BT VRE125 VRE150 VRE125SF Service Manual 7549080-040 – PDF DOWNLOAD

Description

BT VRE125 VRE150 VRE125SF Service Manual 7549080-040 – PDF DOWNLOAD

DESCRIPTION:

BT VRE125 VRE150 VRE125SF Service Manual 7549080-040 – PDF DOWNLOAD

How to use this manual:

The repair manual is divided into chapters containing the following information:
• General safety rules
• Operation and connection sequences – This chapter provides a basic description
of the main functions of the truck and their inter-dependance.
• Parameters – This chapter provides a basic description of the truck parameters.
• Installation – This chapter describes the preparatory work that is to be
done before the truck is used for the first time.
• Maintenance – This chapter provides an overview of periodic maintenance.
• Troubleshooting – This chapter describes the action you should take when
the truck is completely or partially malfunctioning. It also describes the
cause of the problem together with suggested remedies.
• C Codes – This chapter describes the various truck systems, e.g. the hydraulic
system and includes descriptions of system parts and the necessary
service procedures. These descriptions are divided according to BT’s
C code system.
• Instructions for disposal instructions – This chapter specifies the proper
sorting category for the materials used in the various truck components.
• Wiring diagram – This chapter provides information on electrical components
and wiring diagrams.
• Hydraulic diagram – This chapter provides information on electrical components
and hydraulic diagrams.
• Tools – This chapter provides a list of the special tools required.
• Service data and grease specifications – This chapter contains information
on general tightening torques and an oil and grease specification.
• Technical data

TABLE OF CONTENTS:

BT VRE125 VRE150 VRE125SF Service Manual 7549080-040 – PDF DOWNLOAD

1 Contents 0
2 General introduction 0
2 1 How to use this manual 0
2 2 Warning levels and symbols 0
2 3 Pictograms 0
3 General safety rules 0
3 1 Work safety 0
3 2 Electrical system 0
3 3 Safe lifting 0
3 4 Truck modifications 0
4 Chassis C0000 0
4 1 Inspection covers C0340 0
4 1 1 Motor hood 0
4 1 2 Battery inspection cover 0
4 2 Battery compartment parts C0390 0
4 2 1 Battery locking mechanism 0
Simple battery locking 0
Battery locking at battery changing equipment 0
4 2 2 Battery side plate (option) 0
4 3 Operator’s cab C0500 0
4 3 1 Versions for cold-store cabs 0
Properties 0
Emergency exit from the cab 0
4 4 Cab windows C0530 0
4 4 1 Electrically heated windows (Option) 0
Activation 0
4 5 Cab door C0550 0
Door handle on cab 0
4 6 Operator’s seat C0620 0
4 6 1 Seat switch [B49] 0
4 7 Cab heating/ventilation C0630 0
4 8 Driver controls (mechanical) C0640 0
4 8 1 Preconditions 0
4 8 2 Brake pedal 0
Monitoring 0
Indications in CID 0
4 8 3 Accelerator 0
Monitoring 0
Indications in CID 0
4 9 Mirrors C0740 0
4 9 1 Mirror types 0
4 10 Overhead guard/roof C0810 0
4 10 1 Protective overhead guard 0
4 10 2 Vertical E-bar 0
4 11 Finger/foot guards C0820 0
4 12 Operator protection C0840 0
4 12 1 Studs 0
4 12 2 Protective grating 0
4 13 Signs, warnings, labels C0850 0
5 Motors C1000 0
5 0 1 Electric pump motor C1710 Description 0
5 1 0
5 1 1 Description 0
5 1 2 Removing the pump motor 0
5 1 3 Fitting the pump motor 0
5 1 4 Replacing the temperature sensor 0
5 1 5 Replacing the speed sensor 0
5 1 6 Cleaning 0
5 1 7 Replacing the oil pump 0
5 1 8 Replacing the bearing 0
5 1 9 Electric steering motor C1730 (steering servo assembly) Description 0
5 1 10 Description 0
5 1 11 Layout of the flange holes 0
5 1 12 View from the underside of the steering motor: a: Attachment, b: Guide, c: Threaded hole for removing steering motor, M10×1,5 Replacing the steering servo motor 0
5 1 13 Electric fan motor/fan C1740 Description 0
5 1 14 Description 0
5 1 15 Indications in CID 0
5 1 16 Replacing the frequency converter fan 0
Method 0
