50 available positions and will cause the previous error to move down one position. In the case of warning code 50–62, the valve, support arm brakes or wiring harness has been interrupted or short-circuited. For warning codes 90–94, an interruption has occurred in the potentiometer or wiring harness. Only the actual function is disabled; other functions are unaffected.
Code
50
Description
Output 710 short circuit/wire break
Error mode
General error
Error cause
Defective cabling/valve Y20 Defective A5 logic card
Remarks
Hydraulic valve Y20 engages cab tilting
1. Disconnect cable 101 from output 710. - Check that the contact pins provide contact and are not loose or oxidised. - Check whether cable 101 is intact between the 701 connector and the X23 connector. - Measure the coil resistance of Y20 between the blue and black cables in X23. Resistance approx. 70 ohms. - Check whether cable 40 is intact from X23 to battery minus. 2. Replace A5 if the error remains. © BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
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Electrical system – 5000.2 Error codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
51
Description
Output 711 short circuit/wire break
Error mode
General error
Error cause
Defective cabling/valve Y21 Defective A5 logic card
Remarks
Hydraulic valve Y21 engages cab lowering
1. Disconnect cable 102 from output 711. - Check that the contact pins provide contact and are not loose or oxidised. - Check whether cable 102 is intact between the 711 connector and the X23 connector. - Measure the coil resistance of Y21 between the blue and black cables in X30. Resistance approx. 70 ohms. - Check whether cable 40 is intact from X23 to battery minus. 2. Replace A5 if the error remains.
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Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical system – 5000.2 Error codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
52
Description
Output 701 short circuit/wire break
Error mode
General error
Error cause
Defective wiring harness/valve Y10 Defective A5 logic card
Remarks
Hydraulic valve Y11 engages fork lifting
1. Disconnect cable 89 from output 701. - Check that the contact pins provide contact and are not loose or oxidised. - Check that cable 89 is intact between contact 701 and contact in X47. - Measure the coil resistance of Y11 between the grey and black cables in X47. Resistance approx. 105 ohms. - Check whether cable 40 is intact from X47 to battery minus. 2. Replace A5 if the error remains.
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Service Manual
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Electrical system – 5000.2 Error codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
53
Description
Output 703 short circuit/wire break
Error mode
General error
Error cause
Defective cabling/valve Y24 Defective A5 logic card
Remarks
Hydraulic valve Y24 , reversing valve
1. Disconnect cable 90 from output 703. - Check that the contact pins provide contact and are not loose or oxidised. - Check that cable 90 is intact between contact 703 and contact in X47. - Measure the coil resistance of Y24 between the yellow and black cables in X47. Resistance approx. 90 ohms. - Check whether cable 40 is intact from X47 to battery minus. 2. Replace A5 if the error remains.
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Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical system – 5000.2 Error codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
61
Description
Output 702 short circuit/wire break
Error mode
General error
Error cause
Defective wiring harness/valve Y10 Defective A5 logic card
Remarks
Hydraulic valve Y10 engages fork lowering
1. Disconnect cable 88 from output 702. - Check that the contact pins provide contact and are not loose or oxidised. - Check that cable 88 is intact between contact 702 and contact in X47. - Measure the coil resistance of Y10 between the white and black cables in X47. Resistance approx. 27 ohms. - Check whether cable 40 is intact from X47 to battery minus. 2. Replace A5 if the error remains.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
18- 165
Electrical system – 5000.2 Error codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
62
Description
Output 801 and/or 803 short-circuited/interrupted
Error mode
General error
Error cause
Defective cabling/brake magnet Y5:1/Y5:2 and/or Y6:1/Y6:2 Defective A5 logic card
Remarks
An error in both support arm brakes on one side will cause a max. travel speed of 9 km/h
Y5/Y6 are coils in the support arm brakes
1. Disconnect cable 63 from output 801. - Check that the contact pins provide contact and are not loose or oxidised. - Check whether cable 63 is intact between the 801 connector and the X38 connector. - Disconnect connector X38. Measure the resistance of the coil at Y5:1 and Y5:2. Resistance approx. 50 ohms. If the coils are measured when connected in parallel from X38, the resistance should be approx. 25 ohms. - Disconnect connector X40. Measure the resistance of the coil at Y6. Resistance = 50 ohms. 18- 166
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Electrical system – 5000.2 Error codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
- Check whether cable 40 from X38 to battery minus is intact. 2. Replace A5 if the error remains.
Code
63 (VRE150 only)
Description
Output 016 short circuit/wire break
Error mode
General error
Error cause
1. Defective cabling/coil to Y25 2. Defective A4 logic card
Remarks
Y25, proportional valve for fork traversing
1. Disconnect cable 93 from output 016 on A4. - Check that the contact pins provide contact and are not loose or oxidised. - Check whether cable 93 is intact between the 016 connector and the X63 connector. - Disconnect connector X63. Measure the resistance of the coil at Y25. Resistance approx. 50 ohms. - Check whether cable 40 is intact from X62 to battery minus. 2. Replace A4 if the error remains.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
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Electrical system – 5000.2 Error codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
64 (VRE150 only)
Description
Output 003 short circuit/wire break
Error mode
General error
Error cause
1. Defective cabling/coil to Y26 2. Defective A4 logic card
Remarks
Y26, proportional valve for fork rotation
1. Disconnect cable 73 from output 003 on A4. - Check that the contact pins provide contact and are not loose or oxidised. - Check whether cable 73 is intact between the 003 connector and the X63 connector. - Disconnect connector X63. Measure the resistance of the coil at Y26. Resistance approx. 50 ohms. - Check whether cable 40 is intact from X62 to battery minus. 2. Replace A4 if the error remains.
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Electrical system – 5000.2 Error codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
66
Description
Output 004 short circuit/wire break
Error mode
General error
Error cause
Defective cabling to Y9 Short-circuit/interruption in routing valve Y9 Defective A4 logic card
Remarks
Y9, valve for traversing to the right
1. Disconnect cable 95 from output 004 on A4. - Check that the contact pins provide contact and are not loose or oxidised. - Check whether cable 95 is intact between the 004 connector and the X63 connector. - Disconnect connector X63. Measure the resistance of the coil at Y9. Resistance approx. 90 ohms. - Check whether cable 40 is intact from X62 to battery minus. 2. Replace A4 if the error remains.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
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Electrical system – 5000.2 Error codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
67
Description
Output 017 short circuit/wire break
Error mode
General error
Error cause
Defective cabling to Y8 Short-circuit/interruption in directional valve Y8 Defective A4 logic card
Remarks
Y8, valve for traversing to the left
1. Disconnect cable 94 from output 017 on A4. - Check that the contact pins provide contact and are not loose or oxidised. - Check whether cable 94 is intact between the 017 connector and the X63 connector. - Disconnect connector X63. Measure the resistance of the coil at Y8. Resistance approx. 90 ohms. - Check whether cable 40 is intact from X62 to battery minus. 2. Replace A4 if the error remains.
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Electrical system – 5000.2 Error codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
68 (VRE150 only)
Description
Output 005 short circuit/wire break
Error mode
General error
Error cause
1. Defective cabling/coil to Y28 2. Defective A4 logic card
Remarks
Y28, valve for clockwise rotation
1. Disconnect cable 75 from output 005 on A4. - Check that the contact pins provide contact and are not loose or oxidised. - Check whether cable 75 is intact between the 005 connector and the X63 connector. - Disconnect connector X63. Measure the resistance of the coil at Y28. Resistance approx. 90 ohms. - Check whether cable 40 is intact from X62 to battery minus. 2. Replace A4 if the error remains.
© BT Europe AB
Service Manual
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Electrical system – 5000.2 Error codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
69 (VRE150 only)
Description
Output 006 short circuit/wire break
Error mode
General error
Error cause
1. Defective cabling/coil to Y27 2. Defective A4 logic card
Remarks
Y27, valve for counter-clockwise rotation
1. Disconnect cable 74 from output 006 on A4. - Check that the contact pins provide contact and are not loose or oxidised. - Check whether cable 74 is intact between the 006 connector and the X63 connector. - Disconnect connector X63. Measure the resistance of the coil at Y27. Resistance approx. 90 ohms. - Check whether cable 40 is intact from X62 to battery minus. 2. Replace A4 if the error remains.
