VR VRSF Vre 244989-English [PDF]

Zitiervorschau

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.

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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.

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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

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Electrical System — 5000.1 Symbol List and Wiring Diagrams T-code 485, 487

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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

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Electrical System — 5000.1 Symbol List and Wiring Diagrams T-code 485, 487

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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

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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

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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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

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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

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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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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

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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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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

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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.

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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

17.2.4 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

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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

17.2.5 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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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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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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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

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Electrical System — 5000.1 Functional Description Order number 244989-040

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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

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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

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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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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

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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

17.2.19 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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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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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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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

%

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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

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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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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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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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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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

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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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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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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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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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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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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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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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Date 2013-03-04

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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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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

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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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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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Date 2013-03-04

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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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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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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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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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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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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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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

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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

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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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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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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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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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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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

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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

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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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

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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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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

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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

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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

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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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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

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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

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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

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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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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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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

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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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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

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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

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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

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

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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

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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Date 2013-03-04

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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

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Service Manual

Std. value

T-code 485, 487

Remarks In increments of 1

Veflex VR, VR SF, VRE150, VRE125SF

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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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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

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

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

--

© BT Europe AB

Service Manual

Steering not possible

Function on A5 stops --

X

--

Veflex VR, VR SF, VRE150, VRE125SF

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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

--

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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

18.11.3 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

18- 134

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

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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

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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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

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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

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

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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

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

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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

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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.

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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.

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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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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.

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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

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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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

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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

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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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

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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

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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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

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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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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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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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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.

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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

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.

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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

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

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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.

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Service Manual

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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

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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

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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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

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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

18- 176

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

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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

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

18- 187

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.

18- 194

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.

18- 196

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.

18- 198

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

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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

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.

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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.

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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

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.

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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

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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

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