5 1 17 Replacing the motor compartment fan 0
5 1 18 Electric drive motor C1760 Replacing the frequency converter fan 0
Method 0
5 1 19 Replacing the motor compartment fan 0
5 2 0
5 2 1 Description 0
5 2 2 Removing the drive motor 0
5 2 3 Fitting the drive motor 0
5 2 4 Replacing the temperature sensor 0
5 2 5 Replacing the speed sensor 0
5 2 6 Disassembly 0
5 2 7 Cleaning 0
5 2 8 Replacing the bearing 0
5 2 9 Assembly 0
6 Drive gear C2000 0
6 1 Drive/Transmission Assembly 0
6 1 1 Overview 0
6 2 Description – Drive gear C2000 0
6 2 1 Oil change 0
6 2 2 Leakage from the lower cover 0
6 2 3 Checking the oil level 0
6 2 4 Removing the drive gear 0
6 2 5 Steering bearing 0
Replacing the steering bearing 0
6 2 6 Mounting the drive gear 0
7 Brake system/Wheels C3000 0
7 1 Brake system C3100 0
7 1 1 Description 0
Travel brake 0
Parking brake 0
Emergency brake 0
7 1 2 Drive motor brake C3180 0
Accelerator released 0
Changing the direction of travel 0
7 2 Support arm brake C3180 0
7 2 1 Overview 0
7 2 2 Support arm brake (option) C3180 0
7 2 3 Test of support arm brake function 0
Access 0
Table for reading the maximum braking distance 0
7 2 4 Support arm brake replacement 0
7 2 5 Checking the brake unit’s air gap 0
7 2 6 Check of discs’ thickness 0
7 2 7 Assembling the brake unit 0
7 2 8 Adjusting the air gap 0
7 3 Parking brake C3370 0
7 3 1 Overview 0
7 3 2 Description – Parking brake C3370 0
7 3 3 Checking the parking brake’s brake force 0
7 3 4 Checking the parking brake air gap 0
7 3 5 Replacing the brake unit 0
7 3 6 Disassembly and inspection of wear 0
7 4 Emergency brake release 0
7 4 1 Releasing the brake in case of a faulty parking brake unit 0
7 4 2 Releasing the brake when the parking brake unit is intact 0
7 5 Wheels C3500 0
7 6 Drive wheel C3530 0
7 6 1 Overview 0
7 6 2 Replacing the drive wheel 0
7 6 3 Wheel stud replacement 0
7 6 4 Support arm wheel C3550 0
7 7 Support arm wheel C3550 0
7 7 1 Overview 0
VRE TH, unbraked wheel 0
VRE TH, braked wheel 0
VRE SF, unbraked wheel 0
7 7 2 Removing the support arm wheel, TH 0
7 7 3 Mounting the support arm wheel, TH 0
7 7 4 Removing the support arm wheel, TH 0
7 7 5 Mounting the support arm wheel, TH 0
7 7 6 Bearing replacement 0
7 8 Side guide wheel C3580 (option) 0
7 8 1 Overview 0
7 8 2 Description 0
7 8 3 Replacing the side guide wheels (High profile) 0
Dismantling 0
Fitting 0
7 8 4 Adjusting the side guide wheels (High profile) 0
7 8 5 Replacing the side guide wheels (Low profile) 0
Dismantling 0
Assembly 0
7 8 6 Adjusting the side guide wheels (Low profile) 0
8 Steering system C4000 0
8 1 Electric steering wheel C4310 0
8 2 Steering unit C4330 0
8 3 Steering angle reference sensor C4350 0
8 4 Steering bearing C4380 0
8 5 Wire guidance C4510 0
8 5 1 Description 0
Wire signal/Antenna coils 0
8 5 2 Operating modes 0
8 6 Rail guidance C4510 0
8 6 1 Description 0
8 6 2 Operating modes 0
8 7 Wire guidance, antenna C4540 0
9 Electrical system C5000 0
9 1 Battery C5110 0
9 1 1 Battery recommendations 0
9 1 2 Measuring discharge current 0
9 1 3 Measuring voltage 0
9 1 4 Charging the battery 0
9 1 5 BDI algorithm and parameter setting 0
9 1 6 Performance limitations due to battery status 0
9 1 7 Performance limitations due to battery status and parameter setting 0
9 1 8 CID symbol 0
9 1 9 Resetting the battery indicator (BDI) 0
9 1 10 Battery weight 0
9 1 11 Parameter overview, battery 0
9 2 General alarm signals (audible/visual) C5160 0
9 2 1 Horn [P4] 0
9 3 Main contactor [Q10] C5190 0
9 4 Instrument panel C5200 0
9 4 1 Operating controls 0
Adjustment 0
Single-function control 0
Central Information Display (CID) 0
LED symbols 0
Screen 0
Calibration functions 0
9 4 2 Load Information Display – LID 0
Technical data 0
Connections 0
LED symbols 0
When the truck travels in the emergency travel mode, all symbols blink at the same time 0
Symbols in the display part 0
9 5 Weighing system 0
9 6 Overload limit 0
9 7 Height measurement system 0