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Electrical system – 5000.2 Error codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
70 (VRE150 only)
Description
Output 018 short circuit/wire break
Error mode
General error
Error cause
1. Defective cabling/coil to routing valve Y16 2. Defective A4 logic card
Remarks
Y16, valve, spare 1A
1. Disconnect cable 76 from output 018 on A4. - Check that the contact pins provide contact and are not loose or oxidised. - Check whether cable 76 is intact between the 018 connector and the X63 connector. - Disconnect connector X63. Measure the resistance of the coil at Y16. Resistance approx. 90 ohms. - Check whether cable 40 is intact from X62 to battery minus. 2. Replace A4 if the error remains.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
18- 173
Electrical system – 5000.2 Error codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
71 (VRE150 only)
Description
Output 019 short circuit/wire break
Error mode
General error
Error cause
1. Defective cabling/coil to routing valve Y17 2. Defective A4 logic card
Remarks
Y17, valve spare 1B
1. Disconnect cable 77 from output 019 on A4. - Check that the contact pins provide contact and are not loose or oxidised. - Check whether cable 77 is intact between the 019 connector and the X63 connector. - Disconnect connector X63. Measure the resistance of the coil at Y17. Resistance approx. 90 ohms. - Check whether cable 40 is intact from X62 to battery minus. 2. Replace A4 if the error remains.
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Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical system – 5000.2 Error codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
76
Description
Incorrect checksum in the parameter memory at start-up
Error mode
Critical error
Error cause
Interference in logic card A Defective A4 logic card
Remarks
Restart can reset error Reset a parameter and restart Download new program.
Code
77
Description
Communication error between the I/O processor and master processor
Error mode
Critical error
Error cause
External interference (static electricity) Defective A4 logic card
Remarks
Restart can reset error
Code
78
Description
Error encountered during test of safety relay (main circuit) at start-up
Error mode
Critical error
Error cause
Defective A4 logic card
Remarks
Restart can reset error
Code
79
Description
Safety relay (main circuit) is open
Error mode
Critical error
Error cause
The A4 logic card has been subjected to mechanical impact (blows, knocks) +48 V power supply missing Defective A4 logic card
© BT Europe AB
Remarks
Restart can reset error
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
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Electrical system – 5000.2 Error codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
80
Description
General communication error. No communication with the A5 logic card
Error mode Error cause
Defective CAN wiring/resistance External CAN unit has been incorrectly connected Interference in logic card A Overmodulated A5 electronic card Defective A4 logic card Defective A5 logic card
Remarks
A restart could reset the error. The fork movement speed is reduced
Code
81
Description
General communication error. No communication with the A4 logic card
Error mode Error cause
Defective CAN wiring/resistance External CAN unit has been incorrectly connected Interference in logic card A Overmodulated A5 electronic card Defective A4 logic card Defective A5 logic card
Remarks
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Service Manual
A restart could reset the error. Travel speed is reduced
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical system – 5000.2 Error codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
90
Description
Potentiometer R6 for fork lift/fork lower supplies incorrect voltage (7.0 V).
Error mode
General error
Error cause
Defective potentiometer/wiring harness Input activated without connected potentiometer Defective A5 logic card
Remarks
Fork control, joystick R6 Pg. 6
27
ELECTRONIC CARD A5
X32 1
R6 Pg. 6
28
X32
X33
82
2
503
INP. JOYSTICK FORK
504
INP. JOYSTICK TRAVERSE
505
INP. JOYSTICK ROTATE
506
INP. JOYSTICK SPARE 1/AUTO ROTATE
3
83
84
85
86
510
206 X
INP. SPEED REDUCTION
202 X OUT. DATA COLLECT, LIFT
81
100
208 X
OUT. DATA COLLECT, DRIVE
204 X
INP. WEIGHT
205 X
INP. OVERRIDE
1. Inspect R6 for correct mounting in the bracket. - Check that the voltage across R6 (yellow and grey cable) is 7-7.5 VDC. - The voltage applied on input 503 should be 3.7 +/- 0.6 VDC when R6 has been correctly adjusted. 2. If the voltage on input 503 is correct and the error remains, replace the A5 electronic card. © BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
18- 177
Electrical system – 5000.2 Error codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
91 (VRE150 only)
Description
Potentiometer R5 for rotation movement supplies incorrect voltage (7.0 V)
Error mode
General error
Error cause
1. Defective potentiometer/wiring harness or input activated without the potentiometer having been connected 2. Defective A5 logic card
Remarks
Fork rotation control, joystick R5 ELECTRONIC CARD A5 82
83
Pg. 6
27
1
28
INP. JOYSTICK FORK
504
INP. JOYSTICK TRAVERSE
505
INP. JOYSTICK ROTATE
X32
R5 Pg. 6
503
X32
X33
84
2 3
85
86
506
INP. JOYSTICK SPARE 1/AUTO ROTATE
510
206 X
INP. SPEED REDUCTION
202 X OUT. DATA COLLECT, LIFT
81
100
208 X
OUT. DATA COLLECT, DRIVE
204 X
INP. WEIGHT
205 X
INP. OVERRIDE
1. Inspect R5 for correct mounting in the bracket. - Check that the voltage across R5 (yellow and grey cable) is 7-7.5 VDC. - The voltage applied on input 505 should be 3.7 +/- 0.6 VDC when R5 has been correctly adjusted. 2. If the voltage on input 505 is correct and the error remains, replace 18- 178
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical system – 5000.2 Error codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
the A5 electronic card.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
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Electrical system – 5000.2 Error codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
92
Description
Potentiometer R4 for traversing movement supplies incorrect voltage (7.0 V).
Error mode
General error
Error cause
Defective potentiometer/wiring harness Input activated without connected potentiometer Defective A5 logic card
Remarks
Fork traversing control, joystick R4 ELECTRONIC CARD A5 82
Pg. 6
27
1
28
INP. JOYSTICK FORK
504
INP. JOYSTICK TRAVERSE
505
INP. JOYSTICK ROTATE
X32
R4 Pg. 6
503
X32
X33
83
3
84
85
86
506
INP. JOYSTICK SPARE 1/AUTO ROTATE
510
206 X
INP. SPEED REDUCTION
202 X OUT. DATA COLLECT, LIFT
81
100
208 X
OUT. DATA COLLECT, DRIVE
204 X
INP. WEIGHT
205 X
INP. OVERRIDE
1. Inspect R4 for correct mounting in the bracket. - Check that the voltage across R4 (yellow and grey cable) is 7-7.5 VDC. - The voltage applied on input 504 should be 3.7 +/- 0.6 VDC when R4 has been correctly adjusted. 2. If the voltage on input 504 is correct and the error remains, replace the A5 electronic card. 18- 180
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical system – 5000.2 Error codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
93 (VRE150 only)
Description
The potentiometer R14 for extra function 1/”auto rotation” or R15 for extra function 2 supplies incorrect voltage (7.0 V).
Error mode
General error
Error cause
1. Parameter 15/16 >0, no potentiometer connected 2. Defective potentiometer/wiring harness 3. Defective A5 logic card
Remarks
Extra hydraulic function, joysticks R14 and R15 ELECTRONIC CARD A5 82
83
84
Pg. 6 Pg. 6
27
503
INP. JOYSTICK FORK
504
INP. JOYSTICK TRAVERSE
505
INP. JOYSTICK ROTATE
506
INP. JOYSTICK SPARE 1/AUTO ROTATE
X32 1
28
X32
R14
X33
85
X33
86
2 3
1
R15
2
510
3 206 X
INP. SPEED REDUCTION
202 X OUT. DATA COLLECT, LIFT
81
100
208 X
OUT. DATA COLLECT, DRIVE
204 X
INP. WEIGHT
205 X
INP. OVERRIDE
1. If no valve is connected, parameter 15/16 must be set to 0. Check parameter 16 as follows and see also chapter “Parameter © BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
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Electrical system – 5000.2 Error codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Settings” in this manual. 2. Check whether the two joysticks used for the optional hydraulic function are stuck in the actuated position. 3. Inspect R14 and R15 for correct mounting in the brackets. The voltage applied on inputs 506 and 510 should be 3.7 +/- 0.4 VDC when R14 and R15 are not actuated and they have been correctly adjusted. 4. If the voltage on inputs 506 and 510 is correct, replace the A5 logic card.
Code
94
Description
Potentiometer R1 for accelerator pedal supplies incorrect voltage (4.6 V).
Error mode
General error
Error cause
Defective potentiometer/wiring harness Defective A5 logic card
Remarks
Speed control, R1
1. Inspect R1 for correct mounting in the bracket. Check that the contact pin in contact X19 is not loose or oxidised. The voltage applied on input 501 should be 3.7 +/- 0.2 VDC when R1 has been correctly mechanically adjusted. 2. If the voltage on input 501 is correct and the error remains, replace the A5 electronic card.
