VR VRSF Vre 244989-English

Service manual en
Veflex VR, VR SF, VRE150, VRE125SF

Applies from serial number: 6004330-
Order number: 244989-020

Issued: 2013-03-04 ITS
© BT Europe AB
Document revisions:
Publishing Order Amendments

date number
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 Date Valid from serial number T-code
244989-040 2013-03-04 6004330- 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
3- Tools ..................................................................................................... 4-1

3.1 Electrical contacts .......................................................................... 4-1
3.1.1 Super Seal connectors .................................................... 4-1
3.1.2 AMP connectors .............................................................. 4-2
3.2 Other tools ..................................................................................... 4-3
4- Chassis – 0000 ..................................................................................... 5-1

4.1 General .......................................................................................... 5-1
4.2 List of tools ..................................................................................... 5-1
4.3 Transporting the truck .................................................................... 5-2
4.4 Assembling the mast...................................................................... 5-3
4.5 Installation in narrow aisles ............................................................ 5-7
4.5.1 General ............................................................................ 5-7
4.5.2 Track-guided truck ........................................................... 5-7
4.5.3 Wire guided truck ............................................................. 5-7
4.5.4 General adjustment ......................................................... 5-7
5- Frame, mounted components — 0400 ............................................... 6-1

5.1 General tightening torque............................................................... 6-1
5.1.1 Galvanised, non oiled bolts ............................................. 6-1
5.1.2 Untreated, oiled bolts ....................................................... 6-2
6- Driver Protection — 0840 .................................................................... 7-1

6.1 General .......................................................................................... 7-1
6.2 Tilt Stops ........................................................................................ 7-2
6.2.1 Inspection and Adjustment .............................................. 7-2
7- Electric Pump Motor — 1710 .............................................................. 8-1

7.1 General .......................................................................................... 8-1
7.2 Dismantling the Pump Motor.......................................................... 8-1
7.3 Removing and Replacing the Pump Motor..................................... 8-2
7.3.1 Dismantling ...................................................................... 8-2
7.3.2 Assembling ...................................................................... 8-3
7.4 Bearing Replacement .................................................................... 8-4
7.4.1 Dismantling ...................................................................... 8-4
7.4.2 Re-Assembly ................................................................... 8-5
7.5 Installation Instructions for External Temperature Sensor ............. 8-6
© BT Europe AB Service Manual Veflex VR, VR SF, VRE150, VRE125SF 1

T-code Valid from serial number Date Order number
485, 487 6004330- 2013-03-04 244989-040
8- Electric Steering Motor — 1730 .......................................................... 9-1

8.1 General .......................................................................................... 9-1
8.2 Replacing the Steering Motor......................................................... 9-1
8.2.1 Dismantling ...................................................................... 9-1
8.2.2 Re-Assembly ................................................................... 9-1
8.3 Removing and Replacing the Carbon Brushes .............................. 9-1
9- Electric Drive Motor — 1760 ............................................................. 10-1

9.1 General ........................................................................................ 10-1
9.2 Dismantling the Drive Motor......................................................... 10-2
9.3 Dismantling and Assembling the Drive Motor .............................. 10-3
9.3.1 Dismantling the Drive Motor .......................................... 10-3
9.3.2 Assembling the Drive Motor .......................................... 10-4
9.4 Bearing Replacement .................................................................. 10-5
9.1.1 Assembling .................................................................... 10-6
9.2 Installation Instructions for External Temperature Sensor ........... 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

244989-040 2013-03-04 6004330- 485, 487
11.7.3 Checking the braking force .......................................... 12-10

11.8 Multiple disc brake, support arm ................................................ 12-12
11.8.1 Assembly ..................................................................... 12-12
11.8.2 Dismantling .................................................................. 12-13
11.8.3 Maintenance ................................................................ 12-14
12- Drive wheel — 3530 ......................................................................... 13-1

12.1 General ........................................................................................ 13-1
12.2 Dismantling the drive wheel ......................................................... 13-1
12.3 Assembling the drive wheel ......................................................... 13-1
13- Fork/support arm wheel – 3550 ...................................................... 14-1

13.1 General ........................................................................................ 14-1
13.2 Dismantling the wheel .................................................................. 14-1
13.3 Assembling the wheel .................................................................. 14-2
13.4 Dismantling/assembling the wheel bearings ................................ 14-4
14- Electric steering wheel/lever — 4310 ............................................. 15-1

14.1 General ........................................................................................ 15-1
14.2 Replacement of the steering
generator 15-1
14.2.1 Dismantling .................................................................... 15-1
14.2.2 Assembly ....................................................................... 15-1
15- Steering angle sensor — 4350 ....................................................... 16-1

15.1 General ........................................................................................ 16-1
15.2 Procedure .................................................................................... 16-1
15.2.1 Adjustment of directional sensor ................................... 16-1
15.2.2 Adjustment of the steering angle sensor ....................... 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

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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

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17.1.10 Parameter 11 ............................................................. 18-114

17.1.11 Parameter 12 ............................................................. 18-114
17.1.12 Parameter 13 ............................................................. 18-115
17.1.13 Parameter 14 ............................................................. 18-115
17.1.14 Parameter 15 ............................................................. 18-115
17.1.15 Parameter 16 ............................................................. 18-115
17.1.16 Parameters 17 and 18 ............................................... 18-115
17.1.17 Parameter 19 ............................................................. 18-115
17.1.18 Parameter 20 ............................................................. 18-116
17.1.19 Parameter 21 ............................................................. 18-116
17.1.20 Parameter 22 ............................................................. 18-117
17.1.21 Parameter 23 ............................................................. 18-117
17.1.22 Parameter 24 ............................................................. 18-117
17.1.23 Parameter 25 ............................................................. 18-117
17.1.24 Parameter 26 ............................................................. 18-117
17.1.25 Parameter 27 ............................................................. 18-117
17.1.26 Parameter 28 ............................................................. 18-118
17.1.27 Parameter 29 ............................................................. 18-118
17.1.28 Parameter 35 ............................................................. 18-118
17.1.29 Parameter 36 ............................................................. 18-118
17.1.30 Parameter 37 ............................................................. 18-118
17.1.31 Parameter 38 ............................................................. 18-119
17.1.32 Parameter 39 ............................................................. 18-120
17.1.33 Parameters 40 to 42 .................................................. 18-120
17.1.34 Parameter 43 ............................................................. 18-120
17.1.35 Parameter 44 ............................................................. 18-121
17.1.36 Parameter 45 ............................................................. 18-121
17.1.37 Parameter 46 ............................................................. 18-121
17.1.38 Parameter 47 (VR) .................................................... 18-121
17.1.39 Parameter 48 (VR) .................................................... 18-121
17.1.40 Parameter 49 (VR SF) ............................................... 18-121
17.1.41 Parameter 50 ............................................................. 18-122
17.1.42 Parameter 51 (VR) .................................................... 18-122
17.1.43 Parameter 53 (VR) .................................................... 18-122
17.1.44 Parameter 54 ............................................................. 18-122
17.1.45 Parameter 55 ............................................................. 18-122
17.1.46 Parameter 56 (VR) .................................................... 18-123
17.1.47 Parameter 57 ............................................................. 18-123
17.1.48 Parameter 58 (VR) .................................................... 18-123
17.1.49 Parameter 59 (VR) .................................................... 18-123
17.1.50 Parameter 60 (VR) .................................................... 18-123
17.1.51 Parameter 61 (VR) .................................................... 18-123
17.1.52 Parameter 62 (VR) .................................................... 18-124
17.1.53 Parameter 63 (VR) .................................................... 18-124
17.1.54 Parameter 64 (VR) .................................................... 18-124
17.1.55 Parameter 65 (VR) .................................................... 18-124
17.1.56 Parameter 66 (VR) .................................................... 18-124
17.1.57 Parameter 67 ............................................................. 18-124
17.2 Instrument Panel and Display .................................................. 18-125
17.2.1 Show .......................................................................... 18-125
17.2.2 Operating Time .......................................................... 18-126
17.2.3 Programming ............................................................. 18-126
17.3 Codes ...................................................................................... 18-128
17.3.1 Warning Codes .......................................................... 18-128
17.3.2 Error mode ................................................................. 18-128
17.3.3 Safety Logic ............................................................... 18-130

485, 487 6004330- 2013-03-04 244989-040
17.3.4 Warning Codes without Registration ......................... 18-130

17.3.5 Warning Codes with Registration .............................. 18-160
17.3.6 Error Codes ............................................................... 18-182
17.3.7 Error Codes with Registration .................................... 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

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18.10 Warning codes ......................................................................... 19-130

18.11 Error codes .............................................................................. 19-131
18.11.1 Error mode ................................................................. 19-131
18.11.2 Safety logics .............................................................. 19-131
18.11.3 Warning code without recording ................................ 19-133
18.11.4 Warning codes with registration ................................ 19-161
18.11.5 Error codes with registration ...................................... 19-183
18.12 Truck log system, code lock ..................................................... 19-219
18.12.1 General ...................................................................... 19-219
18.12.2 SD 16 ......................................................................... 19-219
18.12.3 Components .............................................................. 19-219
18.13 I/O module ............................................................................... 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
20- Hydraulic pump — 6140 .................................................................. 21-1

20.1 General ........................................................................................ 21-1
20.2 Replacing the hydraulic pump...................................................... 21-2
20.2.1 Dismantling .................................................................... 21-2
20.2.2 Assembling .................................................................... 21-4
21- Hydraulic connections — 6230 ...................................................... 22-1

21.1 General ........................................................................................ 22-1
21.2 Tightening torque for hydraulic connections................................. 22-1
21.2.1 Conical connection with O-ring ...................................... 22-1
21.2.2 Tredo seal ...................................................................... 22-2
21.2.3 Pipe couplings ............................................................... 22-2
21.2.4 Connections screwed into aluminium ............................ 22-2
21.2.5 Connections screwed into steel ..................................... 22-3
21.3 Quick connection ......................................................................... 22-6
21.3.1 Assembling .................................................................... 22-6
21.3.2 Dismantling .................................................................... 22-7
22- Main lift chain system — 7120 ........................................................ 23-1

22.1 General ........................................................................................ 23-1
22.2 Checking the chain setting ........................................................... 23-1
22.3 Chain inspection .......................................................................... 23-1
22.3.1 Noise ............................................................................. 23-1
22.3.2 Surface rust ................................................................... 23-1
22.3.3 Rusty links ..................................................................... 23-1
22.3.4 Stiff links ........................................................................ 23-2

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22.3.5 Bolt rotation ................................................................... 23-2

22.3.6 Loose bolts .................................................................... 23-2
22.3.7 Outline wear .................................................................. 23-3
22.3.8 Stretching ...................................................................... 23-4
22.3.9 Damage ......................................................................... 23-4
22.3.10 Damaged discs .............................................................. 23-5
22.3.11 Damaged bolts .............................................................. 23-5
22.3.12 Dirty chain ...................................................................... 23-5
22.4 Cleaning....................................................................................... 23-5
22.5 Lubrication ................................................................................... 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) ................................ 25-1
24.1 Maintenance ................................................................................ 25-1
24.1.1 Maintenance schedule ................................................... 25-2
24.1.2 Lubrication ..................................................................... 25-4
24.1.3 Adjustment of chains ..................................................... 25-5
24.2 Replacement of shuttle fork unit................................................... 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

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25.1.4 Printing to a printer ...................................................... 26-13

25.2 Trouble shooting ........................................................................ 26-14
25.1.1 Error messages, analysis and actions ......................... 26-14
25.2 Service actions........................................................................... 26-16
25.1.1 Switching to timer charging ......................................... 26-16
25.1.2 Replacing the display card .......................................... 26-16
25.1.3 Replacing the computer board .................................... 26-17
25.1.4 Replacing the motherboard ......................................... 26-17
25.1.5 Replacing the diodes ................................................... 26-17
25.2 Preventive maintenance ............................................................ 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

485, 487 6004330- 2013-03-04 244989-040

Technical data
244989-040 2013-03-04 6004330- 485, 487
1- Technical data
Model VR SF VR
VR SF C VR C
Drive motor
Type TSP 112/4-165-t TSP 112/4-165-t
Power, kW 7,5 7,5
Intermittence, % 60 60
Insulation class B B
Transmission/gear
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
Wheels
Drive wheel Diameter 350x130 Diameter 350x130
Wheel pressure without load 2020a
Wheel pressure with rated load 1420b
Wheel bolts’
tightening torque, Nm 130 130
Support arm wheels Diameter 230x85 alt. Diameter 230x85 alt.
230x110 230x110
Axle pressure with rated load, kg 5800c
© BT Europe AB Service Manual Veflex VR, VR SF, VRE150, VRE125SF 1- 1

Technical data
485, 487 6004330- 2013-03-04 244989-040
Model VR SF VR
VR SF C VR C
Hydraulic system
Pump motor, Type TSP 112/4-195-T TSP 112/4-195-T
Power, kW 14 14
Pressure with rated load, 35
litres/min.
Tank volume, litres 38 38
Oil type:
At normal temperature ISO-L-HM32 ISO-L-HM32
<-15°
Hydraulic pressures
Work pressure when lifting 1000 kg,
MPa
Work pressure when traversing
1000 kg, MPa
Work pressure when rotating ----------
1000 kg, MPa
Relief pressure, MPa 19,5
Steering motor
Type 3C-483031CJ 3C-483031CJ
Power, kW 0,17 0,17
Min. carbon brush length, mm 9 9
Min. commutator diameter, mm 22,9 22,9
Fuses
F1, Drive motor 160 A/29223 160 A/29223
F3, Pump motor 300 A/29674 300 A/29674
F60, Supply voltage A5 10 A/161640-100 10 A/161640-100
F61, Steering servo 30 A/161640-300 30 A/161640-300
F62, Input from main contactor 10 A/161640-100 10 A/161640-100
F63, Extra equipment 10 A/161640-100 10 A/161640-100
1- 2 Service Manual Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB

Technical data
244989-040 2013-03-04 6004330- 485, 487
Model VR SF VR
VR SF C VR C
Battery
Dimensions WxLxH, mm 355/427/499x1223x784 355/427/499x1223x784
Capacity, Ah 480 - 900 480 - 900
Weight, kg 900 - 1400 900 - 1400
Driving speed
Without load, without support arm brake, 2,5 2,5
m/s
With rated load, without support arm 2,5 2,5
brake, m/s
Without load, with support arm brake, m/
s
With rated load, with support arm brake,
m/s
Lifting/lowering speed, speeds fork unit
Lifting without load, m/s 0,37 0,37
Lifting with 1000 kg, m/s 0,32
Lifting with rated load, m/s 0,29 0,29
Lowering without load, m/s 0,48 0,48
Lowering with 1000 kg load, m/s 0,49
Lowering with rated load, m/s 0,50 0,50
Traversing forks without load, m/s 0,30-0,40 0,21
Traversing forks with rated load, m/s
Fork rotation 180 degrees without load, ---------- 7,5
s
Fork rotation 180 degrees with ---------- 9,5
rated load, s

Technical data
485, 487 6004330- 2013-03-04 244989-040
Model VR SF VR
VR SF C VR C
Power consumption, driving
Driving without load, A
Driving with rated load, A
Power consumption, free lift
Lifting without load, A
Lifting with rated load, A
Power consumption, main lift
Lifting without load, A
Lifting with rated load, A
Power consumption, Fork movements
Fork rotation without load ----------
Fork rotation with rated load ----------
Traversing forks without load
Traversing forks with rated load
a. Chassie width=1420 mm, Wheel base=1900 mm, Lift height=10000 mm, Arm length=600 mm,
Battery weight=1116kg
b. Chassie width=1420 mm, Wheel base=1900 mm, Lift height=10000 mm, Arm length=600 mm,
c. Chassie width=1420 mm, Wheel base=1900 mm, Lift height=10000 mm, Arm length=600 mm,
NOTE:
Data may be missing in the table due to uncompleted tests or insuffi-
cient information being available.