9 7 1 Monitoring 0
9 8 Height preselector (Option) 0
9 8 1 Symbols 0
9 8 2 Travel warning 0
9 8 3 Height preselector levels 0
9 8 4 Level selection 0
9 8 5 Using the height preselector 0
Aisle and level selection 0
Presets 0
9 8 6 Program the level 0
9 8 7 Deleting a level 0
9 8 8 Height preselector and TruckCom 0
9 8 9 Lifting/lowering movement 0
Parameter settings, lift/lowering movement 0
9 8 10 Parameter overview, height preselector 0
9 9 Transistor panel C5460 0
9 10 Work function harnesses/fuse C5590 0
9 10 1 Fuse panel – FCM [A9] 0
Fuse panel overview 0
Fuses 0
[K20] Key relay 0
[S133] Emergency brake release 0
9 11 Main processor – MCU C5710 0
9 12 Fork control unit – FCU C5720 0
9 12 1 Hydraulic functions 0
Turret head fork unit 0
Telescopic fork unit 0
Common and other functions 0
9 13 Expansion unit – GFU C5730 0
9 14 Sending units and sensors C5800 0
9 14 1 Inductive sensors 0
9 14 2 Position sensor 0
Steering reference sensor 0
9 14 3 Pressure sensor 0
9 14 4 Pulse transducer 0
Steering sensor 0
Traversing sensor 0
9 14 5 Angle sensor 0
9 15 Safety probes/sensors C5830 0
9 15 1 Safety pedal [B31] 0
Indications in CID 0
9 15 2 Safety switch, door [B31] 0
Location 0
Task and function 0
Indications in CID 0
9 15 3 Emergency switch off [S21] 0
9 16 Narrow aisle sensor C5840 0
9 16 1 Magnet sensor 0
9 16 2 Photocell 0
9 16 3 Narrow aisle detection 0
[B110] and [B111] – Magnet sensor 0
Power supply 0
Magnet detection 0
[B111] and [B115] – Photocells 0
9 16 4 [B112]/[B113] End of aisle retardation 0
Power supply 0
Magnet detection 0
9 16 5 [B116] and [B117] End of aisle stop 0
Photocell 0
Power supply 0
Status – MCU inputs 0
9 16 6 [B172] – [B174] Aisle ID 0
Photocell 0
Power supply 0
Status – GFU inputs 0
10 Hydraulic system C6000 0
10 1 Hydraulic unit C6100 0
10 1 1 Tank C6110 0
10 1 2 Filter C6130 0
10 1 3 Hydraulic pump C6140 0
10 2 Main valve unit C6210 0
10 2 1 Definitions 0
10 2 2 Valve unit design, DX 0
Inserts for quick change connector 0
Lift function 0
Regenerative lowering function 0
Pressure limitation 0
Manual lowering function 0
10 2 3 Valve unit design, TX 0
Inserts for quick change connector 0
Lift function 0
Regenerative lowering function (TX) 0
The pump rotates clockwise and the rpm determines the speed of the function 0
Pressure limitation 0
Manual lowering function 0
10 2 4 Pressure sensor 0
10 3 Mast valve units C6310 0
10 3 1 Valve unit design, SF 0
Inserts for quick change connector 0
Traversing 0
Pressure limitation 0
10 3 2 Valve unit design, fork valve unit without extra functions 0
Inserts for quick change connector 0
Shunt function 0
10 3 3 Valve unit design, fork valve unit with extra functions with load holding 0
Inserts for quick change connector 0
10 3 4 Valve unit design, fork valve unit with extra functions without load holding 0
10 4 Calibration of proportional valves 0
10 5 Hydraulic cylinders C6600 0
10 5 1 Main lift C6610 0
Bleeding the main lift cylinders 0
10 5 2 Free lift C6620 0
10 5 3 Tilt (Option) C6660 0
10 5 4 Other hydraulic cylinders C6670 0
Rotation 0
Fork spread (Option) 0
10 6 Filtering the hydraulic oil 0
10 7 Pressure relief 0
11 Mast C7000 0
11 1 Disassembling the mast 0
11 2 Assembling the mast 0
12 Peripherals C8000 0
12 1 Magnet layout 0
12 1 1 Overview 0
12 1 2 Function 0
Rail guidance 0
Wire guidance 0
12 1 3 Alternative layout 0
12 2 Photocell layout 0
12 2 1 “In narrow aisle” 0
12 2 2 Aisle ID 0
12 2 3 End of aisle stop 0
13 Options/Extra equipment C9000 0
13 1 Extra electrical equipment C9300 0
13 1 1 Personal Protection System (PPS) 0
General 0
Installation 0
Service and spare parts 0
Operator environment 0
Connections 0
13 2 Radio equipment C9330 0
13 3 Extra lighting C9360 0
13 4 Extra warning lights/alarm C9370 0
13 4 1 Travel alarm 1 – Buzzer 0
13 4 2 Travel alarm 2 – Warning lamp 0
13 4 3 Direction indicators 0
13 5 Positioning/TV equipment C9390 0
13 6 Extra electrical equipment C9400 0