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Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical system – 5000.2 Error codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
18.11.5 Error codes with registration Code
104
Description
Output 802 short circuit/wire break
Error mode
Critical error
Error cause
Emergency drive switch for Y1 activated Defective wiring harness/valve Y1 Defective A5 logic card
Remarks
Parking brake, Y1
1. Check that switch S131 is open. 2. Disconnect cable 64 from output 802. - Check that the contact pins provide contact and are not loose or oxidised. - Check whether cable 64 is intact between terminal 802 and coil on Y1. - Measure the resistance of the coil on Y1 between the contacts in X37. Resistance approx. 33 ohms. - Check whether cable 40 is intact to battery minus. 3. Replace A5 if the error remains.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
18- 183
Electrical system – 5000.2 Error codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
106
Description
Output 804 short circuit/wire break
Error mode
Critical error
Error cause
Defective wiring harness/contactor K10 Defective A5 logic card
Remarks
Main contactor, K10, coil
ELECTRONIC CARD A5 1
Pg.3
72
71
70
MAIN CONTACTOR
Pg.2
40
603
INP. BATT. INDI.CURRENT -(+)
602
INP. BATT. INDI.-, CURRENT -(-)
601
INP. BATT. INDI.+
804 X
OUT. MAIN CONTACTOR
808
INP. MAIN CONTACTOR
K10 31 A1
A2 10A
F62 2
Pg.2
1
23
8
1. Disconnect cable 31 from output 804. - Check that the contact pins provide contact and are not loose or oxidised. - Check that cable 31 is intact to contactor K10:A2. - Measure the ohms for the coil on K10 between A1 and A2. Resistance approx. 150 ohms. - Check that cable 40 is intact between contactor K10: A1 and battery minus. 2. If the voltage on input 601 is correct and the error remains, replace the A5 electronic card.
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Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical system – 5000.2 Error codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
107
Description
The main contactor K10 does not close at key-on and the emergency switch off not active
Error mode
Critical error
Error cause
Defective contactor K10 Defective A5 logic card
Remarks
Main contactor, K10, contactor points
ELECTRONIC CARD A5 1
Pg.3
72
71
70
MAIN CONTACTOR
Pg.2
40
603
INP. BATT. INDI.CURRENT -(+)
602
INP. BATT. INDI.-, CURRENT -(-)
601
INP. BATT. INDI.+
804 X
OUT. MAIN CONTACTOR
808
INP. MAIN CONTACTOR
K10 31 A1
A2 10A
F62 2
Pg.2
1
23
8
1. Check the voltage on contact 808. It should be battery plus nominal +48 VDC, when the key (S17) is on. - If there is no voltage, check fuse F62 (10 A). - If the fuse is intact, check that cable 23 is intact. - If cable 23 is OK, check the contactor points on K10. - If the contactor points are OK, check that cable 1 is OK. 2. If terminal 808 on the logic card has a voltage of +48 VDC and the error remains, replace the A5 logic card.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
18- 185
Electrical system – 5000.2 Error codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
108
Description
The main contactor does not open at key-off and the emergency stop switch not active
Error mode
Critical error
Error cause
Defective contactor K10 Defective A5 logic card
Remarks
Main contactor, K10, contactor points
ELECTRONIC CARD A5 1
Pg.3
72
71
70
MAIN CONTACTOR
603
INP. BATT. INDI.CURRENT -(+)
602
INP. BATT. INDI.-, CURRENT -(-)
601
INP. BATT. INDI.+
804 X
OUT. MAIN CONTACTOR
808
INP. MAIN CONTACTOR
K10 Pg.2
40
31 A1
A2 10A
F62 2
Pg.2
1
23
8
1. Check the voltage on contact 808. It should be 0 VDC when the key (S17) is off. - If there is voltage, check that the contactor points on K10 are not welded together. - If the contactor tips are OK, check that cables 23 and 8 are not short-circuited to a live component. 2. If terminal 808 on the logic card has a voltage of 0 VDC and the error remains, replace the A5 logic card.
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Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical system – 5000.2 Error codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
109
Description
Keypad relay does not open.
Error mode
Travel speed reduced to crawl speed
Error cause
1. Short-circuited cable 2. Defective keypad
Remarks
ELECTRONIC CARD A5
21 X30
805
+48VDC
24
807
INP. KEY
43
110
INP. LEFT FOOT SWITCH
EMERGENCY SWITCH OFF 24
S21
X30
22
809
+48VDC SUPPLY OUTPUTS
39
111
INP. DRIVE. CHANGE DIR
45
104
INP. DRIVE, FORKS DIR, CREEP.
46 105
INP. DRIVE, STEER WHEEL DIR, CREEP
47
106
INP. DRIVE, FORK DIR
107
INP. DRIVE, STEER WHEEL DIR
203
INP. SEAT SWITC
48 49
1. Check the voltage in cable 24. Should be 0 VDC if red button on keypad is activated If the voltage is correct, disconnect cable 24. If the voltage is still correct, then replace the A16 keypad.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
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Electrical system – 5000.2 Error codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
111
Description
Potentiometer R2 for brake pedal supplies incorrect voltage (4.6 V).
Error mode
Critical error
Error cause
Defective potentiometer/wiring harness Defective A5 logic card
Remarks
Potentiometer R2, brake control
1. Inspect R2 for correct mounting in the bracket. - Check that the voltage across R2 (1 and 2) is 7-7.5 VDC. - The voltage on input 502 should be 1.7 VDC when R2 is in the neutral position and 4.1 VDC when the brake pedal is fully depressed. - If the voltage is 4.6 VDC, 0 V is missing. If the cables are intact, replace potentiometer R2. 2. If the voltage on input 505 is correct and the error remains, replace the A5 electronic card.
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Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical system – 5000.2 Error codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
112
Description
Error detected during brake input test
Error mode
Critical error
Error cause
Defective A5 logic card
Remarks
Code
114 (VRE150 only)
Description
Too quick regenerative lowering of the forks.
Error mode
Critical error
Error cause
1. Battery is fully charged. 2. Defective lift transistor regulator A2
Remarks 1. If the battery has been newly charged and the forks are lowered with a very heavy load, the battery could accept an additional charge. The charge current from the lift controller in this case will increase as the lowering speed also increases. If the lowering speed becomes too high, the error code is generated. Drive the truck for a few minutes until the battery has become slightly discharged. This will cause the error to disappear. 2. If in spite of the above, the error returns, then replace the lift controller A2.
Code
120
Description
Memory cell for steering set point contains an incorrect value
Error mode
Steering error
Error cause
Interference in A5 electronic card Defective A5 logic card
Remarks
Restart can reset error
1. Temporary interference could have affected the card. Try to restart the truck.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
18- 189
Electrical system – 5000.2 Error codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
121
Description
The steering safety relay has been deactivated as a result of incorrect voltage in the drive stage or a communication error with the master processor
Error mode
Steering error
Error cause
Interference in A5 electronic card Defective A5 logic card
Remarks
Restart can reset error
1. Temporary interference could have affected the card. Try to restart the truck.
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Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical system – 5000.2 Error codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
122
Description
Warning temperature in steering servo
Error mode
Steering error
Error cause
High ambient temperature Jammed steering Defective steering motor Defective wiring harness to steering motor Defective A5 logic card
Remarks
Steering motor, M6
1. Check the ventilation around the A5 card. 2. Lift up the truck. - Check that the steering is not seized. - Inspect current in steering unit, approx. 5 A. 3. Inspect cables 60 and 61 as well as terminals 903 and 904. 4. Inspect the steering motor. - Brushes and brush holders, see MSM 1730. - Armature windings 5. If the error remains, replace the A5 card. © BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
18- 191
Electrical system – 5000.2 Error codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
123
Description
The output voltage to the steering motor does not correspond to requested steering command
Error mode
Steering error
Error cause
Defective steering motor Defective wiring harness to steering motor Defective A5 logic card
Remarks
Steering motor, M6
1. Inspect cables 60 and 61 as well as terminals 903 and 904. 2. Inspect the steering motor - Regarding the brushes and brush holders, see tab S1730 “Electric steering motor”. - Armature windings. 3. If the error remains, replace the A5 card.