Maintenance
Introduction and safety, maintenance
244989-040 2013-03-04 6004330- 485, 487
2- Maintenance
2.1 Introduction and safety,

maintenance
To assure maximum safety and minimum downtime, all items in the
service programme should be covered. The service intervals are only
guidelines and need not be strictly followed. The truck operators should
adapt these to local requirements, however, it is important that the inter-
vals coincide with the minimum BT requirements.
The service intervals are based on truck operating hours and can be
adapted to most common 8-hour shifts. The service intervals should be
shorter if the truck is used more often or is operated in tougher environ-
ments, e.g cold stores, dusty or corrosive environments. When calcu-
lating the service intervals, the following operating hours have been
used:
Day time:08.00-17.00 (20 hours/week)
Double shift:06.00-14.00, 14.00-22.00 (40 hours/week)
Triple shift:06.00-14.00, 14.00-22.00, 22.00-06.00
(60 hours/week)
Make sure regular maintenance service is performed on the truck after
500 operating hours. The truck´s safety, efficiency and service life is
dependent on the service and maintenance it receives.
Only use BT approved spare parts when service and repair work are
carried out.
2.2 Safety regulations during

maintenance work
Only personnel that have been trained in the service and repair of this
type of truck are authorised to carry out service and repair work.
• Do not carry out any maintenance work on the truck unless you have
the correct training and knowledge to do so
• Keep the area where you carry out the service clean. Oil or water
makes the floor slippery
• Never wear loose objects or jewellery when working on the truck
WARNING!
Short-circuiting/Burns.
When working with the truck’s electrical system, short-circuiting/
burns can occur if a metal object comes into contact with live electri-
cal connections.
Remove watches, rings or other types of metal jewellery.

Maintenance
Safety regulations during maintenance work
485, 487 6004330- 2013-03-04 244989-040
• Unless otherwise indicated in this service handbook, always discon-

nect the battery connector prior to performing maintenance work on
the truck
• Always switch off the truck’s power supply before opening the cov-
ers on the drive unit or electrical system
• Relieve the system pressure slowly before starting work on the
truck’s hydraulic system
• Use paper or a rigid sheet of cardboard when checking for oil leak-
age. Never use your hand
• Bear in mind that the oil in the transmission or the hydraulic system
can be hot
WARNING!
Risk of burns.
Hot transmission and hydraulic oil.
Let the truck cool before changing the oil.
• Only fill the hydraulic system with new and clean oil
WARNING!
The hydraulic system can be damaged.
If the oil is contaminated hydraulic components can be damaged.
Always use new and clean oil in the hydraulic system.
• Store and dispose of changed oil in accordance with local directives
• Do not flush solvents, etc. used for cleaning into drains that are not
specifically suited for this. Follow local regulations with regards to
destruction of oil, solvents, etc.
• Disconnect the battery when welding on the truck
NOTE!
The battery can be damaged.
When welding using an electric power source, the welding current
can enter the battery.
The battery should therefore be disconnected.
• Prior to welding or grinding on painted surfaces, be sure to scrape
off the paint at least 100 mm around the welding/grinding site using
blasting or a paint remover
CAUTION!
Unhealthy gasses.
Paint, which is heated, generates unhealthy gasses.
Remove the paint 100 mm around the working place.

Maintenance
Safety regulations during maintenance work
244989-040 2013-03-04 6004330- 485, 487
2.2.1 Tilting the cab up on a cold store truck

Before commencing service on the truck, make sure there is sufficient
space for tilting the cab.
Before performing service in the motor compartment, be sure to tilt the
cab fully up. While the cab is tilted, only cab tilting up/down can be
operated and the truck can only travel at inching speed.
• Move the hydraulic lever for fork lowering to the full lowering position
and turn on the key. The display will show 6 lines.
• Pull back on the hydraulic lever for fork lifting.
• When the cab stops (at 15-degree inclination), loosen the lock lever
(2) to release the cab.
• Continue pulling back on the lever until the cab stops (at a 45-degree
angle).
WARNING!
The cab may fall down!
If tilted more than 45 degrees, the cab will fall down without any
dampening.
Because the cab is heavy, make sure the receiving person has full
control over the situation. If possible, use an overhead crane.
• Take hold of the overhead guard and tilt the cab to 90 degrees.
NOTE!
The cab may fall down!
Insert the cotter (located under the seat plate) in the tilt rod to prevent
the cab from accidentally falling back during service on the truck.
2.2.2 Tilting the cab down on a cold store

truck
Make sure there is no one in or near the motor compartment when tilt-
ing back the cab.
WARNING!
Risk of crushing.
The risk of injury is very high if someone is servicing the motor com-
partment when the cab is tilted back in place.
Make sure there is no one in or near the motor compartment when tilt-
ing the cab.
• Remove the cotter from the tilt rod.
• Take hold of the overhead guard and return the cab to 45 degrees.
• Push the hydraulic lever for fork lifting forwards until the cab stops in
tilted down position.

Maintenance
Cleaning and washing
485, 487 6004330- 2013-03-04 244989-040
2.3 Cleaning and washing

Cleaning and washing of the truck is important to ensure the truck’s reli-
ability.
• Carry out general cleaning and washing weekly.
NOTE!
Risk of short-circuiting.
The electrical system can be damaged.
Prior to washing, be sure to disconnect the battery by disconnecting
the battery connector.
2.3.1 External cleaning

• Remove rubbish, etc. from the wheels daily
• Use a well-known degreasing agent, diluted to a suitable concentra-
tion
• Rinse off loose grime using tepid water
NOTE!
Seizure, corrosion.
Mechanical components can be damaged.
Following washing of the truck, lubricate it according to the Mainte-
nance section and the lubrication schedule.
2.3.2 Cleaning the motor compartment

• Cover the electric motors, connections and valves before washing
NOTE!
The electrical system can be damaged.
Electrical components must not be cleaned with a high pressure
washing unit.
• Clean the motor compartment using a well-known degreasing agent,
diluted to a suitable concentration
• Rinse off loose grime using tepid water

Maintenance
Safe lifting
244989-040 2013-03-04 6004330- 485, 487
2.3.3 Electrical components

• Blow electric motors down using compressed air
• Clean electric panels, logic cards, contactors, connectors, magnetic
valves, etc. with a rag moistened with water and a suitable deter-
gent.
NOTE!
Electrical components can be damaged.
Do not break the guarantee seal on the electronic board.
2.4 Safe lifting

Perform all lifts on level, slip-proof and firm surfaces. Avoid newly laid
asphalt on warm summer days.
• Always apply the parking brake to prevent the truck from moving
during lifting. If the brake wheel needs to be lifted, be sure to block
the other wheels to make sure the truck will stand still
• Select a lifting point that will make the lift as light as possible (one
corner at a time). If the lifting points on the truck are indicated on the
lower part of the chassis, be sure to use these to assure balanced
lifting
• Ensure that the surface where the jack is placed is clean and free
from oil
• Use clean hands and make sure the jack handle is free from grease
and oil
• Use the handle supplied with the jack. Too short a handle will require
more strength than necessary. Too long a handle may result in over-
loading of the jack
• Secure the truck with trestles, etc.
- as close to the lifted part of the chassis as possible in order to re-
duce the falling height if the truck should collapse
- to prevent the truck from rolling
• Never chock up the jack in order to achieve a higher lifting height
• Never work under a lifted truck unless it has been securely chocked
up
WARNING!
Risk of crushing.
A badly supported truck can fall.
Never work under a truck that is not supported on trestle-blocks and
secured by a lifting device.

Maintenance
Maintenance chart
485, 487 6004330- 2013-03-04 244989-040
2.5 Maintenance chart

Check the following (location according to C code; the interval in hours
indicates operating hours, b in the display):
Pos. Work to carry out

no. Interval in hours Pro- 20 250 500 1000 3000
file 5
Interval in days/weeks/months 1d 1 w 3 m 6 m 12 m 36 m
0000 Chassis
0000.1 Inspect for cracking and other damage O X
0340.1 Inspect door locking operation and lubricate A
the door hinge
0390.1 Inspect the battery lock for correct installa- O X
tion and possible wear
0510.1 Retighten hinges and adjust alignment of X
the cab.
0620.1 Inspect mounting of the chair and the X
adjustment functions
0640.1 Check the function of the driver’s control O X
0640.2 Inspect steering wheel operation O X
0640.3 Inspect the brake function O X
0640.4 Inspect the operation of the pedals O X
0640.5 Check the function of the horn O X
0810.1 Retighten the machine house and over- X
head guard mounts
0840.1 Inspect the operation of the emergency O X
switch
0840.2 Inspect the emergency exit O X
0840.3 Lubricate the emergency door hinges A

Maintenance
Maintenance chart
244989-040 2013-03-04 6004330- 485, 487

file 5
1700 Electric motors
1700.1 Inspect all connectors for looseness X
1700.2 Retighten the mounting bolts X
1700.3 Inspect any noise in the bearings X
1730.3 Inspect the steering motor carbons X
1800 Hydraulic motors
1820.1 Inspect mounting, and retighten the mount- X
ing bolts
1820.2 Inspect for leakage X
2550 Drive unit
2550.1 Inspect the oil level X
2550.2 Replace the oil C2 C
2550.3 Inspect for noise and leakage O X

2550.4 Retighten the support arm mounts X
2550.5 Lubricate the gear rim H
3370 Brake
3370.1 Inspect the brake disc for wear X
3370.2 Inspect play in the neutral position X
3370.3 Inspect the brake torque X
3500 Wheels
3530.1 Remove strings and other rubbish O X
3530.2 Inspect the drive wheel for wear and the O X
bolts
3550.1 Remove strings and other rubbish O X
3550.2 Inspect support arm wheel rotation and cor- O X
rect mounting
3550.3 Inspect the support arm wheels for wear O X

Maintenance
Maintenance chart
485, 487 6004330- 2013-03-04 244989-040

file 5
4100 Steering console
4100.1 Inspect mounting and locking of the steer- O X
ing console
4100.2 Inspect the strength of the gas strut and the O X
locking performance.
5000 Electric panel
5000.1 Clean and inspect the mounting devices X
5000.2 Retighten cable connections X4 X
5000.3 Inspect the emergency drive function X

5000.4 Check the error code log and operating O X
times
5190.1 Inspect the contactor tips X
5190.2 Inspect the movement of the contactor X
5280.1 Inspect the electric limiter functions X
5110 Battery
5110.1 Inspect the electrolyte level (10-15 mm O X
above the cell plates)
5110.2 Inspect the connections to battery, truck O X
and charger
5110.3 Inspect the cell and terminal covers. O X
5110.4 Inspect fluid density O X
5110.5 Inspect the temperature O X
5110.6 Remove overflow fluid from the battery O X
trough
6000 Hydraulic system
6110.1 Inspect the reservoir for proper mounting X
and leakage
6110.2 Inspect the oil level X
6110.3 Clean or replace the oil B
6120.1 Inspect hoses, pipes and joints for leakage O X
6120.2 Inspect the mast and shuttle fork unit hoses X
for wear

Maintenance
Maintenance chart
244989-040 2013-03-04 6004330- 485, 487

file 5
6130.1 Replace the air and oil filters X1 X
6170.1 Inspect the overflow pressure X

6600 Cylinders
6600.1 Inspect for leakage O X
6600.2 Check the mountings X
7100 Mast
7100.1 Inspect for cracking and other damage X
7110.1 Lubricate the mast members at the guide A
rollers and side guide rollers
7120.1 Inspect the lifting chains and chain rollers X
for wear
7120.2 Inspect the adjustment of the lifting chains. X
Inspect the chain bolts and the chain
mounting.
Retighten the locking nuts to the correct
torque and inspect the safety cotter pin.
7120.3 Grease the lift chains D
7150.1 Check the rollers for any play. X
7190.1 Retighten the mast mounts. X3 X
7190.2 Retighten the mast stay mounts X

(VR)
7200.1 Inspect the extra functions A
(VR)
7400.1 Inspect the forks for wear O X
(VR)
7700 Turret head fork unit (VR)
7700.1 Lubricate the turning chain D
7700.2 Lubricate the cog axle/gear racks A
7700.3 Lubricate the turning bearings I
7700.4 Lubricate the support roller contact sur- A
faces
7700.5 Inspect the gear flank play of the drive shaft X

Maintenance
Maintenance chart
485, 487 6004330- 2013-03-04 244989-040

file 5
7800 Shuttle fork unit (VR SF)
7800.1 Lubricate the drive chain D
7800.2 Lubricate the shuttle fork chain D
7800.3 Lubricate the guide rack A
7800.4 Lubricate the support roller contact sur- A
faces of the guide
7800.5 Inspect the adjustment of the drive chain X
7800.6 Inspect the adjustment of the shuttle fork O X
chain
1)
Replace the filter after 250 h, and after this every 1000 h.
2) Replace the oil after 250 h, and after this every 3000 h.
3)
Retighten after 250 h, and after this every 1000 h.
4) Retighten after 250 h, and after this every 500 h.
U indicates items listed in the section “Daily inspection and operational
inspection” in the Operating Instructions and what should be performed
at the 500-hour service intervention.
X indicates items to be performed during service of the truck. The other
letters indicate the oil and grease qualities.
Unless otherwise indicated above, whenever performing service
according to longer service intervals, all service items at shorter inter-
vals should also be carried out.

Maintenance
Maintenance chart
244989-040 2013-03-04 6004330- 485, 487
VR SF

Maintenance
Maintenance chart
485, 487 6004330- 2013-03-04 244989-040
VR

Maintenance
Maintenance chart
244989-040 2013-03-04 6004330- 485, 487
VRE150, VRE125SF
0640.5
0640.2 0640.1
0840.1

Maintenance
Maintenance chart
485, 487 6004330- 2013-03-04 244989-040
VR SF/VRE125SF

Maintenance
Maintenance chart
244989-040 2013-03-04 6004330- 485, 487
VR/VRE150

Maintenance
Maintenance chart
485, 487 6004330- 2013-03-04 244989-040
VR SF/VR

Maintenance
Maintenance chart
244989-040 2013-03-04 6004330- 485, 487
VRE150/VRE125SF
5000.4 5280.1
5000.3
4100.1
4100.2
5000.1
5000.2

Maintenance
Maintenance chart
485, 487 6004330- 2013-03-04 244989-040
VR SF/VRE125SF

Maintenance
Maintenance chart
244989-040 2013-03-04 6004330- 485, 487
VR/VRE150

Maintenance
Maintenance chart
485, 487 6004330- 2013-03-04 244989-040
VR SF

Maintenance
Maintenance chart
244989-040 2013-03-04 6004330- 485, 487
VR/VRE150

Maintenance
Oil and grease specifications
485, 487 6004330- 2013-03-04 244989-040
2.6 Oil and grease specifications

Pos. Lubricant Specification Application area
> - 15°C < - 15°C
A Grease BT 26777 (Spray) BT 26777 (Spray) Bearings and bushings
B Hydraulic oil ISO-L-HM32 ISO-L-HV32 Hydraulic system
C Transmission oil Hypoid oil Hypoid oil Gears
SAE 80W/90 SAE 75W
D Grease BT 73040 or BT 163588 Chains
BT 165148 (Klüber (Klüber 4LC-68)
Hotemp 2000)
A Grease BT 29916 BT 177094 Gear racks and support
(Texaco Molytex (Shell Aeroshell roller contact surfaces
EP2) Grease 17)
G Grease Topas Topas Steering motor gear
NB 52 NB 52
H Grease Grafloscon Grafloscon Gear rim
A-G1 (Klüber) A-G1 (Klüber)

Tools
Electrical contacts
244989-040 2013-03-04 6004330- 485, 487
3- Tools
3.1 Electrical contacts
3.1.1 Super Seal connectors
3
3
Figure 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)

Tools
Electrical contacts
485, 487 6004330- 2013-03-04 244989-040
3.1.2 AMP connectors
Figure Number Use

31-151080 Removal of pins/sleeves
1=163787 Crimping of sleeves

2=163788
1
2
1=163789 Crimping of pins
2=163790 1: For 0.2–0.5 mm2
3=163791
2: For 0.5-1.0 mm2
3: For 1.5-2.5 mm2

Tools
Other tools
244989-040 2013-03-04 6004330- 485, 487
3.2 Other tools

Figure Number Use
7516708 Service instrument (CAN)
1=163793 Service instrument for

2=163792 program modifications
1=7521083 Service instrument

1 2=163973 (CASTOR USB)
for programming
08-15444 Drive motor/Pump motor

Tools
Other tools
485, 487 6004330- 2013-03-04 244989-040
Figure Number Use

10-15639 Socket for drive gear nuts
08-13022 Drive gear puller
31-150030 Cab tilt tool
Complete set = Oil cleaning

V1015191 1=Filter for cleaning
1=V10-15191-1 2=Filter for removal of water
2=V10-15191-2 3=Pipe
-1
-2 3=V10-15191-3 4=Pipe
4=V10-15191-4
-3
-4
08-13585 Wheel shaft tool

Tools
Other tools
244989-040 2013-03-04 6004330- 485, 487
Figure Number Use

V11-1133/1 Lifting yoke for mast.
651154 Jacking blocks

Tools
Other tools
485, 487 6004330- 2013-03-04 244989-040

Chassis – 0000
General
244989-040 2013-03-04 6004330- 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
• Cloth
• Absorbent
• Cable ties

Chassis – 0000
Transporting the truck
485, 487 6004330- 2013-03-04 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 trans-
port 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.