13 6 1 Extra power socket 0
13 6 2 Longitudinal positioning lamp 0
13 7 Truck log equipment, code lock C9420 0
13 7 1 Toyota Wireless Information System (T W I S ) 0
13 8 Other extra equipment C9500 0
13 8 1 Horizontal E-bar 0
13 8 2 Fire extinguisher 0
14 Operation and connection sequences 0
14 1 Battery is connected 0
1 Battery is connected 0
2a Login via unit connected to the MCU 0
2b Login via keypad 0
2c Login via “ID key” option 0
2d Login to emergency driving mode 0
3 Basic conditions 0
4 Driving in fork direction 0
5 Driving in the drive wheel direction 0
6 Braking in neutral 0
7 Reverse braking 0
8 Automatic braking 0
9 Depressing the brake pedal 0
10 Manual control 0
11 Wire search 0
13 In rail-guided narrow aisle 0
14 Fork lifting 0
15 Fork lowering 0
16 Traversing to the right 0
17 Traversing, left 0
18 Clockwise rotation 0
19 Anticlockwise rotation 0
20 Auto-rotation, traversing to the left/clockwise rotation 0
21 Auto-rotation, traversing right/anticlockwise rotation 0
22 Traversing right (SF) 0
23 Traversing left (SF) 0
24 Extra hydraulic function <TBD> 0
25 Logout 0
26 Emergency lowering 0
15 Parameters 0
15 1 General 0
15 2 Parameter settings 0
15 2 1 Operator parameters 0
Access 0
Parameter screens 0
15 2 2 Parameter menu (PAR) 0
Access 0
Parameter screens 0
15 3 Operator parameters 0
15 3 1 Overview 0
15 3 2 Connection to logged-in operator 0
15 3 3 Description 0
Parameter 1 – Steering 0
Parameter 2, 3 6 and 7 – Maximum travel speed 0
Parameters 4 and 5 – Acceleration/Deceleration 0
15 4 General service parameters 0
15 4 1 Overview 0
15 4 2 Description 0
Parameter 101/104 – Service/Log-out 0
Parameter 105/106/114/115/117/118/119 (Travel alarms 1 and 2) 0
Parameter 107/108/113 – Battery 0
Parameter 109/110/111/112 – Collision sensor 0
Parameter 116 (Door on cold store cabs) 0
15 5 Service parameters, travel functions 0
15 5 1 Overview 0
15 5 2 Description 0
Parameter 201 – Retardation when reversing 0
Parameter 202/203/204 – Adjusting condition-related maximum travel speeds 0
Parameters 205/206/207 – Adjusting function-related, maximum travel speeds 0
Parameter 208 – Creep speed in travel direction control 0
Parameter 209/210 – Adjustment of maximum travel speed above a certain lift height 0
Parameters 211/212/213/214/215/216 – Adjusting application-related, maximum travel speeds 0
15 6 Service parameters, hydraulics 0
15 6 1 Overview 0
15 6 2 Description 0
Parameter 341/342 – Adjustment of application related, maximum lift/ lowering speeds 0
Parameter 343 – Oil filtration 0
Parameter 344 – Reduction of fork lowering speed before floor level 0
Parameter 347/348 – Prevent the lifting/lowering of forks 0
Parameter 350 – Hydraulic function priority 0
Parameter 356 – Limitation of maximum travel speed under certain lift height with load on forks 0
Parameters 361/362/363/364/365 /366 – Function related, maximum lifting/lowering speeds 0
Parameter 367/368 – Lowering height limitation 0
Parameter 369 – Fork height for limitation of lifting speed, forks not in home position 0
Parameter 371 through 379 – Height preselector 0
Parameter 380 through 386 – Lift height limitations in aisle 0
Parameters 387 through 394 – Configuration of lift height limitations 0
Parameter 354/355 – Configuration of lift height limitations outside of aisle 0
Parameters 395/396/397 – Function-related, maximum lift heights 0
Parameters 398/399 – Operator profile dependent, maximum lift heights 0
15 7 Service parameters, CID 0
15 7 1 Overview 0
15 7 2 Description 0
Parameter 503 – Login method 0
Parameters 504/505/506/507 – Smart Access 0
Parameter 508/509/512/513 – CID configuration 0
Parameters 510/511 – Height pre-selection 0
15 8 Service parameters, VNA 0
15 8 1 Overview 0
15 8 2 Description 0
Parameters 601/602/603/604/605 – Truck over wire 0
Parameter 606 – Wire guidance frequency 0
Parameters 607/608/609/610 – Speed reduction and stop at aisle ends 0
15 9 Service parameters, FCU 0