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Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical system – 5000.2 Error codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
125
Description
Steering generator error during test
Error mode
Steering error
Error cause
Defective generator/brushes Defective wiring harness Defective A5 logic card
Remarks
Steering generator, U1
1. Check cables 62 and 129. 2. Inspect the steering generator. - Brushes and commutator, see tab S 4100 “Mechanical steering system”. - Armature windings. 3. If the error remains, replace the A5 card.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
18- 193
Electrical system – 5000.2 Error codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Code
126
Description
Steering motor error during test
Error mode
Steering error
Error cause
Defective fuse F61
Order number 244989-040
Defective steering motor/brushes Defective wiring harness Defective A5 logic card Remarks
Steering motor, M6
1. Inspect the fuse F61, 30A, and cables 1 and 25 as well as contact 901. 2. Inspect cables 60 and 61 as well as terminals 903 and 904. 3. Inspect the steering motor. - Brushes and brush holders, see MSM 1730. - Armature windings. 4. If the error remains, replace the A5 card.
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Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical system – 5000.2 Error codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
127
Description
Communication error between the steering processor and master processor
Error mode
Steering error
Error cause
External interference (static electricity) Defective A5 logic card
Remarks
Restart can reset error
1. Temporary interference could have affected the card. Try to restart the truck.
Code
128
Description
Memory cell for steering set point contains an incorrect value
Error mode
Critical error
Error cause
External interference (static electricity) Defective A5 logic card
Remarks
Restart can reset error
1. Temporary interference could have affected the card. Try to restart the truck.
Code
130
Description
Communication error between the I/O processor and master processor
Error mode
Critical error
Error cause
External interference (static electricity) Defective A5 logic card
Remarks
Restart can reset error
1. Temporary interference could have affected the card. Try to restart the truck.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
18- 195
Electrical system – 5000.2 Error codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
131
Description
Error encountered during test of safety relay (steering) at start-up
Error mode
Steering error
Error cause
Defective fuse F61 Defective wiring harness to F61 Defective A5 logic card
Remarks
Fuse F61, 30 A
1. Inspect the fuse F61, 30 A. 2. Inspect cables 1 and 25 as well as contact 901. 3. If the error remains, replace the A5 card.
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Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical system – 5000.2 Error codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
133
Description
Error encountered during test of safety relay (steering) at start-up
Error mode
Steering error
Error cause
Defective A5 logic card
Remarks 1. Temporary interference could have affected the card. Try to restart the truck. 2. If in spite of repeated start attempts the error remains; replace the A5 card.
Code
134
Description
Safety relay (steering) is open
Error mode
Steering error
Error cause
The A5 electronic card has been subjected to mechanical impact (blows, knocks) Defective A5 logic card
Remarks 1. The relay may have opened if the truck was driven over a very uneven surface or ran into something that significantly affected the truck. Try to restart the truck. 2. If in spite of repeated start attempts the error remains; replace the A5 card.
Code
135
Description
Error encountered during test of safety relay (main circuit) at start-up
Error mode
Critical error
Error cause
Defective A5 logic card
Remarks 1. Temporary interference could have affected the card. Try to restart the truck. 2. If in spite of repeated start attempts the error remains; replace the A5 card.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
18- 197
Electrical system – 5000.2 Error codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
136
Description
Error encountered during test of safety relay (main circuit) at start-up
Error mode
Critical error
Error cause
Defective A5 logic card
Remarks 1. Temporary interference could have affected the card. Try to restart the truck. 2. If in spite of repeated start attempts the error remains; replace the A5 card.
Code
137
Description
Safety relay (main circuit) is open
Error mode
Critical error
Error cause
The A5 electronic card has been subjected to mechanical impact (blows, knocks) Defective A5 logic card
Remarks
Restart can reset error
1. The relay may have opened if the truck was driven over a very uneven surface or ran into something that significantly affected the truck. Try to restart the truck. 2. If in spite of repeated start attempts the error remains; replace the A5 card.
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Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical system – 5000.2 Error codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
140
Description
Incorrect checksum in the parameter memory at start-up
Error mode
Critical error
Error cause
Interference in A5 electronic card Defective A5 logic card
Remarks
A restart could reset the error. Change a parameter and restart the truck. Download new program.
1. Temporary interference could have affected the card. - Try to restart the truck. - Change a parameter and restart the truck. - Download new software. 2. If the error remains, replace the A5 card.
Code
141
Description
Incorrect checksum for the current software
Error mode
Critical error
Error cause
Incorrectly downloaded software from the PC Defective A5 logic card
Remarks
Download new program via CAN Change program memory
1. Temporary interference could have affected the card. Download new software. 2. If the error remains, replace the A5 card.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
18- 199
Electrical system – 5000.2 Error codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
150
Description
No communication with the frequency converters during start-up
Error mode
Traction regulator error and lift transistor regulator error
Error cause
Defective CAN wiring harness/resistor 15 V is missing Defective frequency converter Defective A5 logic card
Remarks
CAN communication
1. Check that cables 117, 118, 119 and 120 have not been shortcircuited and that they are not interrupted. Also inspect the resistors R100 and R101. 2. Check that +15 VDC is supplied at output 401 on the A5 card. 3. Try by using a new A1 drive controller. 4. Try by using a new A2 lift regulator. 5. Try with a new A5 card.
18- 200
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Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical system – 5000.2 Error codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
151
Description
No communication with the drive motor frequency converter at start-up
Error mode
Drive regulator error
Error cause
Defective CAN wiring harness/resistor Defective frequency converter
Remarks
CAN communication between A5 and A1
1. Check that cables 117, 118, 119 and 120 have not been shortcircuited and that they are not disconnected. Also inspect the resistor R101. 2. Try by using a new A1 drive controller.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
18- 201
Electrical system – 5000.2 Error codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
152
Description
No communication with the drive motor frequency converter during truck operation
Error mode
Drive regulator error
Error cause
Defective CAN wiring harness/resistor Defective frequency converter
Remarks
CAN communication between A5 and A1
1. Check that cables 117, 118, 119 and 120 have not been shortcircuited and that they are not disconnected. Also inspect the resistor R101. 2. Try by using a new A1 drive controller.
18- 202
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Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical system – 5000.2 Error codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
153
Description
No communication with the pump motor frequency converter at start-up
Error mode
Lift transistor regulator error
Error cause
Defective CAN wiring harness/resistor Defective frequency converter
Remarks
CAN communication between A5 and A2
1. Check that cables 117, 118, 119 and 120 have not been shortcircuited and that they are not disconnected. Also inspect the resistor R101. 2. Try by using a new A2 lift regulator.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
18- 203
Electrical system – 5000.2 Error codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
154
Description
No communication with the pump motor frequency converter during truck operation
Error mode
Lift transistor regulator error
Error cause
Defective CAN wiring harness/resistor Defective frequency converter
Remarks
CAN communication between A5 and A2
1. Check that cables 117, 118, 119 and 120 have not been shortcircuited and that they are not disconnected. Also inspect the resistor R101. 2. Try by using a new A2 lift regulator.
18- 204
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Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical system – 5000.2 Error codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
155 - 163
Description
General communication error
Error mode
Drive regulator error
Error cause
Defective CAN wiring harness/resistor External CAN unit has been incorrectly connected Interference in A5 electronic card Defective A5 logic card
Remarks
CAN communication
1. Check that cables 117, 118, 119 and 120 have not been shortcircuited and that they are not disconnected. Also inspect the resistors R100 and R101. Disconnect the battery connector and measure the resistance between the cables 119 and 120. The result should be 60 Ohms (+/- 5 Ohms) 2. Check that the CAN bus has been connected correctly to all units. 3. Temporary interference could have affected the card. Try to restart the truck. 4. If in spite of repeated start attempts the error remains; replace the A5 card.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
18- 205
Electrical system – 5000.2 Error codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
170 - 177
Description
Error related to wire guidance
Error mode
Wire guidance error
Error cause
Check the error type on the A3 display. See the loop steering description for interpretation of error messages
Remarks
See the wire guidance instructions, C code 4500
Code
175
Description
Aisle centre sensor has been activated outside a narrow aisle (narrow aisle sensors not activated)
Error mode
General error
Error cause
Sensors S4 or S9 have been subjected to mechanical impact (blows, knocks) Defective sensor S4 or S9 Defective cabling to S4 or S9 Defective A5 logic card
Remarks
Sensors S4 and S9
1. One or both of the magnetic sensors have been activated. LED 11 lights. Reset the magnetic sensors by sweeping a magnet in front of the sensors. 2. If the error remains, inspect the cabling from the sensors. 3. If it is intact, replace the sensor. 18- 206
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Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical system – 5000.2 Error codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
203
Description
CPU or memory error in the drive motor frequency converter
Error mode
Drive regulator error
Error cause
Defective frequency converter
Remarks 1. Replace driving regulator A1.