Chassis – 0000
Assembling the mast
244989-040 2013-03-04 6004330- 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.

Chassis – 0000
Assembling the mast
485, 487 6004330- 2013-03-04 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).

Chassis – 0000
Assembling the mast
244989-040 2013-03-04 6004330- 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 C-
code 7120.
• Adjust if necessary.
• Fill the hydraulic system with oil
• Test the lifting and lowering functions as well as all fork unit's func-
tions.
• 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

Chassis – 0000
Assembling the mast
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• Dismantle the lifting eyes if these are regarded as unnecessary.

Chassis – 0000
Installation in narrow aisles
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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 pa-
rameter 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.

Chassis – 0000
Installation in narrow aisles
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This page is intentionally left blank

Frame, mounted components — 0400
General tightening torque
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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

Frame, mounted components — 0400
General tightening torque
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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.

Driver Protection — 0840
General
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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 trans-
port 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.
.

Driver Protection — 0840
Tilt Stops
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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.

Electric Pump Motor — 1710
General
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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

Removing and Replacing the Pump Motor
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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.

Removing and Replacing the Pump Motor
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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).
• Replace both mounting attachments (12) on the pump motor (8).
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 meas-
uring contacts (6) and the power cables (7).
• Fill the hydraulic tank with new oil.

Bearing Replacement
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7.4 Bearing Replacement

19 16 6 2 1 26 25 10 36
13 22 17 9 4 11 24 27
3
8
23
D N
30 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.

Bearing Replacement
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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.

Installation Instructions for External Temperature Sensor
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7.5 Installation Instructions for External

Temperature Sensor
Number 170384.

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• The temperature sensor can be mounted to the right or left of the

connection terminal block, depending on which side is easiest to ac-
cess.
• 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.

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• Fasten the metallic lacquer and the sensor with masking tape and al-
low 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.

Electric Steering Motor — 1730
General
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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 con-
sole.
• 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.

Electric Steering Motor — 1730
Removing and Replacing the Carbon Brushes
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Electric Drive Motor — 1760
General
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9- Electric Drive Motor — 1760
9.1 General
The drive motor is a three-phase AC motor. In the motor, there is a ther-
moelement 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.

Dismantling the Drive Motor
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9.2 Dismantling the Drive Motor

Dismantling and Assembling the Drive Motor
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63 9.3 Dismantling and Assembling the

14
31 Drive Motor
60
9.3.1 Dismantling the Drive Motor
• Cut the voltage by turning off the key and removing the battery plug.
61
• Remove the temperature, braking and speed measurement con-
tacts (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.
62 7 NOTE
Risk of damage to the gear wheel (51).
51 The gear wheel on the end of the motor is easily damaged.
Lift away the motor with care.
54
• 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.
• Remove the key (7) holding the gear wheel (51) in place.
55 6 33 37
• 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

Dismantling and Assembling the Drive Motor
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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.
• Lock the nut with a centre punch in the key track.
62 7
• Attach a lifting eye to the motor axle and lift the motor axle into the
transmission using an overhead crane.
51
54 NOTE
Risk of damage to the gear wheel (51).
The gear wheel on the end of the motor is easily damaged.
• Tighten the motor (61) into the transmission to a torque of 20 Nm.
63 • Re-attach the temperature, braking, and speed measurement con-
14 tacts (14, 31) and power cables (60) to the motor.
31
• Remove the lifting eye.
60
• For adjustment of the brakes, see C-code 3100.
61

Bearing Replacement
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9.4 Bearing Replacement

14 31
23 24 8 55 33
54 51 12 11 2 4 10 1 9 22 25 3 34 6 38
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.

Bearing Replacement
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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).

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9.2 Installation Instructions for External

Temperature Sensor
Number 170384.

485, 487 6004330- 2013-03-04 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 ac-
cess.
• 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.

244989-040 2013-03-04 6004330- 485, 487
• Fasten the metallic lacquer and the sensor with masking tape and al-
low 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.

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Mechanical Drive Gear Unit — 2550
General
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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 refit-
ting 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 per-
sonnel.

Drive/Transmission Assembly's Main Components and Technical Data
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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
Position Nr. Component

1 Drive motor
2 Drive assembly cowl

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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

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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

Replacing the Drive Motor/Drive Transmission
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10.3 Replacing the Drive Motor/Drive

Transmission
63
14 10.3.1 Dismantling the Drive Motor
31
• Cut the voltage by turning off the key and removing the battery plug.
60
• Remove the temperature, braking and speed measurement con-
tacts (14, 31, 63) and power cables (60) from the motor (61).
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).
• Cover the hole to the transmission when the motor is removed to
prevent anything from falling inside the transmission housing.
29 Removing the gear wheel

27
• Bend away the locking tab on the lock washer (53) at the end of the
53 52 motor, unscrew the nut (54) and remove the washer (52).
62 7 • Pull off the gear wheel (51) using a gear puller.

• Remove the key (7) holding the gear wheel (51) in place.
51 • Remove the lock ring (27) holding the bearing bracket (29) in place.
54 A
• Pull off the bearing bracket (29) using a gear puller.

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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).

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10.3.3 Assembling the Drive Transmission

• Assembling the steering bearing (16): Replace the steering bear-
ing (16) with the 15 hexagon socket bolts (19) on the drive transmis-
sion (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 steer-
ing 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 cen-
tred 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 di-
odes 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.

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29 10.3.4 Installing the Drive Motor

27 If you replaced the drive transmission (17), also replace the gear wheel
53 52 (51) on the drive motor.
If you replaced the drive motor, use the old gear wheel on the new
62 7 motor.
51 Assembling the gear wheel

54 A
• 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
place.
60
• 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 transmis-
sion using an overhead crane.
NOTE
Risk of damage to the gear wheel (A).
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.

Checking/Replacing the Oil
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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 operat-
ing 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."

Repairs
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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 chap-
ter "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 wash-
ers' combined thickness and replace them before re-assembly.
• Remove the gasket ring (7) from the drive shaft.
7 6 5 2

Repairs
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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 transmis-
sion 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 transmis-
sion.
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."

Repairs
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10.1.1 Leakage from the Upper Cover

Follow instructions below in the event of leakage from the transmis-
sion'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 seal-
ant surfaces carefully, both on the cowl and the transmission hous-
ing.
• Apply sealant such as Curil K2 to the surfaces. Follow the instruc-
tions 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.

Repairs
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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 cen-
tre 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.

Repairs
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Travel brake system — 3100
Brake system
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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 sub-
systems.
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).

Description of function
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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 C-
code 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 medi-
um 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.

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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.

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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 electrome-
chanical 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.

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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.

Electromechanical disc brake, drive motor
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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 com-
ponents.
Technical data
Description
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
8
6
2
4
10

Disassembly
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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 compo-
nent 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 fric-
tion 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).

Assembly
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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 correspond-
ing 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 neces-
sary.
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 po-
sition the brake disc correctly.
10. Mount the brake unit in the truck. Check that the splines on the fric-
tion 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

Maintenance
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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 ad-
justment 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.

Maintenance
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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 ad-
justing play.
7. Check the braking force once more using the torque wrench.

Maintenance
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Troubleshooting chart
Fault Cause Action
The brake does Too low power supply Check the power supply
not release
Too large/too small play Adjust the play
Worn friction discs/rotor disc Replace/adjust play
Damaged coil Replace brake
Corrosion between the friction This fault may arise in damp environments
plates and the rotor 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 brake is not The current is switched off Check the power supply
engaging
Grease on the friction surfaces Replace/adjust play
One of the springs is broken Replace brake
Unreliable Too low power supply Check the power supply
brake action

Multiple disc brake, support arm
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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 mag-
net 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 lock-
ing 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 en-
gaged).
It may be necessary to adjust the amount of play, see section on ad-
justing.
NOTE!
Check the amount of play at two points simultaneously with 180° be-
tween 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 re-
cess in the support arm.
• Connect the brake cable harness (14) and check the braking func-
tion by pressing the brake pedal fully down.

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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).

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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 individual-
ly.
• 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 inter-
vals 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.

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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° be-
tween 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, as-
semble the brake in the wheel and the wheel in the truck.

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Drive wheel — 3530
General
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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 tight-
ened 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.

Drive wheel — 3530
Assembling the drive wheel
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Fork/support arm wheel – 3550
General
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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.(*)

Assembling the wheel
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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 be-
come 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.

Assembling the wheel
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• 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.

Dismantling/assembling the wheel bearings
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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 out-
side 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.

Electric steering wheel/lever — 4310
General
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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.

Electric steering wheel/lever — 4310
Replacement of the steering generator
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Steering angle sensor — 4350
General
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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 lev-
el 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 sur-
face.
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

Steering angle sensor — 4350
Procedure
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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 sen-
sor 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

Automatic steering system — 4500
General
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16- Automatic steering system —

4500
Wire guidance
16.1 General
Wire guidance is used for automatic steering in narrow aisles. A gener-
ator 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.

Generator
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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.

Power supply Model LDU-22 Model LDU-21
220 V 50Hz 110 V 50/60Hz
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

Wire guidance system overview
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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 fre-
quency and amplitude.
Frequencies within the range 1 to 10 kHz and amplitudes within the
area 14 mA to 1900 mA RMS.

Wire guidance components
485, 487 6004330- 2013-03-04 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.

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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 brack-
et 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.

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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 parame-
ters through learning of the antenna-offset, frequency and amplitude.
Learnt data is saved after the learning process is completed and con-
firmed 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.
Term. Typ No. Active Function

e
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

e
JP2:3 Out 67 +48 V Wire guidance OK

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e
JP2:9 In 112 +12 V Steering angle, refer-
ence
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 No. Active Function

JP3:1 In/Out RS-232 communication
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 Screen
JPW1:14 Out Violet 0V Supply voltage
JPW1:15 Out Grey +12 V Supply voltage

JPW2:1 In Black Right-hand coil
JPW2:2 In Brown Left-hand coil
JPW2:3 In Red Supply voltage

485, 487 6004330- 2013-03-04 244989-040

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 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 parame-
ters.
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

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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.

Operating description
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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 (steer-
ing 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 igni-
tion 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.

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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 val-
ue 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, calcu-
lated 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 direc-
tions 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 steer-
ing angle sensor, pulse sensor U15, until the truck’s both antennae are
straight over the loop.

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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 anten-
nae’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“.

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Parameters
The following parameters affect wire guidance when adjusted:
No. Parameter type Unit Min./max. Std. Comments

value
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 0.6-2.0 1.6 In steps of 0.2
s
73 Angle, stop Degree 2.0-4.0 3.0 In steps of 0.2
s
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 cali-
brate the components in WG-control unit through “Learn mode“, anten-
nae 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.

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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 adjust-
ment 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.

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• Switch S120 on, off and on. The display message “Learn“ disap-
pears.
• 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“ disap-
pears.
• 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 fre-
quency.
• 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 fin-
ished.
• Switch 120 off to save.
• Change parameter 71 to 2 after the learning process is completed.

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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 corre-
spond as set out in the table below to receive the correct reference sig-
nal.
Parameter value kHz mA RMS Notes

0 5.2 90
1 6.25 75
2 1 - 10 14 - 1900 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.

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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

Error Codes
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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 trans-
lated 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 cause Driver error. Switch S120 must be activated in wire
guidance aisle
Faulty switch S120
Faulty wiring to S120
Faulty A5 electronic card
Comments

Error Codes
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Code 172
Signal name “See loop“ signal not received (loop not detected)
Error cause Faulty parameter values for A3
Faulty wiring to A3
Faulty A3 electronics card
Faulty wire guidance generator
Comments Perform wire guidance learning, parameter 36
Code 173
Signal name Lost loop (derailment)
Faulty wiring to A3
Substandard installation
Code 174
Signal Excessive steering movement in wire guidance
description aisle
Faulty potentiometer
Faulty wiring to potentiometer
Substandard installation

Error Codes
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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
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
Comments Restart can reset

Error Codes
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Code 177
Signal name General communications error
No communications with A3 electronics card
Error mode
Error cause Faulty CAN wiring/resistance
Dislodged A3 electronics card
Dislodged 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 dis-
play.
Code, WG-display is the code shown on the 7 segment display on the
control unit.
Code 85
WG-display 1P
code
Code-name Steering not learnt
Error WG parameters outside of limit
How to reset Perform learning Offset and Frequency, parameter
36

Error Codes
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Code 181
WG-display 52
code
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 C2
code
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 sen-
sor.
Code 183
WG-display C3
code
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
How to reset Restart the truck and check the steering angle sen-
sor, home position sensor and steering motor cir-
cuits

Error Codes
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Code 184
WG-display C5
code
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 sen-
sor. Replace the WG-control unit
Code 185
WG-display C6
code
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 96
code
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

Error Codes
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Code 187
WG-display 9L
code
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 92
code
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
Code 189
WG-display 91
code
Code-name Steering angle>10 degrees
Error Steering angle > 10 degrees when driving on the
loop
How to reset Restart the truck

Error Codes
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Code 190
WG-display 93
code
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“
Code 191
WG-display 94
code
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“
Code 192
WG-display 9C
code
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

Error Codes
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Code 193
WG-display 9h
code
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
Code 194
WG-display 9J
code
Code-name Antenna in the fork direction (W1), signal too high
Error The signal “See loop“ higher than 4.75 volt
Code 195
WG-display 9K
code
Code-name Antenna in the steering wheel direction (W2), sig-
nal too high
Error The signal “See loop“ higher than 4.75 volt

Error Codes
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Code 196
WG-display 9E
code
Code-name No “Search and lock“ signal
Error The truck runs on the loop but the steering signals
do not vary
Code 197
WG-display CU
code
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 CE
code
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

Error Codes
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Code 199
WG-display C1
code
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 F9
code
Code-name COP time-out
Error Internal error
Replace the control unit
WG-display FA
code
Code-name OPCODE invalid
WG-display Fb
code
Code-name WSI, CAN reset

Electrical System — 5000.1
General
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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 ena-
bled 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 compo-
nents 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.