15 9 1 Overview 0
15 9 2 Description 0
Parameter 751 – Stroke length for half pallets 0
Parameters 752/755/758 – Adjusting application dependent, maximum fork unit speeds 0
Parameters 753/754/756/757 Acceleration/deceleration distance, fork unit functions 0
Parameters 760/761/762/763 – Extra hydraulic functions 0
Parameter 764/765/766 – Reversed direction, fork unit functions 0
15 10 General factory parameters 0
15 10 1 Overview 0
15 10 2 Description 0
Parameters 1001/1003/1007/1008/1011/1070/1071/1072/1078/1080/1081/ 1082/1083 – General factory parameters with several choices 0
Parameter 1011 – Rated weight 0
Parameter 1072 – Boom length 0
Parameter 1078 – Camera switch 0
Parameter 1080 – Operating controls 0
Parameter 1081 – Fork unit weight 0
Parameter 1083 – Fork valve unit type 0
15 11 Factory parameters, narrow aisle 0
15 11 1 Overview 0
15 11 2 Description 0
Parameter 1020 – Distance between wire guidance antennas 0
Parameter 1021 – Aisle indication, wire guidance 0
Parameter 1022 – Aisle indication, rail guidance 0
Parameter 1023 – support for RFID (TNS) 0
Parameter 1024 – Aisle layout 0
Parameter 1025 – Sensor direction 0
15 12 Factory parameters, activation of options 0
15 12 1 Overview 0
15 12 2 Description 0
15 13 Factory parameters, calibration 0
Hydraulic system 0
16 Installation 0
16 1 Transporting the truck 0
16 2 Transporting the mast 0
16 3 Safe lifting 0
16 4 Commissioning 0
16 4 1 Common steps for both rail and wire guidance 0
Method 0
16 4 2 Rail guidance 0
16 4 3 Wire guidance 0
16 4 4 Parameter setting 0
Setting battery parameters 0
Setting maximum travel speed 0
General 0
16 4 5 Configuration 0
Calendar 0
PIN-code handling 0
16 4 6 Test driving and checks 0
Functions 0
In narrow aisle 0
18 Maintenance 0
18 1 Introduction 0
18 2 Safety precautions for maintenance work 0
18 3 Maintenance instructions 0
18 3 1 Cleaning and washing 0
18 3 2 High-pressure washers 0
18 3 3 Degreasing agents 0
18 3 4 Cleaning the exterior 0
18 3 5 Cleaning the chain 0
18 3 6 Cleaning the motor compartment 0
18 3 7 Electric components 0
18 4 Lubricants specification 0
18 5 Symbols 0
18 6 Safety checks 0
18 7 Periodic maintenance 0
18 7 1 Every 500 operating hours/180 days 0
18 7 2 Every 1000 operating hours/360 days 0
18 7 3 Every 2000 operating hours/720 days 0
18 7 4 Every 3000 operating hours/1080 days 0
18 Troubleshooting 0
18 1 Auxiliary functions 0
18 1 1 Error log menu 0
Description 0
Access 0
18 1 2 Error information menu 0
Description 0
Access 0
18 1 3 Diagnostic screens 0
Description 0
Access 0
Screen 1 – CID analogue inputs 0
Screen 2 – CID digital inputs 0
Screen 3 – MCU analogue inputs 0
Screen 4 – MCU digital inputs 0
Screen 5 – MCU digital outputs 0
Screen 6 – Pulse-width modulated outputs 0
Screen 7 – FCU 0
Screen 8 – FCU 0
Screen 9 – GFU digital inputs/outputs 0
Screen 11 – Temperatures 0
Screen 12 – Voltages 0
Screen 13 – travel function 0
Screen 14 – Steering function 0
Screen 15 – Hydraulic functions 1 0
Screen 17 – Hydraulic information 0
Screen 18 – VNA functions 0
Screen 19 – Pressure sensor 0
18 2 Initial troubleshooting 0
18 3 Troubleshooting using a blocking symbol 0
18 4 Troubleshooting using error codes 0
18 4 1 CID – Group 1 0
18 4 2 MCU – Group 2 0
18 4 3 Drive system – Group 3 0
18 4 4 Hydraulic system – Group 4 0
18 4 5 Steering system – Group 5 0
18 4 6 Narrow aisle equipment – Group 6 0
18 4 7 FCU – Group 7 0
18 4 8 GFU – Group 8 0
18 5 Troubleshooting without an error code 0
19 Chassis C0000 0
19 1 Hatches, covers C0340 0
19 1 1 Open/close motor cover 0
19 1 2 Replacing the motor cover 0
19 1 3 Adjusting the motor cover 0
19 1 4 Remove/fit the floor 0
19 2 Installing counterbalance C0370 0
Method 0
19 3 Cab windows C0530 0
19 3 1 Fitting a window 0
19 3 2 Electrically heated windows (Option) 0
Activation of the function 0
19 4 Cab door C0550 0
19 4 1 Disassembly of the door lock 0
19 4 2 Disassembly of the lock device 0
19 5 Operator’s seat C0620 0