Code
205
Description
Temperature in drive motor too high
Error mode
Drive regulator error
Error cause
Motor overloaded Defective wiring harness/temperature sensor
Remarks
Restart is possible
Temperature sensor B1 in drive motor M1
1. Check that the ventilation is OK, especially fan M10 in the motor compartment. 2. Inspect B1. - Disconnect terminal X26. Measure ohms at B1 in X26, approx. 570 ohm at 20oC. - Check that cable 11 is intact between X26 and connection 4 on A1. - Check that cable 14 is intact between X26 and connection 7 on A1. © BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
18- 207
Electrical system – 5000.2 Error codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
- Check that the contact pins in the connections are not loose or oxidised.
Code
206 - 207
Description
Temperature in the drive motor frequency converter too high
Error mode
Drive regulator error
Error cause
Defective cooling fan Defective motor Defective frequency converter
Remarks
Restart is possible
1. Inspect the fan M12 at the controllers. 2. Inspect the drive motor and its cabling. 3. If everything else is OK, replace A1.
Code
208
Description
Current in the drive motor frequency converter too high
Error mode
Drive regulator error
Error cause
Motor cables incorrectly connected. Defective frequency converter
Remarks
Drive motor circuit
1. Check that the motor cables are intact and that they have been 18- 208
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical system – 5000.2 Error codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
correctly connected. 2. Replace the drive controller, A1.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
18- 209
Electrical system – 5000.2 Error codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
209 - 210
Description
Voltage in the drive motor frequency converter too high
Error mode
Drive regulator error
Error cause
Defective battery Defective motor Defective frequency converter
Remarks 1. Check that the battery is intact, sufficiently charged and of the right model. 2. Check that the drive motor is OK. 3. If everything else is OK, replace A1.
18- 210
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Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical system – 5000.2 Error codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
211 - 212
Description
Voltage in the drive motor frequency converter too low
Error mode
Drive regulator error
Error cause
Defective cabling/fuse F62 External electric consuming components incorrect connected Defective A5 logic card Defective frequency converter
Remarks
Main contactor, K10
ELECTRONIC CARD A5 1
Pg.3
72
71
70
MAIN CONTACTOR
Pg.2
40
603
INP. BATT. INDI.CURRENT -(+)
602
INP. BATT. INDI.-, CURRENT -(-)
601
INP. BATT. INDI.+
804 X
OUT. MAIN CONTACTOR
808
INP. MAIN CONTACTOR
K10 31 A1
A2 10A
F62 2
Pg.2
1
23
8
1. The error code is generated if the operator forgets to switch off the truck and disconnects the battery connector. 2. Check that the electric system is not overloaded by optional equipment. 3. Check that there is 48 VDC in on input 808, cable 23 when K10 is activated. If not, inspect fuse F62 (10 A), the contactor tips on K10 and cables 1, 8 and 23. 4. If this does not rectify the problem, replace A1. 5. Replace A5.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
18- 211
Electrical system – 5000.2 Error codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
213 - 214
Description
CAN error in the drive motor frequency converter
Error mode
Drive regulator error
Error cause
Defective frequency converter
Remarks
Code
223
Description
CPU or memory error in the pump motor frequency converter
Error mode
Lift transistor regulator error
Error cause
Defective frequency converter
Remarks
18- 212
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical system – 5000.2 Error codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
225
Description
Temperature in pump motor too high
Error mode
Lift transistor regulator error
Error cause
Motor overloaded Defective wiring harness/temperature sensor
Remarks
Restart is possible
Temperature sensor B2 in the pump motor
1. Check that the ventilation is OK, especially fan M10 in the motor compartment. 2. Inspect B2. - Disconnect the cable from B2. Measure the resistance in B1, approx. 570 ohms at 20oC. - Check whether cable 16 is intact between B2 and terminals 4 and 8 on A1. - Check whether cable 19 is intact between B2 and terminal 7 on A1. - Check that the contact pins in the connections are not loose or oxidised.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
18- 213
Electrical system – 5000.2 Error codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
226 - 227
Description
Temperature in the pump motor frequency converter too high
Error mode
Lift transistor regulator error
Error cause
Defective cooling fan Defective motor Defective frequency converter
Remarks
Restart is possible
Pump motor circuit
1. Inspect the fan M12 at the controllers. 2. Inspect the motor cables 5, 6 and 7 as well as the pump motor M3. 3. If everything is OK, replace A2.
18- 214
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Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical system – 5000.2 Error codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
228
Description
Current in the pump motor frequency converter too high
Error mode
Lift transistor regulator error
Error cause
Motor cables incorrectly connected. Defective frequency converter
Remarks
Pump motor, M3
1. Check whether the motor cables 5, 6 and 7 are intact and that they have been correctly connected. 2. If the cabling is OK, replace A2.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
18- 215
Electrical system – 5000.2 Error codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
229 - 230
Description
Voltage in the pump motor frequency converter too high
Error mode
Lift transistor regulator error
Error cause
Defective battery Poor contact in the K10 contact points Defective frequency converter
Remarks
Battery circuit
1. Check that the battery is intact, sufficiently charged and of the right model. 2. Inspect the K10 contact points. 3. If everything is OK, replace A2.
18- 216
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical system – 5000.2 Error codes Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Code
231 - 232
Description
Voltage in the pump motor frequency converter too low
Error mode
Lift transistor regulator error
Error cause
Defective cabling/fuse F62 External electric consuming components incorrect connected Defective A5 logic card Defective frequency converter
Remarks
Main contactor, K10
1. The error code is generated if the operator forgets to switch off the truck and disconnects the battery connector. 2. Check that the electric system is not overloaded by optional equipment. 3. Check that there is 48 VDC on input 808, cable 23 when K10 is activated. If not, inspect fuse F62 (10 A), the contactor tips on K10 and cables 1, 8 and 23. 4. If this does not rectify the problem, replace A2. 5. Replace A5.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
18- 217
Electrical system – 5000.2 Error codes T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Code
233 - 234
Description
CAN error in the pump motor frequency converter
Error mode
Lift transistor regulator error
Error cause
Defective CAN wiring harness/resistor Defective frequency converter
Remarks
CAN communication between A5 and A2
1. Check that cables 117, 118, 119 and 120 have not been shortcircuited and that they are not disconnected. Also inspect the resistor R101. 2. Try by using a new A2 lift regulator.
18- 218
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Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical system – 5000.2 Truck log system, code lock Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
18.12 Truck log system, code lock 18.12.1 General BT TLS - Truck Log System The truck may be equipped with various versions or combinations of a code lock generally referred to as TLS. The Truck Log System (TLS) is designed to only allow trained operators to start the truck. Depending on the system in use, the truck can be started by entering a personal PIN code using the keypad or by using a personal code card. When the correct code has been entered, the truck can be operated. Entry of the correct code is confirmed by the display lighting up or by other visual indications. The total operation hours of the truck are recorded in the truck log on the SD 16.
18.12.2 SD 16 Logging in with a code (5 digits) Enter the personal five-digit PIN code each the truck needs to be started. • To start the truck, enter the PIN code via the keypad, 00001, 00002 or 00003, and then press the green button (standard code for initial log-in). If an incorrect PIN code is entered, the red LED is lit. Re-enter the code once the LED goes out. To change the log-in code, see the Davis Derby information.
Logout Be sure to always log out when leaving the truck. • Press the red button on the keypad to log out and prevent unauthorised operation of the truck. If the operator has not logged out, the TLS will automatically perform the log-out operation after a specified time.
18.12.3 Components
© BT Europe AB
Symbol
Designation/function
A16 A20 A23 X3, X30
Keypad TLS, CU TLS, shock sensor Connector
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
18- 219
Electrical system – 5000.2 Truck log system, code lock T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Symbol
Designation/function
X48-X49 W7
Connector Antenna
W7
A20
X30
X48, X49
A16
X3
A23
A23
X48 X49
A23
18- 220
Service Manual
A20
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Electrical system – 5000.2 I/O module Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
If the truck does not start: • Check there is 48 V on cable 21 measured with a minus on cable 40. • Check whether there is minus on terminal X3:9. This activates the TLS function. • In case of error codes 3 (shock sensor activated) and 4 (truck disabled), see the chapter “Warning codes without recording” under C code 5710 in this manual. For additional information, see the Davis Derby information.
18.13 I/O module The I/O module is used to communicate with the [A5] logic card. The module has 2 outputs that can handle a load up to max. 100mA, resulting in an output voltage of 48V. Communication with the I/O module is handled via the CAN bus. The inputs are not used.