General
485, 487 6004330- 2013-03-04 244989-040
VR SF

General
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VR

Electronics Card, traction controller A1 and lift controller A2
485, 487 6004330- 2013-03-04 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 communi-
cations, 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 dis-
play.
The controller can be reprogrammed via CAN.

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17.2.2 Terminal Connections and Pole Bolts

I: Input, O: Output
Term. Cable Designation Active Input/out-

A1/A2 put
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. I
8 -/16 CAN ID0 1: Open I
(Not connected when used 0: Sensor, -
as A1)
9 NC I
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

485, 487 6004330- 2013-03-04 244989-040
17.2.3 Technical Data

Parameter Setting Unit Description
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 -35–+55 oC
temperature
Current limit, down-regu- 85 o
C 0 A at 125o C
lation at cooling block
overheating
Current limit, down-regu- -20 oC 50% current limiting at start
lation at cooling block
overheating
Current limiting 350 A 2 minutes
Speed 100 % Modulation
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 pro-
grams to the electronics card. See the Truck Com user manual for a
description of the procedure.

Electronics Card, Fork Apparatus, A4
244989-040 2013-03-04 6004330- 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 appara-
tus 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.

485, 487 6004330- 2013-03-04 244989-040
17.1.1 Terminal Connections

I: Input, O: Output
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 Directional valve, traversing right +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, +15 V I
phase 1
012 55 Pulse generator for height measurement free lift, +15 V I
phase 2
013 104 Height measurement for free lift, reference sen- +15 V I
sor
014 NC Reserve (0-10 V or I
0-48 V)
015 40 Battery - 0V I
016 NC 0-24 V O
017 94 Directional valve, traversing left +48 V O
018 NC +48 V O
019 NC +48 V O
020 150 Switch signal, with twin camera system U
021 NC Reserve (0-20 V) I
022 NC Reserve I
023 NC Reserve I
024 NC Reserve I
025 NC Reserve I

244989-040 2013-03-04 6004330- 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
030 NC Reserve O
031 NC (0-24 V) O
032 NC Reserve O
033 NC Reserve O
034 NC Reserve O
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

485, 487 6004330- 2013-03-04 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:
= part number for the card including program.
= only part number for the card.
17.1.3 Programming

Electronics Card, Main Card, A5
244989-040 2013-03-04 6004330- 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 parame-
ters 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, perti-
nent 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.

485, 487 6004330- 2013-03-04 244989-040
17.2.2 Terminal Connections and Voltages on

A5
The LEDs at the connection terminals are indicated in the tables as fol-
lows:
I:Input, green light emitting diode (LED)
O:Output, red light emitting diode (LED)
Other:Yellow light emitting diode (LED)
10X
Term. Cable Description Active LED

(V)
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 +48 I
speed
105 46 Direction of travel for steering wheel-direction +48 I
at creep speed
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

244989-040 2013-03-04 6004330- 485, 487
20X
Term. Cable Designation Active LED

(V)
201 22 Personal protective equipment, I
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, +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
30X

(V)
301 98 Height meter, channel A 0 -(+)15 I
302 99 Height meter, channel B 0 -(+)15 I
303 NC Reserve I
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

485, 487 6004330- 2013-03-04 244989-040
40X

(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 (0-10 V or 0-
50 V)
50X

(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 +0.77-3.7-6.6
point
505a 84 Potentiometer rotation of forks, set point +0.66-3.7-6.6
506a 85 Potentiometer auto-rotation/extra (1) hydrau- +0.66-3.7-6.6

lic function, set point
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, +0.66-3.7-6.6

set point
511 129 Steering tachometer (-) 0
a.Used on VR only.

244989-040 2013-03-04 6004330- 485, 487
60X

(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 (0-10 V or
0-50 V)
70X

(V)
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

485, 487 6004330- 2013-03-04 244989-040
80X

(V)
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 0
807 24 Battery voltage, (+) 48 V after key +48 +48 V
KEY
808 23 Battery voltage, (+) 48 V after main contactor +48
809 22 Battery voltage, (+) 48 V after emergency stop +48 +48 V
ESO
810 29 Voltage meter measurement sensor, (+) 15 V +15
811 30 Minus feed sensor 0
90X

(V)
901 25 Battery voltage, (+) 48 V +48
902 40 Battery voltage, minus 0
903 60 Steering motor, (+) +48
904 61 Steering motor, (-) +48

244989-040 2013-03-04 6004330- 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:
= part number for the card including program.
= only part number for the card.
17.2.4 Programming

Electrical System, Overview
485, 487 6004330- 2013-03-04 244989-040
17.3 Electrical System, Overview

VR SF

244989-040 2013-03-04 6004330- 485, 487

485, 487 6004330- 2013-03-04 244989-040
VR

244989-040 2013-03-04 6004330- 485, 487

Symbol List and Wiring Diagrams
485, 487 6004330- 2013-03-04 244989-040
17.4 Symbol List and Wiring Diagrams

17.1 Symbol List
Symbol Description Symbol Description

Battery
Brake coil, normally dis- Brake coil, normally con-

connected nected
Switch, normally open Switch, normally closed
Push-button switch, nor- Push-button switch, nor-

mally open mally closed
Spring-back switch, nor- Spring-back switch, nor-

Non-spring-back, push- Emergency switch

button switch, normally
open
Key switch, normally open Push-button switch, non-

spring-back and spring-
back
Electro-magnetic switch, Electro-magnetic switch,

normally open normally closed

244989-040 2013-03-04 6004330- 485, 487

Pressure-sensitive switch, Pressure-sensitive
normally open switch, normally closed
Capacitive switch, nor- Capacitive switch, nor-

Inductive sensor, nor- Inductive sensor, nor-

Pulse generator
Seat heater with thermo- Thermoelectric sensor

stat
Motor, general Series motor, armature

winding, DC
Series motor, DC Motor, permanent mag-

net
Three-phase motor, AC
Series winding Shunt winding
Transducer, AC/DC Transducer, AC/DC

485, 487 6004330- 2013-03-04 244989-040

Variable resistor (potenti- Resistor
ometer)
Contactor Horn
Lamp Valve
Fuse Diode
Zener diode Light emitting diode

(LED)
Contact Contact, multiple-poles
Capacitor Feed cable

244989-040
Order number
© BT Europe AB
X1 G1 48 V X1 SHUNT WIRE
1 + - 40
Sh. 3 Sh. 2
Date
ELECTRONIC CARD
2013-03-04
MEASURING WIRES A5
72
603 INP. BATT. INDI. CURRENT -(+)
71
602 INP. BATT. INDI. -, CURRENT -(-)
Service Manual
6004330-
70
601 INP. BATT. INDI. +
MAIN CONTACTOR
K10
40 A1 A2 31
804 OUT. MAIN CONTACTOR
10A
F62
2 1 23
808 INP. MAIN CONTACTOR
Valid from serial number
8
Sh. 2
S1 X30
22 3 4 34
Sh. 2 101 INP. SETUP SELECT
S2 X30
17.1.1 Wiring diagrams VR SF
3 4 35
102 INP. SETUP UP
T-code
485, 487
S3 X30
3 4 36
103 INP. SETUP DOWN

209398
1/24, Prod C
17- 25
17- 26
T-code
485, 487
FREQUENCY INVERTER, DRIVE
A1
160A
F1
8
Sh. 1 7 B + +
2
U DRIVE MOTOR
40 M1
Sh. 1 4 B- - U
THERMO ELECTRICAL SENSOR IN M1 3 V M
V
14 W M
7 3~A
B1 4
W
11
4
6004330-
ELECTRONIC CARD
10 A5
3
SPEED MEASURING IN M1
Service Manual
U11 117
12 401 OUT. CAN +15VDC
105 Red Bl 12
5
B
+
118
13 402 OUT. CAN GND
Bk Wh 13
6
A
-
119
10 403 INP./OUT. CAN H
X30
22 120
Sh. 1 3 1 11 404 INP./OUT. CAN L
Date
SERVICE KEY INTERFACE

X41
2013-03-04
X45 X31
1 117
X45 X31
2 118 117
Sh. 7
X45 X31
3 119 118
Sh. 7
X45 X31
4 120 119
Sh. 7
244989-040
R100 120
Sh. 7
Order number
209398
2/24, Prod C
Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB

244989-040
Order number
© BT Europe AB
Date
2013-03-04
ELECTRONIC CARD
A5
10A
F60
Service Manual
1 21
6004330-
Sh. 1 5 805 + 48VDC
X30
24 24
Sh. 13 807 INP. KEY
S23
1 3 43
110 INP. LEFT FOOT SWITCH
KEY EMERGENCY SWITCH OFF
X30 S17 S21 X30

15 61a 24 1 2 22
809 + 48VDC SUPPLY OUTPUTS
X32
45
104 INP. DRIVE, FORK DIRECTION, CREEP
S26
X32
22 3
Sh. 2 4 X32
2 46
105 INP. DRIVE, STEER WHEEL DIRECTION,
1
CREEP
T-code
485, 487
X25 S89 X25

1 3 49
203 INP. SEAT SWITCH

209398
3/24, Prod C
17- 27
17- 28
T-code
485, 487
ELECTRONIC CARD
A5
27 27
Sh. 6 507 POT. FEED 7-7,5VDC

6004330-
1
50
R1 501 INP. SPEED REFERENCE VALUE
Service Manual
28 28
Sh. 6 508 POT. GND
M12
Bl - +R 107
M 307 OUT. POWER, FAN ELECTRIC PANEL
Date
X32 S18 X32

54 3 4
2013-03-04
X30
IN
22 40
Sh. 3 5 + - Sh. 2 5
HORN
H1
SEAT HEATER
X25 E10 X25
244989-040
Order number
FAN PUMPMOTOR 209398

X35 M10 X35 3/24, Prod C
M

244989-040
Order number
ELECTRONIC CARD
© BT Europe AB
A5
29 29
Sh. 11 810 + 15VDC
Date
30 30
Sh. 11 811 GND
S66
2013-03-04
Br Bk 58
210 INP. STEER WHEEL ANGLE A
Wh
Bl
C4 59
211 INP. STEER WHEEL ANGLE B
S65
X30
Service Manual
22 Br Bk 57
6004330-
Sh. 4 6 209 INP. STEER WHEEL REFERENCE

180 DEG.
Bl
806
40 40
Sh. 4 6 902 GND
30A
F61
1 25
Sh. 3 10 901 + 48VDC STEER SERVO
M6
Bk Red 60
M 903 OUT. + , STEER MOTOR
61
904 GND, STEER MOTOR
T-code
U1
485, 487
X32
Bk Red 62
M 509 INP. STEERING WHEEL TACHO +

X34
129
511 GND, TACHO
209398
5/24, Prod C
17- 29
17- 30
T-code
EMERGENCY MODE 485, 487
X30 S131
22 1 2
Sh. 5 7 ELECTRONIC CARD
A5
Y1
40 64
Sh. 5 7 802 OUT. PARKING BRAKE
DISPLAY
A6
X46
121
SERIE + 1 405 SERIE +
X46
122
SERIE - 2 406 SERIE -
RS 485
X46
125
RX + 3 407 TX+
6004330-
X46
126
RX - 4 408 TX-
Service Manual
27
Sh. 4 8
1
51
R2 502 INP. BRAKE REFERENCE VALUE
2
28
Sh. 4 8
LEFT ARM, INNER
Y5:1
RIGHT ARM, INNER

Date
Y5:2 X38
63
801 OUT. SUPPORT ARMBRAKE 1
X38
2013-03-04
LEFT ARM, OUTER

Y6:1 X38
68
RIGHT ARM, OUTER
Y6:2
126
Sh. 10
125
244989-040
Sh. 10
Order number
209398
6/24, Prod C

244989-040
Order number
© BT Europe AB
Date
2013-03-04
FREQUENCY INVERTER, PUMP

A2
300A
F3
8 5
Sh. 2 B + + U PUMP MOTOR
M3
U
Service Manual
6004330-
40 6 V M
Sh. 6 8 B- - V
W M
3~A
7
8 ID W
THERMO ELECTRICAL SENSOR IN M3

19
7
B2
16 117
4 12 Sh. 2
15 118
3 13 Sh. 2
U12
155 Red Bl 17 119
5 10 Sh. 2 12
B
+
T-code
485, 487
Bk Wh 18 120
6 11 Sh. 2 12
A
-

X30
22
Sh. 6 8 1
209398
7/24, Prod C
17- 31
17- 32
T-code
485, 487
ELECTRONIC CARD
X32
27 A5
Sh. 6
1
X33
82
R6 503 INP. JOYSTICK FORK
3
X32
28
Sh. 6
1
X33
83
R4 504 INP. JOYSTICK TRAVERSE
3
206 INP. SPEED REDUCTION

6004330-
202 OUT. DATA COLLECT, LIFT
Service Manual
208 OUT. DATA COLLECT, DRIVE
22
201 INP. PERS. PROT. 1 (NOT ACTIVE)
(WHEN USED, SEE PAGE 21)
22
X30
S61 X31
22 5 1 81
Sh. 7 9 204 INP. WEIGHT
Date
X30 X32 S33 X33

5 1 100
205 INP. OVERRIDE
2013-03-04
ELECTRONIC CARD
A4
X14 X16 X49 Y8

40 94
Sh. 7 9 017 OUT. TRAVERSE LEFT
Y9
95
004 OUT. TRAVERSE RIGHT
244989-040
Order number
209398

8/24, Prod C
244989-040
Order number
© BT Europe AB
ELECTRONIC CARD
A5
X47 Y10 X47

40 88
Sh. 8 10 702 OUT. FORK LOWER
Date
X47 Y11 X47

89
701 OUT. FORK LIFT
2013-03-04
X47 Y24 X47

90
703 OUT. SELECT FORK MOVE
FORK DIRECTION 1
X30 X14 S5 X15
22 Br Bl 41
Sh. 8 10 106 INP. IN AISLE, SIGNAL 1
STEER WHEEL DIRECTION 1
S6
Service Manual
6004330-
Br Bl
STEER WHEEL DIR. RIGHT
S156
Br Bk
Bl
FORK DIRECTION 2
X14 S7 X15
Br Bl 42
107 INP. IN AISLE, SIGNAL 2
S8
Br Bl
FORK DIR. LEFT
S178
X69 X69
Br Bk
X69
T-code
Bl
485, 487
FORK DIRECTION
X14 S9 X15

Br Bl 44
111 INP. IN AISLE, MIDDLE
STEER WHEEL DIRECTION
S4
Br Bl
209398
9/24, Prod C
17- 33
17- 34
T-code
485, 487
ELECTRONIC CARD
A5
X45 S90 X45 X31

22 1 5 91
Sh. 9 11 305 INP. HALF PALLET HANDLING MODE
680~E/2W
X31 X45 H90 R34 X45 X31
40 10 9 920 92
Sh. 9 11 306 OUT. HALF PALLET HANDLING
INDI. LAMP
680~E/2W
X31 H95 R30 X30
- + 320 32
705 OUT. FORKS IN HOME POSITION
680~E/2W
X31 H18 R31 X30
- + 330 33
706 OUT. IN AISLE INDICATION LAMP
X31 X36 H2 X36 X30

6004330-
- + 37
708 OUT. WARNING LAMP (MOTION)
H3
X31 X37 X37 X31
Service Manual
- + 38
707 OUT. TRAVEL ALARM
47~E/50W
H96 R32
- + 109 108
709 OUT. LENGTH INDICATION LAMP
(IN AISLE)
X23 Y20 X23