19 5 1 Adjustment: 0
Seat heater button (Option) 0
19 5 2 Replacing the seat assembly 0
19 5 3 Replacing the seat switch 0
19 5 4 Replacing the back rest 0
19 5 5 Replacing the chair seat 0
19 5 6 Replacing the seat heater switch 0
19 5 7 Installing the safety belt/armrest (Option) 0
19 6 Cab heating/ventilation C0630 0
19 6 1 Replacing the air filter on the cold store cab 0
19 6 2 Replacement of wiring harness with potentiometer 0
19 6 3 Replacing the air outlet 0
19 6 4 Climate control knobs 0
19 7 Operator controls (mechanical) C0640 0
19 7 1 Replacing pedals 0
19 8 Overhead guard/roof C0810 0
19 8 1 Overview 0
19 8 2 Removing the overhead guard 0
19 8 3 Fastening the overhead guard 0
19 8 4 Removing the roof cassette 0
19 8 5 Fastening the roof cassette 0
19 9 Finger/foot guards C0820 0
19 9 1 Replacing a figure guard 0
19 10 Operator protection C0840 0
19 10 1 Replacing the fender 0
19 10 2 Adjusting tilt stops 0
20 Motors C1000 0
20 1 Electric pump motor C1710 0
20 1 1 Overview 0
20 1 2 Removing the pump motor 0
20 1 3 Fitting the pump motor 0
20 1 4 Replacing the temperature sensor 0
20 1 5 Replacing the speed sensor 0
20 1 6 Cleaning 0
20 1 7 Replacing the RPM-sensor 0
20 1 8 Replacing the bearing 0
20 2 Electric steering motor C1730 0
20 2 1 Overview 0
20 2 2 Replacing the steering servo motor 0
20 3 Electric fan motor/fan C1740 0
20 3 1 Overview 0
20 3 2 Replacing the frequency converter fan 0
Method 0
20 3 3 Replacing the motor compartment fan 0
20 4 Electric drive motor C1760 0
20 4 1 Overview 0
20 4 2 Removing the drive motor 0
20 4 3 Fitting the drive motor 0
20 4 4 Replacing the temperature sensor 0
20 4 5 Replacing the speed sensor 0
20 4 6 Disassembly 0
20 4 7 Cleaning 0
20 4 8 Replacing the bearing 0
20 4 9 Assembly 0
21 Drive gear C2000 0
21 1 Drive/Transmission Assembly 0
21 1 1 Overview 0
21 1 2 Oil change 0
21 1 3 Leakage from the lower cover 0
21 1 4 Checking the oil level 0
21 1 5 Removing the drive gear 0
21 1 6 Steering bearing 0
Replacing the steering bearing 0
21 1 7 Mounting the drive gear 0
22 Brake system/Wheels C3000 0
22 1 Support arm brake C3180 0
22 1 1 Overview 0
22 1 2 Test of support arm brake function 0
Access 0
Table for reading the maximum braking distance 0
22 1 3 Support arm brake replacement 0
22 1 4 Checking the brake unit’s air gap 0
22 1 5 Check of discs’ thickness 0
22 1 6 Assembling the brake unit 0
22 1 7 Adjusting the air gap 0
22 2 Parking brake C3370 0
22 2 1 Overview 0
22 2 2 Checking the parking brake’s brake force 0
22 2 3 Checking the parking brake air gap 0
22 2 4 Replacing the brake unit 0
22 2 5 Disassembly and inspection of wear 0
22 3 Emergency brake release 0
22 3 1 Releasing the brake in case of a faulty parking brake unit 0
22 3 2 Releasing the brake when the parking brake unit is intact 0
22 4 Wheels C3500 0
22 5 Drive wheel C3530 0
22 5 1 Overview 0
22 5 2 Replacing the drive wheel 0
22 5 3 Wheel stud replacement 0
22 6 Support arm wheel C3550 0
22 6 1 Overview 0
VRE TH, unbraked wheel 0
VRE TH, braked wheel 0
VRE SF, unbraked wheel 0
22 6 2 Removing the support arm wheel, TH 0
22 6 3 Mounting the support arm wheel, TH 0
22 6 4 Removing the support arm wheel, TH 0
22 6 5 Mounting the support arm wheel, TH 0
22 6 6 Bearing replacement 0
22 7 Side guide wheel C3580 (option) 0
22 7 1 Overview 0
22 7 2 Removing the side guide wheels 0
22 7 3 Mounting the side guide wheels 0
22 7 4 Replacing the bracket 0
22 7 5 Adjusting the side guide wheels 0
23 Steering system C4000 0
23 1 Electric steering wheel C4310 0
23 1 1 Replacing the steering wheel 0
23 1 2 Replacing the steering knob 0
23 1 3 Adjustment 0
23 1 4 Replacing pulse transducer [B13] 0
23 1 5 Removing the steering console from the truck 0
23 1 6 Replacing the wiring harness in the steering console 0
23 1 7 Fit the steering console in the truck 0
23 2 Steering angle reference sensor C4350 0
23 2 1 Overview 0
23 2 2 Replacing the steering angle reference sensor [B59] 0