I/O
© BT Europe AB
Service Manual
CAN
Veflex VR, VR SF, VRE150, VRE125SF
18- 221
Electrical system – 5000.2 I/O module T-code 485, 487
18- 222
Valid from serial number 6004330-
Service Manual
Date 2013-03-04
Order number 244989-040
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Hydraulic system — 6000 General Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
19- Hydraulic system — 6000 19.1 General The truck has a hydraulic unit in the motor compartment that consists of a pump motor, a pump and a main valve block mounted directly on the outlet of the pump. In the main valve block there is one select valve for mast or fork unit, and two directional valves for lifting and lowering. When the select valve is closed the oil goes to the mast lift cylinders. When lifting, one of the directional valves is opened and the oil flows through a pressure oil filter to the cylinders and thereby lifting of the fork unit takes place. When lowering, the other directional valve is opened, the return oil flows from the lift cylinders through the pressure filter, the main valve block and the pump back to the tank. The pump motor is now forced to run backwards, braked by the electronics, as a generator. The generated current is fed back to the truck’s battery, regenerative lowering. When lifting or lowering is activated it is not possible to use any other hydraulic functions. When the select valve is open the oil goes to the fork unit for use of the different fork functions. The fork unit’s functions can be used simultaneously. The return oil from the fork unit goes directly through the return filter, on the tank, back to the tank. See hydraulic schematics and functional description.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
19- 1
Hydraulic system — 6000 Hydraulic schematics T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
19.2 Hydraulic schematics 19.2.1 Symbols The table gives explanations to symbols that can be used in the hydraulic schematics.
Symbol
19- 2
Description
Symbol
Description
Single-acting hydraulic cylinder
Single-acting hydraulic cylinder, air drained
Double-acting hydraulic cylinder with damper (reduction)
Filter
Reservoir (tank)
Non-return valve
Non-return valve, spring loaded (valve for broken hoses)
Gate valve (emergency lowering)
Directional control valve 2/2, two ports, two distinct positions, electro-magnetic controlled
Directional control valve 3/2, two ports, two distinct positions, electro-magnetic controlled
Directional control valve 4/3, four ports, three distinct positions, electro-magnetic controlled
Servo-valve, electro-magnetic controlled
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Hydraulic system — 6000 Hydraulic schematics Order number 244989-040
Symbol
M
Date 2013-03-04
Valid from serial number 6004330-
Description
Symbol
T-code 485, 487
Description
Servo-valve, electro-magnetic controlled
Servo-valve, electro-magnetic controlled
Pressure sensor, normally open
Pressure regulator valve
Pressure relief valve
Pressure relief valve
Electric motor and one pump with fixed displacement, two directions of flow
Hydraulic motor with fixed displacement, two directions of flow
Enclosure of two or more functions contained in one unit
Pilot (control) line
Working line
Working lines cross over
Working line with junction
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
19- 3
Hydraulic system — 6000 Hydraulic schematics T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
19.2.2 Hydraulic schematics (VR SF)
19- 4
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Hydraulic system — 6000 Hydraulic schematics Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
19.2.3 Component description (VR SF) Pos.
Description
Function
F1
Filter
Pressure oil filter
F2
Filter
Return oil filter
P1
Pump
Hydraulic pump
Y8
Solenoid valve
Directional valve, traverse left
Y9
Solenoid valve
Directional valve, traverse right
Y10
Solenoid valve
Directional valve, fork lower
Y11
Solenoid valve
Directional valve, fork lift
Y20
Solenoid valve
Directional valve, cab tilt
Cold store cab
Y21
Solenoid valve
Directional valve, cab lowering
Cold store cab
Y24
Solenoid valve
Directional valve, select fork movement
1
Pressure relief valve
Open by overload
2
Non-return valve
3
Emergency lowering valve
Emergency lowering of forks
4
Pressure relief valve
Open by overload
50 bar
5
Loadholding valve
Traverse
80 bar
6
Shock/pressure limit valve
Open by overload
45 bar
7
Hydraulic motor
Overhead movement
8
Non-return valve
Safety valve
9
Cylinders
Main lift
10
Cylinder
Free lift
11
Cylinder
Cab tilt
Cold store cab
12
Pressure relief valve
Open by overload
90 bar
13
Pressure regulating valve
© BT Europe AB
Remark
System pressure
Gives a controlled lowering speed in case of a broken hose
80 bar
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
19- 5
Hydraulic system — 6000 Hydraulic schematics T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
19.2.4 Hydraulic schematics (VR)
19- 6
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Hydraulic system — 6000 Hydraulic schematics Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
19.2.5 Component description (VR) Pos.
Description
Function
F1
Filter
Pressure oil filter
F2
Filter
Return oil filter
P1
Pump
Hydraulic pump
Y8
Solenoid valve
Directional valve, traverse left
Y9
Solenoid valve
Directional valve, traverse right
Y10
Solenoid valve
Directional valve, fork lower
Y11
Solenoid valve
Directional valve, fork lift
Y16
Solenoid valve
Directional valve, option 1A
Extra hydraulic function
Y17
Solenoid valve
Directional valve, option 1B
Extra hydraulic function
Y20
Solenoid valve
Directional valve, cab tilt
Cold store cab
Y21
Solenoid valve
Directional valve, cab lowering
Cold store cab
Y24
Solenoid valve
Directional valve, select fork movement
Y25
Proportional valve
Traverse movement
Y26
Proportional valve
Rotate movement
Y27
Solenoid valve
Directional valve, rotate counter clockwise
Y28
Solenoid valve
Directional valve, rotate clockwise
1
Pressure relief valve
Open by overload
2
Non-return valve
3
Emergency lowering valve
Emergency lowering of forks
4
Pressure relief valve
Open by overload
140 bar
5
Overcentre valve
Traverse
See chapter 3.3
6
Overcentre valve
Rotate
See chapter 3.3
7
Non-return valve
Safety valve
Gives a controlled lowering speed in case of a broken hose
8
Cylinders
Fork rotation
9
Hydraulic motor
Overhead movement
10
Cylinders
Main lift
11
Cylinder
Free lift
12
Cylinder
Cab tilt
Cold store cab
13
Pressure relief valve
Open by overload
90 bar
14
Pressure regulating valve
© BT Europe AB
Remark
System pressure
80 bar
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
19- 7
Hydraulic system — 6000 Hydraulic components, positioning T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
19.3 Hydraulic components, positioning 19.3.1 Overview
19- 8
Pos
Description
Remark
1
Hydraulic unit
Pump motor, pump, main valve block
2
Oil tank with return filter
3
Main lift cylinders
4
Free lift cylinder
5
Distribution block
6
Pressure oil filter
7
Fork unit hydraulics
Service Manual
Hydraulic motor, valve block, rotate cylinders
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Hydraulic system — 6000 Hydraulic components, positioning Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
VR SF
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
19- 9
Hydraulic system — 6000 Hydraulic components, positioning T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
2
1
3
4
7
5
6
VR
19- 10
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Hydraulic system — 6000 Hydraulic components, positioning Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
19.3.2 Hydraulic unit
1
G
3
2 H
5
4
P
T
Y11
6
Y24
Y10
M
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
19- 11
Hydraulic system — 6000 Hydraulic components, positioning T-code 485, 487
19- 12
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Pos
Description
1
Pump motor
2
Hydraulic pump
3
Main valve block
4
Pressure relief valve
5
Nipple for pressure gauge
6
Emergency lowering valve
Y10
Directional valve, fork lower
Y11
Directional valve, fork lift
Y24
Directional valve
G
Outlet to fork unit
H
Outlet to main lift
M
Port for pressure gauge nipple
P
Pressure port
Inlet from pump
T
Tank port
Return to tank
Service Manual
Remark
Opens when selecting fork movement
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Hydraulic system — 6000 Hydraulic components, positioning Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
19.3.3 Hydraulic components in the fork unit (VR SF)
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
19- 13
Hydraulic system — 6000 Hydraulic components, positioning T-code 485, 487
19- 14
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Pos
Description
Y8
Directional valve, traverse left
Y9
Directional valve, traverse right
1
Loadholding valve, traverse left
Loadholding pressure = 80 bar
2
Loadholding valve, traverse
Loadholding pressure = 80 bar
3
Pressure relief valve
Relief pressure = 50 bar
4
Shock valve
Opening pressure = 45 bar
5
Shock valve
Opening pressure = 45 bar
6
Hydraulic motor
7
Manifold
A1
Port A
Traverse
B1
Port B
Traverse
P
Pressure port
Inlet from pump
R
Tank port
Return to tank
Service Manual
Remark
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Hydraulic system — 6000 Hydraulic components, positioning Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
19.3.4 Hydraulic components in the fork unit (VR)
Y26
Y28
1
Y27
A B P
A1 A(X)
T B1
B(X)
Y8 Y25 Y9
2 Y16
© BT Europe AB
Service Manual
3
Y17
Veflex VR, VR SF, VRE150, VRE125SF
19- 15
Hydraulic system — 6000 Hydraulic components, positioning T-code 485, 487
19- 16
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Pos
Description
Y8
Directional valve, traverse left
Y9
Directional valve, traverse right
Y16
Directional valve, option 1A
Extra hydraulic function
Y17
Directional valve, option 1B
Extra hydraulic function
Y25
Proportional valve, traverse
Y26
Proportional valve, rotate
Y27
Directional valve, rotate counter clockwise
Y28
Directional valve, rotate clockwise
1
Overcentre valve, rotate
Opening pressure: Arm length < 900 mm = 220 bar Arm length > 900 mm = 200 bar
2
Overcentre valve, traverse
Opening pressure: Arm length < 900 mm = 240 bar Arm length > 900 mm = 200 bar
3
Pressure relief valve
Relief pressure = 120 bar
A
Port A
Rotation
B
Port B
Rotation
A1
Port A
Traverse
B1
Port B
Traverse
A(X)
Port A
Extra hydraulic function
B(X)
Port B
Extra hydraulic function
P
Pressure port
Inlet from pump
T
Tank port
Return to tank
Service Manual
Remark
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Hydraulic system — 6000 Hydraulic components, positioning Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
19.3.5 Cab tilt function (cold store cab)
© BT Europe AB
Pos
Description
Y20
Directional valve, cab tilt
Y21
Directional valve, cab lowering
1
Pressure relief valve
Opening pressure = 90 bar
2
Pressure regulating valve
80 bar
Service Manual
Remark
Veflex VR, VR SF, VRE150, VRE125SF
19- 17
Hydraulic system — 6000 Hydraulic components, positioning T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
This page is intentionally left blank
19- 18
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Hydraulic pump — 6140 General Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
20- Hydraulic pump — 6140 20.1 General There is one pump size in the truck that has a max flow of 60 litres per minute. These service instructions contain a description on how to replace the hydraulic pump.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
20- 1
Hydraulic pump — 6140 Replacing the hydraulic pump T-code 485, 487
Valid from serial number 6004330-
3
Date 2013-03-04
Order number 244989-040
20.2 Replacing the hydraulic pump
6 7 12 4
20.2.1 Dismantling • Disconnect the battery plug. • Drop the forks to the lowest position to reduce pressure in the hoses and pump. • Pump the oil out of the hydraulic tank 3 with filter pump V10-15191. • Remove the bumper (4) so that the bolt joint (5) to the pump motor mounting is accessible. • Remove the temperature/speed measuring contacts (6) and power cables (7) from the pump motor (8).