101
710 OUT. CABIN LIFT
X23 Y21 X23

102
711 OUT. CABIN LOWER
LENGTH INDICATOR
Date
A9
X45 X45 X46
125
3 +48V RX+ 5 Sh. 6 11
2013-03-04
1 ID
X31 X45 X45 X46
126
4 0V RX- 2 Sh. 6 11
EXTERNAL EQUIPMENT
10A X42 X42 WORKING LIGHT
F63 X30 S99 E4 E3
1 26 1 1 26 1 5 191 192
Sh. 5 13
X31
244989-040
40 2 2 40
Order number
209398

10/24, Prod C
244989-040
Order number
© BT Europe AB
LIFTING HEIGHT INDICATOR
A8
X45 X45 X46
22 125
Sh. 10 12 3 +48V RX+ 5 Sh. 10
X45 X46
126
4 0V RX- 2
Date
Sh. 10
X30 X45
PRE SELECTION HEIGHT
X31 A7
2013-03-04
X32 X34
40
Sh. 10 12 6 0V RX+ 7
X32 X34
ELECTRONIC CARD
4 +48V RX- 3
A5
X34
127
TX+ 1 409 RX+ HEIGHT UNIT
Service Manual
6004330-
X34
128
TX- 5 410 RX- HEIGHT UNIT
U10
X15 X17 X17 X15
29 Red Wh 98
Sh. 5 301 INP. HEIGHT COUNTER > FREELIFT
A
+ PULSE A
X15 X17 X17 X15

30 Bk Bl 99
B
- PULSE B
ELECTRONIC CARD, TURRET UNIT

A4
U9
20 Red Wh 55
Sh. 12 012 INP. HEIGHT COUNTER < FREELIFT
A
+ PULSE A
T-code
485, 487
X14 X16 X49

Bk Bl 56
011 INP. HEIGHT COUNTER < FREELIFT
B
- PULSE B

S93
104
013 INP. FORKS < REFERENCE HEIGHT
Br Bl
209398
11/24, Prod C
17- 35
17- 36
T-code
485, 487

A4
X30 X14 X16 X49

22 22
Sh. 11 13 001 INP. + 48VDC SUPPLY
X14 X16 X49

40 40
Sh. 11 13 029 GND
6004330-
015 GND
Service Manual
X15 X16 X49
119 119
Sh. 7 14 027 INP./OUT. CAN H
R109 120~E / 1W
X15 X16 X49
120 120
Sh. 7 14 042 INP./OUT. CAN L
20 20
Sh. 11 18 028 OUT. + 15VDC SUPPLY
041 INP. STEER SAFETY RELAY

Date
U13
Red Bl 52
009 INP. TRAVERSE COUNTER PULSE A
2013-03-04
A
+
Bk Wh 53
008 INP. TRAVERSE COUNTER PULSE B
B
-
S50
Br Bk 103
010 INP. FORKS IN HOME POS. INDICATOR
Bl
244989-040
Order number
209398
12/24, Prod C

OPTION E98 HEATER IN COLD STORE CABIN
COLD STORE CABIN 30A
1
244989-040
Sh. 10 22
30A
Order number
© BT Europe AB
30A
30A
5A
Date
24
Sh. 3
(Red)
S68 COMFORT HEATER (1500W)

2013-03-04
FAN SPEED / MASTER ON/OFF S69 THERMOSTAT

(Wh) (Ye) 2 4
X30 X45 S97

22 1 5 157
Sh. 12 14
15 18 750W
E1
Service Manual
6004330-
DEFROST START (1500W)

COURTESY LIGHTS IN CABIN
(Bk)
TIMER
S70
A1
(Bl) Y1
E2
750W
A2
(Gn)
X31 X45
(Or)
750W
(Gn)
T-code
(Ye)
485, 487
750W
0/1/2/3
FAN M

40
Sh. 12 14
209398
13/24, Prod C
17- 37
17- 38
T-code
485, 487
OPTION
WIRE GUIDANCE, PAGE 14 TO 17. WIRE GUIDANCE
A3
X30 X48
22 22
Sh. 13 15 JP2:11 INP. + 48VDC SUPPLY
6004330-
X48
40 40
Sh. 13 18 JP2:24 GND
Service Manual
111
JP2:21 OUT. + 12VDC
S85
Br Bk 112
JP2:9 INP. STEER WHEEL IN HOME POS.
Bl
113
JP2:23 GND
X48
119 119
Sh. 12 JP4:6 INP./OUT. CAN H
Date
X48
120 120
Sh. 12 JP4:5 INP./OUT. CAN L
2013-03-04
JP3:1
JP3:2
JP3:4
244989-040
Order number
209398
14/24, Prod C

244989-040
Order number
© BT Europe AB
Date
OPTION
2013-03-04
WIRE GUIDANCE, PAGE 14 TO 17.

WIRE GUIDANCE
A3
131
JP1:12 GND
Service Manual
130
6004330-
JP1:21 OUT. + 5VDC
ENCODER
U15
Br Gr 132
JP1:7 INP. ENCODER PULSE A
A
+
Wh Ye 133
JP1:8 INP. ENCODER PULSE B
B
680~E/2W
X30 X32 H120 R35 X32 X48
22 10 9 670 67
Sh. 14 19 JP2:3 OUT. ON WIRE
T-code
485, 487
ELECTRONIC CARD
A5

X32 S120 X32
5 7 66
304 INP. WIRE GUIDANCE OFF
VRSF WITHOUT WIRE GUIDANCE

209398
15/24, Prod C
17- 39
17- 40
T-code
485, 487
OPTION
ANTENNA 1 WIRE GUIDANCE, PAGE 14 TO 17. WIRE GUIDANCE
W1 A3
BLACK
J1L:1 JPW1:1 INP. RIGHT COIL
BROWN
J1L:2 JPW1:2 INP. NEAR WIRE COIL
6004330-
RED
J1L:3 JPW1:3 INP. LEFT COIL
Service Manual
ORANGE
J1L:5 JPW1:5 OUT. T0
YELLOW
GREEN
Date
BLUE
2013-03-04
VIOLET GND
J1L:14 JPW1:14
GREY
J1L:15 JPW1:15 OUT. + 12VDC
J1L:13 JPW1:13 SHIELD

244989-040
Order number
209398
16/24, Prod C

244989-040
Order number
© BT Europe AB
OPTION
Date

W2 A3
2013-03-04
BLACK
J1T:1 JPW2:1 INP. RIGHT COIL
BROWN
J1T:2 JPW2:2 INP. NEAR WIRE COIL
RED
J1T:3 JPW2:3 INP. LEFT COIL
Service Manual
6004330-
ORANGE
J1T:5 JPW2:5 OUT. T0
YELLOW
GREEN
BLUE
VIOLET GND
J1T:14 JPW2:14
T-code
485, 487
GREY
J1T:15 JPW2:15 OUT. + 12VDC

J1T:13 JPW2:13 SHIELD
209398
17/(24, Prod C
17- 41
17- 42
T-code
485, 487
CAMERA SELECTOR ELECTRONIC CARD, TURRET UNIT

A54 CAMERA ON FORKS, BT-BRAND EXCLUDING COLDSTORE CABIN A4
PAGE 18 AND 20.
150 150
INP. SWITCH SIGNAL SET:1 020 OUT. SWITCH SIGNAL
SET
40 20
GND SET:2 030 INP. 15 VDC
PAGE 19 X49
PAGE 19 X16
6004330-
PAGE 19 X14
TV-MONITOR
A49
Service Manual
X61 X60 X151 X55
210 110 110
VIDEO SIGNAL OUT:1 A:1 VIDEO SIGNAL
X61 X60 X151 X55

114 114 114
+ 12VDC OUT:2 B:1 + 12VDC
OUT
X61 X60 X151 X55
115 115 115
GND OUT:3 B:2 GND
X61 X60 X151 X55

256 156 156
PAGE 19 SHIELD OUT:4 A:2 SHIELD
Date
20
Sh. 12 19
2013-03-04
40 WHEN STEREO/CD
Sh. 14 19
X52
115
Sh. 23
244989-040
Order number
X52
114
Sh. 23 209398
18/24, Prod C

244989-040
Order number
OPTION
© BT Europe AB
A54 CAMERA ON FORKS, COLDSTORE CABIN AND TOYOTA BRAND. A4
CAMERA ON FORKS, PAGE 19 AND 20.
150 150
SET
Date
40 20
PAGE 19 X49
2013-03-04
PAGE 19 X16
PAGE 19 X14 TV-MONITOR

R49
A50
X61 X60 120~E/0,6W X:A50

210 210
Service Manual
6004330-
X61 X60 X:A50

114 114
OUT
X61 X60 X:A50
115 115
GND OUT:3 B:2 GND
X61 X60 X:A50

256 256
20 VOLTAGE CONVERTER
Sh. 18 A14
X30
22 22
Sh. 15 21 + INP. + 48VDC
X30
40 40
Sh. 18 21 - INP. GND
T-code
485, 487
115
- OUT. GND

114
+ OUT. + 12VDC
209398
19/24, Prod C
17- 43
17- 44
T-code
485, 487
OPTION
CAMERAS ON FORKS
CAMERA ON FORKS, LEFT CAMERA SELECTOR
A51 A54
310 310
VIDEO SIGNAL 101 IN1:1 VIDEO SIGNAL 1
114 114
+ 12VDC 102 IN1:2 + 12VDC
6004330-
IN 1
115 115
GND 103 IN1:3 GND
Service Manual
256 256
SHIELD 104 IN1:4 SHIELD
PAGE 18
PAGE 18
VIDEO SIGNAL PAGE 18
CAMERA ON FORKS, RIGHT
A52
Date
410 410
2013-03-04
114 114
+ 12VDC 102 IN2:2 + 12VDC
IN 2
115 115
GND 103 IN2:3 GND
PAGE 18
256 256
244989-040
Order number
209398
20/24, Prod C

244989-040
Order number
© BT Europe AB
OPTION
PERSONAL PROTECTION SYSTEM, PAGE 21 AND 22.
Date
ELECTRONIC CARD
A5
X30
2013-03-04
33 33
Sh. 22 706 OUT. IN AISLE INDICATION LAMP
OVERRIDE EMERGENCY MODE / OVERRIDE LIFT HEIGHT
X33
S33 100
X30 X32 205 INP. OVERRIDE
22 1
Sh. 19 23
3
7
Service Manual
6004330-
X33
165 2
Sh. 22
4
8
X34
166
Sh. 22
PERSONAL PROTECTION SYSTEM

TBM GM-107ECO
X150
163
INP. DRIVE, FORK DIRECTION X2:3 208 OUT. DRIVE, FORK DIRECTION
INP. 0VDC SUPPLY X2:4

T-code
X150
485, 487
164
INP. DRIVE, STEER WHEEL DIRECTION X2:5 202 OUT. DRIVE, STEER WHEEL DIRECTION

NOTE! OUTPUT FOR AUDIBLE AND VISIBLE ALARM FROM TBM GM-107ECO EQUIPMENT NOT SHOWED.
X150
40
Sh. 19 22
209398
21/24, Prod C
17- 45
17- 46
T-code
485, 487
OPTION PERSONAL PROTECTION SYSTEM

PERSONAL PROTECTION SYSTEM, PAGE 21 AND 22. GM-107ECO
7,5A 8A
F64 X150 F
1 9
Sh. 13 X9:1 INP. +48VDC SUPPLY
X150
40
Sh. 21 23 X9:2 0 VDC SUPPLY
X150
ELECTRONIC CARD
X1:1 INP. EMERGENCY RELAY
A5
X150
6004330-
160
INP. PERSONAL PROTECTION 1 201 X1:3 OUT. EMERGENCY RELAY
X150
Service Manual
X150
161
X150
X1:6 INP. WARNING RELAY
X150
162
INP. SPEED REDUCTION 206 X1:7 OUT. WARNING RELAY
Date
X150
33
Sh. 21 X2:10 INP. IN AISLE
2013-03-04
X2:12 INP. 0 VDC SUPPLY
X150
165
Sh. 21 X1:12 OUT. +24VDC
X150
166
Sh. 21 X1:13 INP. OVERRIDE EMERGENCY MODE
244989-040
Order number
209398
22/24, Prod C

DC/DC CONVERTER
OPTION A10
X44 STEREO/CD
22 22
Sh. 21 24 6 INP. +48V
244989-040
Order number
X44
© BT Europe AB
40 40
Sh. 22 24 3 INP. GND
114 114
Sh. 18 4 OUT. +12V
Date
115 115
Sh. 18 5 OUT. GND (GALV. SEPARATED)
X51
2013-03-04
340
2 OUT. GND (GALV SEPARATED)
X51
312
1 OUT. +12V
STEREO/CD
Service Manual
6004330-
A11
312
A:7 INP. +12VDC
312
A:4 INP. +12V KEY
340
A:8 INP.GND
H4 X56
LEFT +
B:5 OUT. LEFT (+)
X56
LEFT -
B:6 OUT. LEFT (-)
H5 X56
T-code
RIGHT +
485, 487
B:3 OUT. RIGHT (+)
X56

RIGHT -
B:4 OUT. RIGHT (-)
W5
209398
23/24, Prod C
17- 47
17- 48
DC/DC CONVERTER
OPTION T-code
A10 485, 487
STEREO/CD ON COLDSTORE CABIN
X:A9
22 22
Sh. 23 + INP. +48V
X:A9
40 40
Sh. 23 - INP. GND
340
- OUT. GND
312
+ OUT. +12V
6004330-
STEREO/CD
A11
Service Manual
312
A:7 INP. +12V
312
A:4 INP. KEY +12V
340
A:8 INP. GND
H4
B:5 OUT. LEFT (+)
Date
B:6 OUT. LEFT (-)

2013-03-04
H5
B:3 OUT. RIGHT (+)
B:4 OUT. (-)
W5
244989-040
Order number
209398
24/24, Prod C

244989-040
Order number
© BT Europe AB
1 + - 40
Sh. 3 Sh. 2
Date
ELECTRONIC CARD
2013-03-04
MEASURING WIRES A5
72
71
Service Manual
6004330-
70
MAIN CONTACTOR
K10
40 A1 A2 31
10A
F62
2 1 23
8
Sh. 2
17.1.2 Wiring diagrams VR
S1 X30
22 3 4 34
Sh. 2 101 INP. SETUP SELECT
S2 X30
T-code
3 4 35
102
485, 487
INP. SETUP UP
S3 X30

3 4 36
103 INP. SETUP DOWN
209397
1/24, Prod C
17- 49
17- 50
T-code
FREQUENCY INVERTER, DRIVE 485, 487
A1
160A
F1
8
Sh. 1 7 B + +
2
U DRIVE MOTOR
40 M1
Sh. 1 4 B- - U
V
14 W M
7 3~A
B1
4
W
11
4
ELECTRONIC CARD
10 A5
6004330-
3
U11 117
Red Bl
Service Manual
12
5
B
+
118
13 402 OUT. CAN GND
Bk Wh 13
6
A
-
119
X30
22 120
Sh. 1 3 1 11 404 INP./OUT. CAN L
Date

X41
X45 X31
1 117
2013-03-04
X45 X31
2 118 117
Sh. 7
X45 X31
3 119 118
Sh. 7
X45 X31
4 120 119
Sh. 7
R100 120
Sh. 7
244989-040
Order number
209397

2/24, Prod C
244989-040
Order number
© BT Europe AB
Date
2013-03-04
ELECTRONIC CARD
A5
10A
F60
1 21
Service Manual
805 + 48VDC
6004330-
Sh. 1 5
X30
24 24
Sh. 14 807 INP. KEY
S23
1 3 43
KEY EMERGENCY SWITCH OFF
X30 S17 S21 X30