23 3 Steering bearing C4380 0
24 Electrical system C5000 0
24 1 Battery C5110 0
24 1 1 Charging the battery 0
24 1 2 Battery installation 0
24 2 Main contactor C5190 0
24 2 1 Replacing the main contactor 0
24 2 2 Overview 0
24 2 3 Replacing the main contactor 0
24 3 Instrument panel C5200 0
24 3 1 Overview 0
24 3 2 Lever replacement/installation 0
Required tools 0
Method 0
24 3 3 Replacing the multi-function control 0
Method 0
Replacing the multi-function control’s buttons 0
24 3 4 Removing the control console from the truck 0
Required tools 0
Method 0
24 3 5 Replacing the access card’s circuit board 0
24 3 6 Dismantling the control console 0
Required tools 0
Method 0
24 3 7 Installing an extra option button 0
24 3 8 Replacing the travel direction selector with signal button 0
24 3 9 Replacing the display 0
24 3 10 Assembling the control console 0
24 3 11 Placing the control console in the truck 0
Required tools 0
Method 0
24 4 Drive motor cables/resistors/fuses C5430 0
24 4 1 Overview 0
24 4 2 Replacing copper braid, VRE125SF and VRE150 0
Method 0
24 4 3 Replacing copper braid, VRE125 0
Method 0
24 4 4 Replacing the fuse [F3], VRE125SF and VRE150 0
24 4 5 Replacing fuse [F3], VRE125 0
24 4 6 Replacing the fuse [F1], VRE125SF and VRE150 0
24 4 7 Replacing fuse [F1], VRE125 0
24 4 8 Replacing the terminal block B+, VRE125SF and VRE150 0
24 4 9 Replacing terminal block B+, VRE125 0
24 4 10 Replacing the terminal block B-, VRE125SF and VRE150 0
24 4 11 Replacing terminal block B-, VRE125 0
24 4 12 Replacing the motor cables 0
24 5 Transistor panel C5460 0
24 5 1 Overview 0
24 5 2 Removing ACT/ACH – VRE150 and VRE125SF 0
24 5 3 Replacing ACT – VRE150 and VRE125SF 0
24 5 4 Replacing ACH – VRE150 and VRE125SF 0
24 5 5 Attaching ACT/ACH – VRE150 and VRE125SF 0
24 5 6 Removing ACT/ACH – VRE125 0
24 5 7 Replacing ACT – VRE125 0
24 5 8 Replacing ACH – VRE125 0
24 5 9 Attaching ACT/ACH – VRE125 0
24 6 Work function harnesses/fuse C5590 0
24 6 1 Fuse panel [A9] 0
Fuse panel overview 0
Replacing fuse 0
Checking fuses 0
Replacing the fuse panel 0
24 7 Main processor – MCU C5710 0
24 7 1 Replacing the MCU 0
24 8 Fork control unit – FCU C5720 0
24 8 1 Replacing FCU [A7] 0
24 8 2 Replacing FCU [A7] SF 0
24 9 Safety probes/sensors C5830 0
24 9 1 Safety pedal 0
Replacing the safety pedal 0
24 9 2 Safety switch, door 0
Replacing the safety switch 0
24 9 3 Emergency switch off 0
Overview 0
Removing the emergency switch off 0
24 10 Calibrations 0
24 10 1 Hydraulic levers 0
24 10 2 Reference sensor – height measurement/rotation angle 0
Calibrating height measurement 0
Calibrating rotational angle 0
24 10 3 Hydraulic valves 0
Free lift valve 0
Free lowering valve 0
Main lift valve 0
Main lowering valve 0
Valve for traversing right 0
Valve for traversing left 0
Valve for anticlockwise rotation 0
24 10 4 Mast transition between free lift and main lift 0
24 10 5 Pressure sensor 0
Zero point, free lift 0
Weight measurement, free lift 0
Zero point, main lift 0
Weight measurement, main lift 0
24 10 6 Wire guidance 0
Steering angle 0
Frequency 0
Offset 0
24 10 7 Semi-automatic calibration of traversing 0
24 10 8 Semi-automatic calibration of rotation 0
25 Hydraulic system C6000 0
25 1 Hydraulic hygiene 0
25 1 1 Washing 0
25 1 2 Packaging 0
25 1 3 Handling 0
25 1 4 Storage 0
25 1 5 Work procedures 0
25 2 Hydraulic system, bleeding 0
25 3 Hose inspection 0
25 4 Quick change connector 0
Overview 0
Assembling the quick change connector 0
Dismantling the quick change connector 0
25 5 Tank C6110 0
25 5 1 Emptying the tank 0
25 5 2 Filling the tank 0
25 5 3 Replacing the tank 0
25 6 Filter C6130 0
25 6 1 Overview 0
25 6 2 Filter replacement (for air and oil) 0
Method 0
25 7 Oil pump C6140 0
25 8 Mast valve units C6310 0
25 8 1 Replacing the control valve assembly [Q28]/[Q29] 0
25 9 Hydraulic cylinders C6600 0
25 9 1 Other hydraulic cylinders C6670 0
Rotation cylinder 0
26 Mast C7000 0