• Loosen the hose clips (10) on the suction hose (9) on the tank and remove the hydraulic hoses. • Loosen the quick couplings and remove the return hose from the fork unit (11) and the return hose to the tank (12) from the valve block. • Loosen the quick couplings and remove the pressure hoses to the mast (13) and the fork unit (14) from the underside of the valve block. • Fasten a lifting eye in the motor axle. • Remove the bolts (5) holding the pump mounting (15) to chassis. • Lift out the hydraulic pump and place it on a clean surface.
20- 2
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Hydraulic pump — 6140 Replacing the hydraulic pump Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
• Remove both mountings (15) from the pump motor (8). • Remove the hose coupling (16) from the pump unit (19). • Remove the valve block (17) from the pump unit. • Remove the bolts (18) and dismount the pump (19). • Remove the carrier.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
20- 3
Hydraulic pump — 6140 Replacing the hydraulic pump T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
20.2.2 Assembling • Replace the drive between the pump (19) and the pump motor (8). • Replace the pump unit on the pump motor. Tighten the bolts (18) to a torque as set out in C-code 0400. • Assemble the valve block (17) on the pump unit. Tighten the bolts to a torque as set out in C-code 0400. • Fit the hose coupling (16) on the pump unit (19). Tighten the bolts to a torque as set out in C-code 0400. • Replace both mountings (15) on the pump motor (8). Tighten the bolts to a torque as set out in C-code 0400. • Assemble the suction hose (9) on the hose coupling (16). Tighten the hose clip. • Screw a lifting eye into the end of the motor axle and connect it to an overhead crane. • Lift the hydraulic unit into the truck while simultaneously refitting the hydraulic hose (9) on the tank (3). • Tighten the hose clip (10). • Secure the two pump mountings (15) to the chassis using the bolts (5). Tighten the bolts to a torque as set out in C-code 0400. • Unscrew the lifting eye. • Connect the hydraulic hoses (13 and 14) on the valve block's underside and the return hoses (11 and 12) as well as the temperature gauge/speedometer connectors (6) and the power cables (7). • Fill the hydraulic tank (3) with 38 litres of new oil. • Test the hydraulic functions up to the overflow pressure, and check that all connections do not leak.
20- 4
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Hydraulic connections — 6230 General Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
21- Hydraulic connections — 6230 21.1 General It is important that hydraulic connections are tightened correctly to give a sealed and robust connection.
21.2 Tightening torque for hydraulic connections 21.2.1 Conical connection with O-ring The nut is screwed by hand down until it stops and is then tightened either to a torque or to a number of degrees as set out in the table below. Usually used on the majority of hydraulic hoses on trucks,
© BT Europe AB
Dimension ø [mm]
Tightening torque [Nm]
Tightening angle [°]
6
23
30-45
10
30
30-45
12
50
30-45
15
60
30-45
18
70
30-45
20
80
30-45
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
21- 1
Hydraulic connections — 6230 Tightening torque for hydraulic connections T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
21.2.2 Tredo seal The nut/connection is screwed by hand down until it stops and is then tightened to a torque as set out in the table below.
Dimension
Tightening torque [Nm]
R 1/8
12-18
R 1/4
25-45
R 3/8
50-70
R 1/2
70-100
R 5/8
100-140
R 3/4
150-200
R1
195-250
R 1 1/4
250-310
R 1 1/2
310-400
M 18
50-70
M 22
100-140
M 26
150-200
21.2.3 Pipe couplings Tighten the coupling by hand and then tighten a half turn to give the correct torque.
21.2.4 Connections screwed into aluminium
21- 2
Designation with cutting edge
Dimension
Torque [Nm]
G 1/8
R 1/8
~7
G 1/4
R 1/4
~12
G 3/8
R 3/8
~20
G 1/2
R 1/2
~30
G 3/4
R 3/4
~80
G1
R1
~100
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Hydraulic connections — 6230 Tightening torque for hydraulic connections Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
21.2.5 Connections screwed into steel
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
21- 3
Hydraulic connections — 6230 Tightening torque for hydraulic connections T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
Pressure class L Designation with cutting edge
Dimension
Torque [Nm]
Designation with EOLASTIC sealing ring
Dimension
Torque [Nm]
GE 6-LM
M 10x1
~20
GE 6-LM-ed
M 10x1
~10
GE 6-LR
R 1/8
~20
GE 6-LR-ed
R 1/8
~10
GE 8-LM
M 12x1.5
~29
GE 8-LM-ed
M 12x1.5
~20
GE 8-LR
R 1/4
~39
GE 8-LR-ed
R 1/4
~20
GE 10-LM
M 14x1.5
~39
GE 10-LM-ed
M 14x1.5
~29
GE 10-LR
R 1/4
~39
GE 10-LR-ed
R 1/4
~20
GE 12-LM
M 16x1.5
~59
GE 12-LM-ed
M 16x1.5
~29
GE 12-LR
R 3/8
~59
GE 12-LR-ed
R 3/8
~39
GE 15-LM
M 18x1.5
~69
GE 15-LM-ed
M 18x1.5
~39
GE 15-LR
R 1/2
~108
GE 15-LR-ed
R 1/2
~59
GE 18-LM
M 22x1.5
~108
GE 18-LM-ed
M 18x1.5
~59
GE 18-LR
R 1/2
~108
GE 18-LR-ed
R 1/2
~59
GE 22-LM
M 26x1.5
~128
GE 22-LM-ed
M 22x1.5
~69
GE 22-LR
R 3/4
~157
GE 22-LR-ed
R 3/4
~88
GE 28-LM
M 33x2
~216
GE 28-LM-ed
M 33x2
~118
GE 28-LR
R1
~265
GE 28-LR-ed
M 33x2
~137
GE 35-LM
M 42x2
~353
GE 35-LM-ed
M 42x2
~196
GE 35-LR
R 1 1/4
~392
GE 35-LR-ed
R 1 1/4
~235
GE 42-LM
M 48x2
~491
GE 42-LM-ed
M 48x2
~294
GE 42-LR
R 1 1/2
~491
GE 42-LR-ed
R 1 1/2
~294
21- 4
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Hydraulic connections — 6230 Tightening torque for hydraulic connections Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
Pressure class S Designation with cutting edge
Dimension
Torque [Nm]
Designation with EOLASTIC sealing ring
Dimension
Torque [Nm]
GE 6-SM
M 12x1.5
~39
GE 6-SM-ed
M 12x1.5
~20
GE 6-SR
R 1/4
~39
GE 6-SR-ed
R 1/4
~20
GE 8-SM
M 14x1.5
~49
GE 8-SM-ed
M 14x1.5
~29
GE 8-SR
R 1/4
~39
GE 8-SR-ed
R 1/4
~20
GE 10-SM
M 16x1.5
~59
GE 10-SM-ed
M 16x1.5
~39
GE 10-SR
R 3/8
~69
GE 10-SR-ed
R 3/8
~39
GE 12-SM
M 18x1.5
~78
GE 12-SM-ed
M 18x1.5
~49
GE 12-SR
R 3/8
~69
GE 12-SR-ed
R 3/8
~39
GE 14-SM
M 20x1.5
~108
GE 14-SM-ed
M 20x1.5
~59
GE 14-SR
R 1/2
~128
GE 14-SR-ed
R 1/2
~69
GE 16-SM
M 22x1.5
~128
GE 16-SM-ed
M 22x1.5
~69
GE 16-SR
R 1/2
~128
GE 16-SR-ed
R 1/2
~69
GE 20-SM
M 27x2
~196
GE 20-SM-ed
M 27x2
~98
GE 20-SR
R 3/4
~206
GE 20-SR-ed
R 3/4
~108
GE 25-SM
M 33x2
~294
GE 25-SM-ed
M 33x2
~157
GE 25-SR
R1
~314
GE 25-SR-ed
R1
~167
GE 30-SM
M 42x2
~491
GE 30-SM-ed
M 42x2
~255
GE 30-SR
R 1 1/4
~491
GE 30-SR-ed
R 1 1/4
~255
GE 38-SM
M 48x2
~589
GE 38-SM-ed
M 48x2
~314
GE 38-SR
R 1 1/2
~589
GE 38-SR-ed
R 1 1/2
~314
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
21- 5
Hydraulic connections — 6230 Quick connection T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
21.3 Quick connection 21.3.1 Assembling
1. Fit the assembly stop (1) on the male fitting and ensure that the dismantling ring (2) runs freely in the groove. 2. Press in the male fitting in the female fitting until the assembly stop has contact with the female fitting. 3. The coupling is now made and locked.