15 61a 24 1 2 22
809 + 48VDC SUPPLY OUTPUTS
X32
45
104 INP. DRIVE, FORK DIRECTION, CREEP
S26
X32
22 3
Sh. 2 4 X32
2 46
105 INP. DRIVE, STEER WHEEL DIRECTION,
1
CREEP
T-code
485, 487
X25 S89 X25

1 3 49

209397
3/24, Prod C
17- 51
17- 52
T-code
485, 487
ELECTRONIC CARD
A5
27 27
6004330-
1
50
Service Manual
2
28 28
Sh. 6 508 POT. GND
M12
Bl - +R 107

Date
X32 S18 X32

54 3 4
2013-03-04
X30 IN
22 40
Sh. 3 5 + - Sh. 2 5
HORN
H1
SEAT HEATER
X25 E10 X25
244989-040
Order number
FAN PUMPMOTOR
X35 M10 X35 209397
M 4/24, Prod C,

244989-040
ELECTRONIC CARD
Order number
A5
© BT Europe AB
29 29
Sh. 11 810 + 15VDC
30 30
Sh. 11 811 GND
Date
S66
Br Bk 58
2013-03-04
Wh
Bl
C4 59
S65
X30
22 Br Bk 57
Sh. 4 6 209 INP. STEER WHEEL REFERENCE
Service Manual
6004330-
180 DEG.
Bl
806
40 40
Sh. 4 6 902 GND
30A
F61
1 25
M6
Bk Red 60
61
U1
T-code
X32
Bk Red
485, 487
62
X34

129
511 GND, TACHO
209397
5/24, Prod C
17- 53
17- 54
EMERGENCY MODE T-code
X30 S131 485, 487
22 1 2
A5
Y1
40 64
DISPLAY
A6
X46
121
X46
122
RS 485
X46
125
RX + 3 407 TX+
X46
126
6004330-
RX - 4 408 TX-
27
Sh. 4 8
Service Manual
1
51
2
28
Sh. 4 8
LEFT ARM, INNER
Y5:1
RIGHT ARM, INNER

Y5:2 X38
63
801
Date
OUT. SUPPORT ARMBRAKE 1

X38
LEFT ARM, OUTER
Y6:1 X38
2013-03-04
68
RIGHT ARM, OUTER
Y6:2
126
Sh. 10
125
Sh. 10
244989-040
Order number
209397

6/24, Prod C
244989-040
Order number
© BT Europe AB
Date
2013-03-04

A2
300A
F3
8 5
M3
U
Service Manual
6004330-
40 6 V M
Sh. 6 9 B- - V
W M
3~A
7
8 ID W

19
7
B2
16 117
4 12 Sh. 2
15 118
3 13 Sh. 2
U12
Red Bl 17 119
5 10 Sh. 2 12
B
+
T-code
485, 487
Bk Wh 18 120
6 11 Sh. 2 12
A
-

X30
22
Sh. 6 8 1
209397
7/24
17- 55
ELECTRONIC CARD
X32
27 A5
Sh. 6
1
X33
82
17- 56
2
T-code
3
X32
28 485, 487
Sh. 6
1
X33
83
3
1
X33
84
R5 505 INP. JOYSTICK ROTATE
3
1
X33
85
R14 506 INP. JOYSTICK SPARE 1/AUTO ROTATE
2
3
6004330-
1
X33
86
Service Manual
R15 510 INP. JOYSTICK SPARE 2
3

Date
201 INP. PERS.PROT. 1 (NOT ACTIVE)

(WHEN USED SEE PAGE 24)
2013-03-04

X30
S61 X31
22 5 1 81
X30 X32 S33 X33

5 1 100
205 INP. OVERRIDE
244989-040
Order number
209397
8/24, Prod C

244989-040
Order number
© BT Europe AB
ELECTRONIC CARD
A5
X47 Y10 X47

40 88
Date
X47 Y11 X47

89
701 OUT. FORK LIFT
2013-03-04
X47 Y24 X47

90
FORK DIRECTION 1
X30 X14 S5 X15
22 Br Bl 41
Service Manual
6004330-
S6
Br Bl
STEER WHEEL DIR., RIGHT
S156
Br Bk
Bl
FORK DIRECTION 2
X14 S7 X15
Br Bl 42
S8
Br Bl
FORK DIR., LEFT
S178
X69 X69
Br Bk
T-code
X69
485, 487
Bl
FORK DIRECTION

X14 S9 X15
Br Bl 44
S4
Br Bl
209397
9/24, Prod C
17- 57
17- 58
T-code
485, 487
ELECTRONIC CARD
A5
X45 S90 X45 X31

22 1 5 91
680 ohm/2W
X31 X45 H90 R34 X45 X31
40 10 9 920 92
Sh. 9 11 306 OUT. HALF PALLET HANDLING INDI. LAMP
680 ohm/2W
X31 H95 R30 X30
- + 320 32
(L,R OR CENTER)
680 ohm/2W
X31 H18 R31 X30
- + 330 33
706
OUT. IN AISLE INDICATION LAMP

6004330-
X31 X36 H2 X36 X30

- + 37
H3
Service Manual
X31 X37 X37 X31
- + 38
47 ohm/50W
H96 R32
- + 109 108
709 OUT. LENGTH INDICATION LAMP (IN AISLE)
X23 Y20 X23

101
710 OUT. CABIN LIFT
X23 Y21 X23

102
Date
LENGTH INDICATOR
A9
X45 X45 X46
125
3 +48V RX+ 5 Sh. 6 11
2013-03-04
1 ID
X31 X45 X45 X46
126
4 0V RX- 2 Sh. 6 11
EXTERNAL EQUIPMENT
F63 X30 S99 E4 E3
1 26 1 1 26 1 5 191 192
Sh. 5 14
244989-040
X31
40 2 2 40
Order number
209397
10/24, Prod C

244989-040
Order number
© BT Europe AB
A8
X45 X45 X46
22 125
Sh. 10 12 3 +48V RX+ 5 Sh. 10
X45 X46
126
4 0V RX- 2
Date
Sh. 10
X30 X45
X31
A7
2013-03-04
X32 X34
40
Sh. 10 12 6 0V RX+ 7
X32 X34
ELECTRONIC CARD
4 +48V RX- 3
A5
X34
127
Service Manual
6004330-
X34
128
U10
X15 X17 X17 X15
29 Red Wh 98
A
+ PULSE A
X15 X17 X17 X15

30 Bk Bl 99
B
- PULSE B

A4
U9
20 Red Wh 55
Sh. 12 012 INP. HEIGHT COUNTER < FREELIFT
A
PULSE A
T-code
+
485, 487
X14 X16 X49

Bk Bl 56
011 INP. HEIGHT COUNTER < FREELIFT
B
- PULSE B

S93
104
Br Bl
209397
11/24, Prod C
17- 59
17- 60
T-code
485, 487

A4
X30 X14 X16 X49

22 22
X14 X16 X49

40 40
Sh. 11 13 029 GND
6004330-
015
Service Manual
GND
X15 X16 X49

119 119
R109 120 ohm/ 1W

X15 X16 X49

120 120
20 20
Sh. 11 028 OUT. + 15VDC SUPPLY
Date

U13
Red Bl
2013-03-04
52
A
+
Bk Wh 53
B
-
S50
Br Bk 103
Bl
244989-040
Order number
209397
12/24, Prod C

244989-040
Order number
© BT Europe AB
Date
ELECTRONIC CARD
A4
2013-03-04
X14 X16 X49 X62 Y25 X63

40 93
Sh. 12 14 016 OUT. PROPORTIONAL VALVE TRAVERSE
X62 Y8 X63
94
017 OUT. TRAVERSE LEFT
X62 Y9 X63
95
Service Manual
6004330-
X62 Y26 X63

73
003 OUT. PROPORTIONAL VALVE ROTATE
X62 Y27 X63

74
006 OUT. ROTATE, COUNTER CLOCKWISE
X62 Y28 X63

75
005 OUT. ROTATE, CLOCKWISE
X62 Y16 X63

76
018 OUT. SPARE 1A
X62 Y17 X63

77
019 OUT. SPARE 1B
T-code
X64
485, 487
39
002 OUT. POT. FEED + 10VDC

X64
65
R8 007 INP. ROTATION ANGLE
X64
209397
13/24, Prod C
17- 61
17- 62
OPTION E98 HEATER IN COLD STORE CABIN T-code
COLD STORE CABIN
485, 487
30A
1
Sh. 10 24
30A
30A
30A
5A
24
Sh. 3
(Red)

(Wh) (Ye) 2 4
X30 X45 S97

22 1 5 157
Sh. 12 15
6004330-
15 18 750W
E1
Service Manual

(Bk)
TIMER
S70
A1
(Bl) Y1
E2
750W
(Gn) A2
X31 X45
(Or)
Date
750W
(Gn)
2013-03-04
(Ye) 750W
0/1/2/3
FAN M
40
Sh. 13 15
244989-040
Order number
209397
14/24, Prod C

244989-040
Order number
© BT Europe AB
OPTION
Date
WIRE GUIDANCE, PAGE 15-18 WIRE GUIDANCE

A3
2013-03-04
X30 X48
22 22
X48
40 40
Sh. 14 19 JP2:24 GND
111
JP2:21 OUT. + 12VDC
Service Manual
6004330-
S85
Br Bk 112
Bl
113
JP2:23 GND
X48
119 119
Sh. 12 JP4:6 INP./OUT. CAN H
X48
120 120
Sh. 12 JP4:5 INP./OUT. CAN L
JP3:1
T-code
485, 487
JP3:2

JP3:4
209397
15/24, Prod C
17- 63
17- 64
T-code
485, 487
OPTION WIRE GUIDANCE

A3
WIRE GUIDANCE, PAGE 15-18
6004330-
131
JP1:12 GND
Service Manual
130
JP1:21 OUT. + 5VDC
ENCODER
U15
Br Gr 132
A
+
Wh Ye 133
B
-
Date
680~E/2W
2013-03-04
X30 X32 H120 R35 X32 X48

22 10 9 670 67
ELECTRONIC CARD
A5
X32 S120 X32

5 7 66
244989-040
Order number
VR WITHOUT WIRE GUIDANCE 209397

16/24, Prod C
244989-040
Order number
© BT Europe AB
OPTION
LOAD ANTENNA WIRE GUIDANCE, PAGE 15-18 WIRE GUIDANCE
Date
W1 A3
2013-03-04
BLACK
BROWN
RED
Service Manual
6004330-
ORANGE
YELLOW
GREEN
BLUE
VIOLET
J1L:14 JPW1:14 GND
T-code
485, 487
GREY

209397
17/24, Prod C
17- 65
17- 66
T-code
485, 487
OPTION
TRACTOR ANTENNA WIRE GUIDANCE, PAGE 15-18 WIRE GUIDANCE
W2 A3
BLACK
BROWN
6004330-
RED
Service Manual
ORANGE
YELLOW
GREEN
Date
BLUE
2013-03-04
VIOLET
J1T:14 JPW2:14 GND
GREY

244989-040
Order number
209397
18/24, Prod C

244989-040
OPTION
Order number
CAMERA ON FORKS. COLDSTORE CABIN.
© BT Europe AB
CAMERA TV-MONITOR
R50
A51 A50
Date
X67 X61 X60 120~E/0,6W X:A50

110
VIDEO SIGNAL 101 A:1 VIDEO SIGNAL
X67 X61 X60 X:A50

2013-03-04
114
+ 12VDC 102 B:1 + 12VDC
X67 X61 X60 X:A50

115
GND 103 B:2 GND
X67 X61 X60 X:A50

156
SHIELD 104 A:2 SHIELD
Service Manual
6004330-
VOLTAGE CONVERTER
A10
X45
22 22
Sh. 16 21 + INP. + 48VDC
X31 X45
40 40
115
T-code
OUT. GND
485, 487
-
114

+ OUT. + 12VDC
209397
19/24, Prod C
17- 67
17- 68
T-code
485, 487
OPTION
CAMERA ON FORKS.
CAMERA TV-MONITOR
A51 A50
X67 X61 X60 X55

110
VIDEO SIGNAL 101 A:1 VIDEO SIGNAL

6004330-
X67 X61 X60 X55

156
SCREEN 102 A:2 SCREEN
Service Manual
X67 X61 X60 X55
114
+12VDC 103 B:1 +12VDC
X67 X61 X60 X55

115
104 B:2
GND GND
Date
2013-03-04
WHEN STEREO/CD
X52
244989-040
114
Sh. 21
Order number
X52
115 209397
Sh. 21 20/24, Prod C

DC/DC CONVERTER
OPTION A10
X44 STEREO/CD
22 22
Sh. 19 22 6 INP. +48VDC
244989-040
X44
40 40
Order number
© BT Europe AB
114 114
Sh. 20 4 OUT. +12VDC
115 115
Date
340
2 OUT. GND (GALV. SEPARATED)
2013-03-04
312
1 OUT. +12VDC
STEREO/CD
A11
Service Manual
6004330-
312
A:7 INP. +12VDC
312
A:4 INP. +12V KEY
340
A:8 INP. GND
H4 X56
B:5 OUT. LEFT (+)
X56
B:6 OUT. LEFT (-)
H5 X56
B:3 OUT. RIGHT (+)
T-code
485, 487
X56
B:4 OUT. RIGHT (-)

W5
209397
21/24, Prod C
17- 69
17- 70
OPTION T-code
DC/DC CONVERTER 485, 487
STEREO/CD COLDSTORE CABIN. A10
X:A9
22
Sh. 21 23 + INP. +48VDC
X:A9
40
340
- OUT.GND
312
+ OUT. +12VDC
6004330-
STEREO/CD
A11
Service Manual
312
A:7 INP. +12VDC
312
A:4 INP. +12V KEY
340
A:8 INP. GND
H4
B:5 OUT. LEFT (+)
Date
B:6 OUT. LEFT (-)
H5
2013-03-04
B:3 OUT. RIGHT (+)
B:4 OUT. RIGHT (-)

W5
244989-040
Order number
209397
22/24, Prod C

244989-040
Order number
© BT Europe AB
OPTION
Date

ELECTRONIC CARD
A5
2013-03-04
X30
33 33
OVERRIDE EMERGENCY MODE / OVERRIDE HEIGHT
X33
S33 100
22 1
Sh. 22
3
7
Service Manual
6004330-
X33
165 2
Sh. 24
4
8
X34
166
Sh. 24

TBM GM-107ECO
X150
163

T-code
485, 487
X150
164

X150
40 209397
Sh. 22 24
23/24, Prod C
17- 71
17- 72
T-code
485, 487
GM-107ECO
7,5A 8A
F64 X150 F
1 9
X150
40
Sh. 23 X9:2 0 VDC SUPPLY
X150
ELECTRONIC CARD
A5
X150
160
X150
6004330-

Service Manual
X150
161
X150
X150
162
X150
Date
33
2013-03-04
X150
165
Sh. 23 X1:12 OUT. +24VDC
X150
166
244989-040
Order number
209397
24/24, Prod C

244989-040 2013-03-04 6004330- 485, 487
17.1.3 Component List, standard truck
Symbol Description/function Component fig-

ure
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
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

485, 487 6004330- 2013-03-04 244989-040

ure
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 1
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

244989-040 2013-03-04 6004330- 485, 487

ure
R15 (VR only) Potentiometer, extra hydraulic function 2
R30 Series resistor, H95
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 wheel- 5
direction
S5 Electro-magnetic switch, aisle indication 1, fork-direc- 5
tion
S6 Electro-magnetic switch, aisle indication 1, steering 5
wheel-direction
S7 Electro-magnetic switch, aisle indication 2, fork-direc- 5
tion
S8 Electro-magnetic switch, aisle indication 2, steering 5
wheel-direction
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 2
speed
S33 Micro-switch, by-pass max. lift height 2
S50 Inductive sensor, forks in home position, traversing 6
S61 Micro-switch, load weighing 1

485, 487 6004330- 2013-03-04 244989-040

ure
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
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 7

X8 Contact, to height indication display
X11 Contact, for joystick in steering wheel console 2

244989-040 2013-03-04 6004330- 485, 487

ure
X14 Contact, at tank, to mast 4
X15 Contact, at tank, to mast 4
X16 Contact, at mast 5
X23 Contact
X25 Contact, seat 3
X30 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
X47 Contact, at tank to pump valve block 4
X48 Contact, at tank for loop steering 4
X49 Contact, at A4 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

485, 487 6004330- 2013-03-04 244989-040

ure
X67 (VR only) Contact, for camera, on fork apparatus 6
Y1 Magnet, parking brakes 4

Y5:1 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

244989-040 2013-03-04 6004330- 485, 487
17.1.4 Component identification

Figure 1
Figure 2
Figure 3

485, 487 6004330- 2013-03-04 244989-040
Figure 4

244989-040 2013-03-04 6004330- 485, 487
Figure 5 (VR SF)

485, 487 6004330- 2013-03-04 244989-040
Figure 5 (VR)

244989-040 2013-03-04 6004330- 485, 487
Figure 6 (VR SF)

485, 487 6004330- 2013-03-04 244989-040
Figure 6 (VR)

244989-040 2013-03-04 6004330- 485, 487
Figure 7 (VR SF)

485, 487 6004330- 2013-03-04 244989-040
Figure 7 (SF)

Functional Description
244989-040 2013-03-04 6004330- 485, 487
17.2 Functional Description

The electronics card for VR/VR SF AC has a microprocessor that mon-
itors 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 bat-
tery power has been switched off, the module is equipped with an inter-
nal battery. Any errors registered by the micro-processor are shown on
the display. Error codes are explained in conjunction with the electron-
ics 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 posi-
tion, have LEDs indicators: green is used for inputs, red for outputs
and yellow for others.
Description Diode number

Designations for card inputs/out- Diode number/name indicating
puts in accordance with wiring the card’s active inputs/outputs
diagrams

485, 487 6004330- 2013-03-04 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 con-
trollers R4–R6, R14–R15.