26 1 Ordering a replacement mast 0
26 2 Disassembling the mast 0
26 3 Assembling the mast 0
26 4 Adjusting/setting mast inclination on the truck 0
Method 0
26 5 Main lifting chain system C7120 0
26 5 1 Check 0
26 5 2 Lubrication 0
26 5 3 Checking/adjusting lifting chains and guide flatness 0
26 5 4 Checking/adjusting fork height – VRE150 0
26 6 Forks C7410 0
26 6 1 Overview 0
26 6 2 Inspection procedures 0
Inspection 0
Inspection intervals 0
Surface cracks 0
Difference in height between the fork tips 0
Position lock 0
Marking legibility 0
Wear – fork blade and fork face 0
Wear – fork mounting fixtures 0
26 6 3 Repairs and testing 0
Repairs 0
Testing the yield point 0
Replacing forks 0
26 7 Turret head fork unit C7700 0
26 7 1 Setting backlash 0
Tools 0
26 8 Traversing function, fork unit C7710 0
26 8 1 Overview 0
26 8 2 Replacing sensor bearings [B9] 0
26 8 3 Removing the hydraulic motor 0
Method 0
26 8 4 Mounting the hydraulic motor 0
Method 0
26 8 5 Replacing the drive unit shaft 0
Method 0
26 8 6 Replacing rollers on the unit arm 0
Method 0
26 8 7 Replacing the reference sensor [B7] 0
26 9 Swivel/rotation function, fork unit C7720 0
26 9 1 Replacing rotation angle sensor [B8] 0
26 10 Shuttle fork unit C7800 0
26 10 1 Adjusting chains 0
Checking drive chain tension 0
Adjusting the drive chain 0
26 10 2 Replacing the idler roller 0
26 10 3 Replacing guide 0
26 11 Shuttle fork power unit C7820 0
26 11 1 Replacing the reference sensor [B7] SF 0
26 11 2 Replacing sensor bearings [B9] SF 0
27 Peripherals C8000 0
28 Options/Extra equipment C9000 0
28 1 E-bar C9500 0
28 1 1 Overview 0
28 1 2 Fitting the E-bar 0
28 1 3 Installing accessories 0
Method 0
29 Instructions for disposal 0
29 1 General 0
29 2 Marking of plastics 0
29 2 1 General marking of products and packaging 0
29 2 2 Marking according to the manufacturer’s standards 0
Abbreviations 0
Marking examples 0
29 3 Pressure vessels 0
29 3 1 Gas struts 0
29 4 Sorting categories 0
30 Wiring diagram 0
30 1 Components 0
30 2 Component location 0
Picture 1 0
Picture 2 0
Picture 3 0
Picture 4 0
Picture 5 0
Picture 6 0
Picture 7 0
Picture 8 0
Picture 9 0
Picture 10 0
Picture 11 0
Picture 12 0
Picture 13 0
Picture 14 0
Picture 15 0
Picture 16 0
Picture 17 0
Picture 18 0
Picture 19 0
Picture 20 0
Picture 21 0
Picture 22 0
Picture 23 0
Picture 24 0
Picture 25 0
Picture 26 0
Picture 27 0
Picture 28 0
Picture 29 0
Picture 30 0
Picture 31 0
Picture 32 0
Picture 33 0
Picture 34 0
Picture 35 0
Picture 36 0
Picture 37 0
Picture 38 0
Picture 40 0
Picture 41 0
30 3 Cable connections and terminal posts 0
30 3 1 ACT [T1] 0
30 3 2 ACH [T2] 0
30 3 3 CID [A1] 0
30 3 4 MCU [A5] 0
30 3 5 FCU [A7] 0
30 3 6 GFU [A8] 0
30 4 Fuse panel [A9] 0
30 5 Overview 0
30 6 Detailed diagram From 6191182 – 6257600 0
30 7 Detailed diagram From 6257601 0
30 8 CC Detailed diagram From 6191182 – 6257600 0
30 9 Detailed diagram From 6257601 0
31 Hydraulics schematics 0
31 1 Main valve unit, VRE duplex 0
31 2 Main valve unit, VRE triplex 0
31 3 Fork valve unit, turret head fork unit 2 functions 0
31 4 Fork valve unit, turret head fork unit 3 functions 0
31 5 Fork valve unit, SF 0
31 6 Valve unit for tilt (Option) 0
31 7 List of symbols 0
31 8 Detailed diagrams 0
TH 0
SF 0
32 Tools 0
32 1 AMP contacts 0
32 2 MQS contacts 0
32 3 CPC contacts 0
32 4 Other tools 0
33 Service data and grease specifications 0
33 1 General tightening torques 0
33 1 1 Galvanised, non-oiled screws 0
33 1 2 Untreated, oiled screws 0
33 2 Oil and grease specification 0
34 Technical data 0
34 1 Basic data 0
34 2 Mast type and weight (kg) 0
34 3 IP classes on components and units 0
34 4 Battery sizes 0
34 5 Truck dimensions 0
34 5 1 VRE125, VRE150 0
34 5 2 VRE125SF 0

IMAGES PREVIEW OF THE MANUAL:

BT VRE125 VRE150 VRE125SF SERVICE MANUAL 7549080-040 – PDF DOWNLOAD:

PLEASE NOTE:

• This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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