21- 6
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Hydraulic connections — 6230 Quick connection Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
21.3.2 Dismantling
1. Remove the assembly stop (by using a screwdriver or the like). 2. Push the male fitting fully in the female fitting. 3. Pull out the male fitting from the female fitting. Fit the assembly stop on the male fitting again.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
21- 7
Hydraulic connections — 6230 Quick connection T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
This page is intentionally left blank
21- 8
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Main lift chain system — 7120 General Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
22- Main lift chain system — 7120 22.1 General Applies to all machines with a mast. NOTE! On machines with T-code 407 RR B7-B8/15, 408 RR B7C-B8C/15, 413 RR E7-E8/15 and 414 RR E7C-E8C the chains should be replaced every 2.5 years.
22.2 Checking the chain setting The lift chains must be adjusted at regular periods due to stretching, see below. The chain setting is checked during servicing as set out in the maintenance schedule. Any adjustment is made with the chain mounting bolts. Adjust the fork height according to C code 7100, 7420, 7700 and 7800 as applicable.
22.3 Chain inspection The chains are exposed to two types of wear, outline wear and stretching. Wear to the bolts and disc holes is caused by stretching. The chains are also affected by the environment they are used in.
22.3.1 Noise If lubrication has been insufficient there will be metallic friction on the chain and this will result in noise. The chain should be replaced.
22.3.2 Surface rust Surface rust is easy to recognize as the chain will be reddish brown. Deep-seated rust has generally started and the chain has impaired strength. The chain should be replaced
22.3.3 Rusty links Fretting corrosion results in a reddish brown powder being visible by the outer discs. It can also appear as if the chain is bleeding when lubricated. The chain should be replaced.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
22- 1
Main lift chain system — 7120 Chain inspection T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
22.3.4 Stiff links If it is not possible to pull out the chain to its normal position this can be because of link rust or seizing. The chain should be replaced.
22.3.5 Bolt rotation Bolt rotation can be a phenomenon of stiff links. The fault is easy to see when comparing with a new chain. The chain should be replaced .
22.3.6 Loose bolts If a bolt is loose it will protrude from the side of the chain, which is due to a stiff link or bolt rotation. The chain should be replaced.
22- 2
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Main lift chain system — 7120 Chain inspection Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
22.3.7 Outline wear P
H2
H3
P = Pitch H2 = Nominal disc height. H3 = Minimum disc height. A new lift chain has a specific nominal disc height, defined as H2 in the figure. As the truck is used the lift chain wears radically, on the side that runs over the chain sprocket. The minimum disc height is define as H3 in the figure and denotes the minimum permitted value of the disc height. Maximal permitted outline wear is 5% of the height H2. If a lift chain reaches the maximum level of wear, the chain should be replaced.
The nominal and minimum disc heights for respective lift chains are stated in the table in the chapter “Stretching”.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
22- 3
Main lift chain system — 7120 Chain inspection T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
22.3.8 Stretching The amount of stretch on a lift chain is measured on the part of the chain that runs over the chain sprocket. The amount of stretch may, at the most, be 2% on the most worn section of the chain. Measurement is suitably made over 300-1000 mm of the chain. The nominal and maximum permitted chain lengths for lift chains are stated in the table below.
Type of chain
Nominal disc height H2 ( mm)
Minimum disc height H3 (mm)
Pitch P (mm)
Nominal chain length for 20/30/ 50 discs (mm)
Maximum permitted chain length for 20/ 30/50 discs (mm)
3/4”, 2x3
17.8
16.9
19.05
381/572/953
389/583/972
3/4”, 3x4
17.8
16.9
19.05
381/572/953
389/583/972
3/4”, 4x6
17.8
16.9
19.05
381/572/953
389/583/972
1”, 4x4
23,6
22,4
25,4
508/762/1270
518/777/1295
1”, 6x6
23,6
22,4
25,4
508/762/1270
518/777/1295
Wear to the bolts and around the holes on the discs are a reason why the chain stretches. The chain should be replaced if stretching is more than 2%.
22.3.9 Damage
The chain should be replaced if damaged in any way.
22- 4
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB
Main lift chain system — 7120 Cleaning Order number 244989-040
Date 2013-03-04
Valid from serial number 6004330-
T-code 485, 487
22.3.10 Damaged discs If a disc has broken on the chain, this can be due to overloading or corrosion. The chain should be replaced.
22.3.11 Damaged bolts It can be difficult to discover whether a bolt has broken. It can appear as bolt rotation and/or that the outer disc is loose. The chain should be replaced.
22.3.12 Dirty chain If a chain is very dirty it is first and foremost recommended that it is replaced. It can also be dismantled and cleaned as set out in the chapter “Cleaning”.
22.4 Cleaning If a chain is very dirty it is recommended that it is replaced. Dirty chains should be cleaned before they are lubricated, e.g. by washing with solvent such as diesel or petrol. The chain should be blown dry using compressed air and lubricated directly after cleaning NOTE! Exercise care with degreasing agent as these can contain abrasives.
© BT Europe AB
Service Manual
Veflex VR, VR SF, VRE150, VRE125SF
22- 5
Main lift chain system — 7120 Lubrication T-code 485, 487
Valid from serial number 6004330-
Date 2013-03-04
Order number 244989-040
22.5 Lubrication Mineral and synthetic oils can be used to relubricate Rexnord chains. NOTE! Lubricant must not contain substances such as molybdenum disulphide, PTFE or the like.
A lift chain should be offloaded from the weight of the fork carriage (hanging free) when lubricated. • Lubrication intervals: - 500 hours with normal operations - 100 hours when driving in rugged environments such as cold stores and corrosive environments. The chains are sprayed with lubricant. Note the entire chain must be lubricated, even the fastening bolts. It is especially important that the part of the chain which runs over the chain sprocket is well lubricated. The lubricate must comply with the viscosity demands at respective temperatures as set out in the table below. The following lubricants are recommended:
Ambient temperature
Viscosity class
Recommended Products*
> - 40°C < - 30°C
VG 15
Klüberoil 4UH 1-15, Klüber Lubrication
> - 30°C < + 5°C
VG 68
> + 5°C < + 45°C
VG 150
>+ 45°C