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 posi-
tion. 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 elec-
tronics 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 elec-
tronics 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 ther-
mostat and the seat heater E10.

244989-040 2013-03-04 6004330- 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.
.

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.

DRIVE, FORK DIR CREEP 104
DRIVE, STEER WHEEL DIR 105
CREEP
The display shows the direction of travel.

485, 487 6004330- 2013-03-04 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 dis-
play.
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 electron-
ics module.

PARKING BRAKE 802

244989-040 2013-03-04 6004330- 485, 487
17.2.5 Travel speeds

Outside narrow aisles and the forks in the “home
position”
- Fork height <1.2 m = speed reduced to
max 9.0 km/h (2.5 m/s).
- Fork height >1.2 m but <3.0 m = speed reduced to
max 4.0 km/h (1.11 m/s).
If the steering movement is >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 <1.2 m =
speed reduced to max 12.0 km/h (3.33 m/s).
- Driving in the direction of the forks, fork height <1.8 m = speed re-
duced to max 11.0 km/h (3.05 m/s).
- Fork height >1.2/1.8 m but <6.9 m gives variable speed reduction
(OPTIPACE), which is dependent on the stability and braking de-
mands.
- Fork height >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).

485, 487 6004330- 2013-03-04 244989-040
Truck without support arm brakes:

- Fork height >3.0 m but <6.9 m gives variable speed reduction
mands.
max 2.5 km/h (0.7 m/s).
- m = speed reduced to max 9.0 km/h (2.5 m/s).
mands.
max 2.5 km/h (0.7 m/s).

244989-040 2013-03-04 6004330- 485, 487
Wire guided truck

- Fork height <3.5m = speed reduced to
max 9.0 km/h (2.5 m/s).
mands.
- Fork height >6,9 m = speed reduced to max 2.5 km/h (0.7 m/s).
max 2.5 km/h (0.7 m/s).

485, 487 6004330- 2013-03-04 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 low-
er 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 cor-
rect 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.

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 elec-
tronics 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.

244989-040 2013-03-04 6004330- 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. Volt-
age 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.

IN AISLE SIGNAL 1 106
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.

485, 487 6004330- 2013-03-04 244989-040
17.2.7 Braking
The truck employs various braking systems:
Auto-brakes
When the driver releases the accelerator pedal, the drive motor auto-
matically brakes the truck to the desired speed. Auto-braking and brak-
ing 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 influ-
enced. 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 activat-
ed, 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.

SUPPORT ARM BRAKE 1 801
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.

244989-040 2013-03-04 6004330- 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 volt-
age 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.

FORKLIFT 701

485, 487 6004330- 2013-03-04 244989-040
17.2.10 Height Indication

Height measurement checks the lift height from the lowest fork position
(floor level) to the highest.
Measurement begins when the height reference switch S93 (after turn-
ing 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 influ-
enced or not.

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 influ-
enced or not.

HEIGHT COUNTER 301
HEIGHT COUNTER 302

244989-040 2013-03-04 6004330- 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.

HEIGHT COUNTER 301
HEIGHT COUNTER 302

485, 487 6004330- 2013-03-04 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 corre-
sponds to the potentiometer value from R6.
Before the lowering movement begins, the lifting cycle is run momen-
tarily 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.

FORK LOWER 702
244989-040 2013-03-04 6004330- 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 fre-
quency inverter A2. Pump motor M3 starts.

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
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 stop-
ping
485, 487 6004330- 2013-03-04 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.

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 sen-
sor 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.
Parameter Function
44 Action length (pre-set at factory)
45 Action length for half pallet (pre-set at factory)
50 Braking distance at end position
55 Traversing speed
57 Braking ramp
244989-040 2013-03-04 6004330- 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.

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 propor-
tional 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.
Parameter Function
51 Braking distance at end position
56 Rotation speed
58 Braking ramp
485, 487 6004330- 2013-03-04 244989-040
17.2.17 Simultaneous Traversing and

Rotation Movement (VR)
Manual
When the driver manoeuvres the hydraulic levers R4 and R5 simulta-
neously, 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 sup-
plied 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.

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.
Parameter Function
53 Symmetries right/left for selected rotation angle
according to parameter 59.
59 Activation and setting of rotation angle when tra-
versing starts.
60 Maximum lift height at which auto-rotation is per-
mitted.
61 Activation and angle adjustment of auto-rotation
90°
66 Start speed for rotation movement before travers-
ing starts
Auto-rotation right (traversing right/rotation coun-

244989-040 2013-03-04 6004330- 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

If the hydraulic lever R14 is manoeuvred (forwards/backwards) one-
third 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.
485, 487 6004330- 2013-03-04 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 direc-
tion 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 direc-
tion valves Y16/Y17.
NOTE
If the auto-rotation function is used, only R15 can be used for extra
hydraulic functions.

Parameter Function
62 Pump motor speed, extra function 1
64 Pump motor torque, extra function 1
244989-040 2013-03-04 6004330- 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 meas-
urement 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 ex-
ample, I, II, III and III to select driver 1 to 10)
For programming of driver combinations, see parameters 10 and 39.

SETUP SELECT 101
SETUP UP 102
SETUP DOWN 103
Parameter
485, 487 6004330- 2013-03-04 244989-040
17.3 Parameter
17.1 Parameter Settings
• 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 dis-
play will blink)”.
NOTE:
Truck operating characteristics.
Changing the truck-specific parameters changes the truck’s operat-
ing characteristics.
Do not change any parameters unless you have the necessary com-
petence.
Nr. Parameter type Unit Min./max. Std. Comments

value
01 Steering sensitivity 1–6 3 1 = Several wheel turns
5 = Few wheel turns
6 = No progression
In steps of 1
02 Drive motor, max. % 10–100 100 See paragraph 7.5
speed in the direc- In steps of 5
tion of the drive
wheel
03 Drive motor, acceler- % 10–100 100 In percent of max. acceleration
ation In steps of 5
04 Drive motor, speed % 0–100 * Percentage of speed retardation
retardation > 0 = no retardation
In steps of 5
05 Drive motor, retarda- % 35–100 80 Percentage of max. retardation
tion when reversing In steps of 5
06 Max. speed in the % 10–100 100 See paragraph 7.5
direction of the drive In steps of 5
wheel in a narrow
aisle
Parameter
244989-040 2013-03-04 6004330- 485, 487

value
07 Drive motor, max. % 10–100 100 See paragraph 7.5
speed in the direc- In steps of 5
tion of the forks
08 Max. speed in the % 10–100 100 See paragraph 7.5
direction of the forks In steps of 5
in a narrow aisle
10 PIN code for driver 0000–3333 0000 0000 = PIN code not used.
selection > 0 = PIN code used.
11 Drive motor, speed % 10–100 100 Percentage of max. speed
reduction In steps of 5
12 Reduced narrow % 10–100 80 Percentage of max. narrow aisle
aisle speed 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 % 0,5–3,0 3,0 Break point for Optipace speed 9
narrow aisle km/h.
In steps of 0.05
16 Final speed, aisle 0-1 0 The truck speed after completed
end slowdown slowdown
0 = 0 m/s
1 = 0.7 m/s
17 Lift height limitation m. 0–13.5 13.5 0 = not connected
level 1 > 0 = connected
In steps of 0.05
18 Lift height limitation m. 0–13.5 13.5 0 = not connected
level 2 > 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 Top side of fork to floor when
table 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)
Parameter
485, 487 6004330- 2013-03-04 244989-040

value
21 Battery size 1–20 12 Selection of size/type of battery,
See increased parameter values
table. result in deeper discharge of bat-
tery
See table.
22 Support arm brakes 0–1 0 0 = Truck without support arm
brakes
1 = Truck with support arm
brakes
23 Running warning, 0–3 0 0: No warning
truck in motion 1 = Warning in fork-direction
2 = Warning in steering wheel-
direction
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 100 h. 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
30- Not used
34
35 Bottom offset par mm 0-500 0 In increments of 10.
Earlier slow-down of the lower-
ing movement close to the bot-
tom position.
Parameter
244989-040 2013-03-04 6004330- 485, 487

value
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 to
1 automatically when key is
turned after initiating learning
mode.
37 Calibration weight kg. 100–5000 1000 In steps of 10
for weighing
38 Calibration of accel- 2 0 Set 1 or 2 for calibration
eration/brake pedal See instructions
or forks
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 appara- 0–1 0 Specify used apparatus type:
tus 0 = Rotating fork apparatus
1 = Telescoping fork apparatus
44 Action length, tra- mm 1000–2500 Set to Factory parameter (pre-set at
versing movement current factory)
In steps of 2
45 Action length, half mm 500–2500 900 Factory parameter (pre-set at
pallet handling factory)
In steps of 2
46 Speed reduction, tra- 0–1 1 Speed reduction depending on
versing movement current lift height
Limit height = 5.0, 7.0 and 9.0 m
0 = Not connected
1 = Connected
47 Pump motor speed, 0-90 34 In steps of 2
(VR) rotation
(VR) traversing and com-
bined movement
Parameter
485, 487 6004330- 2013-03-04 244989-040

value
(VR telescopic forks
SF)
50 Braking distance, 0–4 4 Distance controlled, end posi-
end position travers- tion-end position
ing movement In steps of 1
51 Braking distance, 0–4 4 Distance controlled, end posi-
(VR) end position rotation tion-end position
movement In steps of 1
52 Not used
53 Rotation angle sym- 0–20 0 See instructions
(VR) metry, angle centring In steps of 1
for parameter 59.
54 Reference height mm 400–800 500 Calibration height for height
free lift measurement within free lift
range
In steps of 2
55 Max. speed, travers- % 60–100 100 Percentage of max. speed
ing speed In steps of 5
56 Not used
57 Braking ramp, tra- 0–4 0 Time for closing of proportional
versing movement valve
In steps of 1
58 Braking ramp, rota- 0–4 0 Time for closing of proportional
(VR) tion movement valve
In steps of 1
59 Start of traversing Deg. 0–50 0 0: Auto-rotation not connected
(VR) movement at auto- >0: Angle at which traversing
rotation may start
In steps of 2
60 Max. permitted lift m. 1–12 2 In steps of 1
(VR) height for auto-rota-
tion
61 Auto-rotation to 0–10 0 0: Auto-rotation to middle, not
(VR) straight ahead posi- connected
tion >0 = Auto-rotation to middle,
connected
Select parameter value for cor-
rection of angle deviation
62 Extra hydraulic func- % 10–100 10 Max. pump motor speed extra
(VR) tion 1, pump motor hydraulic function, pot 1
speed In steps of 5
Parameter
244989-040 2013-03-04 6004330- 485, 487

value
63 Extra hydraulic func- % 10–100 20 Max. pump motor speed extra
speed In steps of 2
64 Extra hydraulic func- % 0–100 0 Max. pump motor torque, extra
torque 0 = No extra function
In steps of 5
65 Extra hydraulic func- % 0–100 0 Max. pump motor torque, extra
torque 0 = No extra function
In steps of 5
66 Start auto rotation 0-255 50 Start speed for rotation with auto
(VR) rotation
In steps of 1
67 Camera switching 0-255 0 0: Not fitted
unit >0: Fitted
In steps of 1
68- Not used
70
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-progres-
sive (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.
Parameter
485, 487 6004330- 2013-03-04 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
the direction of the drive wheel in narrow aisle mode.
17.1.7 Parameter 7
the direction of the forks, outside of narrow aisles.
17.1.8 Parameter 8
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.
With this parameter, you set the maximum permitted running speed in
narrow aisle mode when input 206 is activated.
Parameter
244989-040 2013-03-04 6004330- 485, 487
the half speed range.
the creep speed range.
With this parameter, you set the lift height at which running speed
begins to decrease as determined by the truck’s OPTIPACE system.
Using this parameter you set the truck's running speed after the com-
pleted 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 nor-
mally used as the maximum height before the mast top is reached.
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
Parameter
485, 487 6004330- 2013-03-04 244989-040
With this parameter you specify the time (A-d or S) that will be dis-
played when the driver uses the truck.
This parameter specifies the truck’s battery type. You may also com-
pensate 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)
1
2
3
4
5
6
7
8
9
10
11 Less discharge 900

12 730, 700, 580 CSM
13 More discharge 600
14
15 480, 450
16
17 360
18
19
20
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.
Parameter
244989-040 2013-03-04 6004330- 485, 487
This parameter activates the function and control of the braking coils.
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.
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.
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.
When you set the parameter to 1, you activate the function and control
of valves for cab tilt on trucks with cold storage cabs.
When you set the parameter to 1, you cancel the lift function’s priority,
meaning that the hydraulic function you are currently using will contin-
ue, regardless of if you activate lift.
Parameter
485, 487 6004330- 2013-03-04 244989-040
This parameter is used to engage the data collection function for TLS
Electric stop at max lifting height.
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.
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.
• Set the parameter to the weight with which the truck will be calibrat-
ed.
• 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.
Parameter
244989-040 2013-03-04 6004330- 485, 487
This parameter automatically resets to 0 after calibration.
Calibration of acceleration and braking potentiome-

ters
• 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.
• Turn the key on and off once.
• Rotate 180° to the other end position. Note that movement acceler-
ates 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 pro-
portional valves for traversing must be calibrated.
Proportional valves, traversing
• Run the fork apparatus out to one of the end positions.
• 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.
Parameter
485, 487 6004330- 2013-03-04 244989-040
Set the parameter to 1 or 2 if only three drivers/truck profiles will be pro-
grammed. 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.
Para- Key S17 switched on, then Switch I and key S17 switched
meter switch I on simultaneously
P39- Clock Parameter Driver Clock Parameter Drivers
-1 Reprgm. See See Not Reprgm. Selected
U. CAN selected reprgm. reprgm.
-1 Reprgm. See See Not Reprgm. All reprgm.
M. CAN selected reprgm.
-2 Reprgm. See See Not Not reprgm. See
U. CAN selected reprgm. selected
-3 Reprgm. See See Not Reprgm. Selected
U. CAN selected reprgm. reprgm.
-4 Reprgm. See See Not Not reprgm. See
U. CAN selected reprgm. selected
17.1.33 Parameters 40 to 42
With these parameters, you can set the year, day and month for error
code logging.
Factory parameter dependent on fork apparatus type.
NOTE
Do not change.
Parameter
244989-040 2013-03-04 6004330- 485, 487
This parameter limits travel of traversing movement for the fork appara-
tus.
The parameter controls the travel-dependent braking at the end posi-
tions. 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.
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.
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.

With this parameter you can adjust the pump motor’s speed for the tra-
versing movement and with combined fork movement.
17.1.40 Parameter 49 (VR SF)

With this parameter you can adjust the pump motor’s speed for the tra-
versing movement.
Parameter
485, 487 6004330- 2013-03-04 244989-040
With this parameter, you can adjust the distance between the end posi-
tion and the braking point or centre point for traversing movement.
The lower the parameter value, the longer the braking distance.

With this parameter, you can adjust the distance between the end posi-
tion and the braking point for rotation movement.
The lower the parameter value, the longer the braking distance.
See parameter 58.

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 posi-
tion.
- 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, in-
crease the parameter value.
- Adjust the parameter value until the start angles are the same.
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.
With this parameter, you set the maximum permitted traversing speed.
Parameter
244989-040 2013-03-04 6004330- 485, 487

With this parameter, you set the maximum permitted rotation speed.
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.

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 dis-
tance, parameter 51, rotation is at creep speed to the end position.

With this parameter, you set the rotation angle at which traversing
movement may start for auto-rotation.

With this parameter, you set the maximum lift height at which auto-rota-
tion is permitted.

With this parameter, you activate or deactivate the auto-rotation func-
tion to the straight ahead position. Parameter value >0.
Select a parameter value to adjust the angle deviation from 90o rota-
tion.
- 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.
Parameter
485, 487 6004330- 2013-03-04 244989-040

With this parameter, you choose the pump motor speed for the first
extra hydraulic function.

With this parameter, you choose the pump motor speed for the second

With this parameter, you choose the pump motor torque for the first

With this parameter, you choose the pump motor torque for the second

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.
This parameter is used for the connection of the mounted camera
switching unit.
Instrument Panel and Display
244989-040 2013-03-04 6004330- 485, 487
17.2 Instrument Panel and Display
17.2.1 Show
The show function allows you to view the driver/machine-specific regis-
ters, 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.
.
485, 487 6004330- 2013-03-04 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. Program-
ming is terminated automatically if no buttons are pressed for 20 sec-
onds.
NOTE
Truck operating characteristics.
Changing the truck-specific parameters changes the truck’s operat-
ing characteristics.
Do not change any parameters unless you have the necessary com-
244989-040 2013-03-04 6004330- 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”.
Codes
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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 dis-
played 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 fol-
lowing 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
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 Main contactor opens
on Parking brakes activated
Steering error Steering safety relay falls
Drive motor reverses to stop
Drive regulator Main contactor opens
error Lift regulator error
Steering enabled
Parking brake activated at braking
Lift regulator error Hydraulics stop
Valves closed
Loop steering error Emergency braking
Codes
244989-040 2013-03-04 6004330- 485, 487
Warning signals for warning codes 11–99 are at 2 Hz.

Warning signals for error codes 100– are at 4 Hz.
Codes
485, 487 6004330- 2013-03-04 244989-040
17.3.3 Safety Logic

This applies to the following functions:
X = Corrective action
-- = Function disabled
Action: K10 Y1 acti- Reversing Steering Function at

Function: open vated with M1 disabled A2 halted
Emergency X X -- --
switch
Key X X -- X --
Steering X X
error
Error at A1 X -- --
Error at A2 X
(and el. valves
off)
Error at A5 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 Cool and check motor/gear
Codes
244989-040 2013-03-04 6004330- 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
Codes
485, 487 6004330- 2013-03-04 244989-040
Code 13
Description No/too few pulses from the height measurement
sensor at fork lift or fork lower
Error cause Defective reference switch
Defective sensor/wiring
Incorrect hydraulic oil quality
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 be-
cause the pulses are 90 degrees out of phase. If this is OK, pro-
ceed 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
Codes
244989-040 2013-03-04 6004330- 485, 487
are not loose or oxidized.

b: If the blinking pattern is sporadic, check whether the wire slips
on the height sensor roller.
c: 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.
d: If the cables and terminals are intact, replace the U10 height
sensor.
e: 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.
f: 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.
g: If the cables and terminals are intact, replace the U9 height sen-
sor.
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.
Codes
485, 487 6004330- 2013-03-04 244989-040
Code 14
Description Seat switch closed more than 20 minutes without
moving the truck
Error cause Bypassed switch
Defective switch/wiring
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.
Codes
244989-040 2013-03-04 6004330- 485, 487
Code 15
Description Safety switch affected more than 20 minutes with-
out moving the truck
Error cause Bypassed switch
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.
Codes
485, 487 6004330- 2013-03-04 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.
Comments Manoeuvre to neutral position
Speed control, R1
1. Check to make sure that the speed control is not stuck in the de-
pressed 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 oxi-
dized. 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.
Codes
244989-040 2013-03-04 6004330- 485, 487
- The speed and brake potentiometers as well as the hydraulic op-

eration 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.
Codes
485, 487 6004330- 2013-03-04 244989-040
Code 17
Description Voltage from brake pedal potentiometer R2 is out-
side of calibrated value at start (+/-0.2 V).
Error cause Depressed pedal at start
Calibration error.
Brake control, R2
1. Check to make sure that the brake pedal is not stuck in the de-
pressed position.
Check whether the contact pins in the terminal are loose or oxi-
the mechanical installation of R2 is correct.
Codes
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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. (Posi-
tion with no actuation).
- 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.
- Use the key switch to switch the power off and then on again.
- The speed and brake potentiometers as well as the hydraulic op-
eration 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.
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.
Codes
485, 487 6004330- 2013-03-04 244989-040
Code 21
Description Potentiometer R6 for fork lift/lower supplies incor-
rect voltage when key turned on
(+/-0.6 V).
Error cause Joystick not in neutral position at start
Fork controls, joystick R6
1. Check to make sure that the fork operation joystick is not stuck in
an actuated position.
Check whether the contact pins in terminal X11 are loose or oxi-
dized. 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 neu-
tral position.
- Use the key switch to switch the power off and then on again. The
joystick is then calibrated.
not rectify the problem, then replace the A5 electronic
card.
Codes
244989-040 2013-03-04 6004330- 485, 487
Code 22
Description Potentiometer R4 for traversing movement sup-
plies incorrect voltage when key turned on (+/-0.6
V).
Error cause Joystick not in neutral position at start
Comments
Traversing, joystick R4
1. Check to make sure that the traversing operation joystick is not

stuck in an actuated position.
dized. The voltage on input 504 should be 3.7 +/- 0.6 VDC when R4
is correctly adjusted.
3. Traversing control calibration.
tral position.
card.
Codes
485, 487 6004330- 2013-03-04 244989-040
Code 23 (VR only)

Description Potentiometer R5 for rotation movement supplies
incorrect voltage when key turned on. (+/-0.6V)
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.
R12 is correctly adjusted.
3. Rotation control calibration.
tral position.
card.
Codes
244989-040 2013-03-04 6004330- 485, 487
Code 24 (VR only)

Description Potentiometer R14 or R15 for extra function “auto-
rotation” and “2” supplies incorrect voltage when
key turned on. (+/-0.6V)
Error cause 1. Joystick not in neutral position at start
2. Defective potentiometer/bracket/wiring
3. Calibration error
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.
dized. The voltage on inputs 506 and 510 should be 3.7 +/- 0.6
VDC when R14 and R15 are correctly adjusted.
Codes
485, 487 6004330- 2013-03-04 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.
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.
Codes
244989-040 2013-03-04 6004330- 485, 487
Code 25
Description Output stage errors
Error cause See codes 50-62 for more information
Comments
1. Proceed as follows to look up warning codes and recorded informa-

tion 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).
• 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.
Codes
485, 487 6004330- 2013-03-04 244989-040
Code 26
Description Output stage errors
Comments

tion in the registers:
- 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.
• Parameters (D).
the right side.
Codes
244989-040 2013-03-04 6004330- 485, 487
Code 27
Description Defective battery feed.
Error mode Battery display blinks
Error cause Poor contact at battery feed cables
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 termi-
nal 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.
Codes
485, 487 6004330- 2013-03-04 244989-040
Code 28
Description Emergency switch is activated
Error mode Emergency switch on
Error cause Driver action
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.
Codes
244989-040 2013-03-04 6004330- 485, 487
Code 29
Description Service time (S) is zero
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.
Codes
485, 487 6004330- 2013-03-04 244989-040
Code 31
Description Phase fault, pulse counter for traversing movement
Error cause Wiring fault
Sensor fault
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 elec-
tronic card.
Codes
244989-040 2013-03-04 6004330- 485, 487
Code 33
Description Previously programmed values missing
Error mode Standard values been loaded
Comments Program A4 card, creep speed only permitted for
fork movement
Code 34
Description Output stage error
Comments

tion in the registers (code 63-81):
- 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.
• Parameters (D).
the right side.
Codes
485, 487 6004330- 2013-03-04 244989-040
Code 35
Description Defective signal from one of the doubled aisle sen-
sors
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.
Codes
244989-040 2013-03-04 6004330- 485, 487
Code 36
Description Learning of wire guidance has failed
Error cause
Comments Carry out “learn” wire guidance again
Code 37
Description Wire guidance limit value exceeded
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 cause Parameter 36 is not set for activation of wire guid-
ance
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
Comments The emergency brakes are applied on the truck
Codes
485, 487 6004330- 2013-03-04 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
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 resist-
ance at B1, which should be approx. 570 ohms at 20oC.
- Check whether cable 11 is intact between B1 and terminal 4 on
A1.
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.
Codes
244989-040 2013-03-04 6004330- 485, 487
Code 41
Description Warning temperature in drive motor’s frequency
inverter
Error cause Overheated frequency inverter
Defective fan
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 cause Faulty frequency inverter
Comments
1. Replace the traction controller, A1.
Codes
485, 487 6004330- 2013-03-04 244989-040
Code 43
Description Incorrect number of pulses from the drive motor's
pulse transducer bearing
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 con-
nection at A12.
Measure the ohm resistance at A12, which should be 100 ohms.
Inspect cable 105 between A12 and U11.
nection at U11.
- Check whether cable 12 is intact between U11 and terminal 5 on
A1.
A1.
- If the cables are intact, replace the transducer layer U11.
2. If the error remains, replace A1
Codes
244989-040 2013-03-04 6004330- 485, 487
Code 45
Description Warning temperature for lift motor
Error cause Overheated lift motor
Comments
Temperature sensor B2 in the pump motor M3
motor compartment.
2. Inspect B2.
- Disconnect terminals 4, 7 and 8 on A2. Measure the ohm resist-
ance 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.
Codes
485, 487 6004330- 2013-03-04 244989-040
Code 46
Description Warning temperature in pump motor’s frequency
inverter
Error cause Overheated frequency inverter
Defective fan
Comments
1. Check to make sure that the ventilation is OK.

2. Inspect the M12 fan next to the motor controllers.
Code 47
Description Current calibration error in pump motor’s fre-
quency inverter
Comments
1. Replace the A2 lift controller.
Codes
244989-040 2013-03-04 6004330- 485, 487
Code 48
Description Incorrect number of pulses from the pump motor's
pulse transducer bearing
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.
nection at A13.
Measure the ohm resistance at A13, which should be 100 ohms.
Inspect cable 155 between A13 and U12.
nection at U12.
Check whether cable 17 is intact between U12 and terminal 5 on
A2.
A2.
- If the cables are intact, replace the U12 transducer layer.
2. If the error remains, replace A2.
Codes
485, 487 6004330- 2013-03-04 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 previ-
ous 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 cause Defective wiring/valve Y20
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.
Codes
244989-040 2013-03-04 6004330- 485, 487
Code 51
Comments
Hydraulic valve Y21 does not engage cab lowering

loose or oxidized.
X23 terminal.
- Measure the ohm resistance on the Y21 coil between the blue
and black cables at X30.
Codes
485, 487 6004330- 2013-03-04 244989-040
Code 52
Comments
Hydraulic valve Y11 does not engage fork lifting

loose or oxidized.
X47 terminal.
- Measure the ohm resistance on the Y11 coil between the grey
Codes
244989-040 2013-03-04 6004330- 485, 487
Code 53
Comments
Hydraulic valve Y24 , reversing valve

loose or oxidized.
X47 terminal.
- Measure the ohm resistance on the Y24 coil between the yellow
Codes
485, 487 6004330- 2013-03-04 244989-040
Code 61
Comments
Hydraulic valve Y10 does not engage fork lowering

loose or oxidized.
X47 terminal.
- Measure the ohm resistance on the Y10 coil between the white
Codes
244989-040 2013-03-04 6004330- 485, 487
Code 62
Description Output 801 and/or 803 short circuit/wire break
Error cause Broken wiring/braking magnet Y5/Y55 and/or Y6/
Y66
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

loose or oxidized.
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.
Codes
485, 487 6004330- 2013-03-04 244989-040
Code 63 (VR only)

Error cause Defective wiring/coil to Y25
Comments
Y25, proportional valve, fork traversing
1. Disconnect cable 93 from output 016 on A4.

loose or oxidized.
X63 terminal.
coil. The resistance should be approx. 50 ohms.
2. If the error remains, replace A4
Codes
244989-040 2013-03-04 6004330- 485, 487
Code 64 (VR only)

Error cause 1. Defective wiring/coil to Y26
Comments
Y26, proportional valve, fork rotation

loose or oxidized.
X63 terminal.
Codes
485, 487 6004330- 2013-03-04 244989-040
Code 66
Error cause Defective wiring to Y9
Short circuit/wire break at direction valve Y9
Comments
Y9, valve for traversing to right

loose or oxidized.
X63 terminal.
Codes
244989-040 2013-03-04 6004330- 485, 487
Code 67
Error cause Defective wiring to Y8
Short circuit/wire break at direction valve Y8
Comments
Y8, valve for traversing to left

loose or oxidized.
X3 terminal.
Codes
485, 487 6004330- 2013-03-04 244989-040
Code 68 (VR only)

Comments
Y28, valve for clockwise rotation

loose or oxidized.
X63 terminal.
Codes
244989-040 2013-03-04 6004330- 485, 487
Code 69 (VR only)

Comments
Y27, valve for counterclockwise rotation

loose or oxidized.
X63 terminal.
Codes
485, 487 6004330- 2013-03-04 244989-040
Code 70 (VR only)

Error cause 1. Defective wiring/coil to direction valve Y16
Comments
Y16, valve for 1A spare

loose or oxidized.
X63 terminal.
Codes
244989-040 2013-03-04 6004330- 485, 487
Code 71 (VR only)

Error cause 1. Defective wiring/coil to direction valve Y17
Comments
Y17, valve for 1B spare

loose or oxidized.
X63 terminal.
Codes
485, 487 6004330- 2013-03-04 244989-040
Code 76
Description Defective check-sum in parameter memory at
start-up
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 cause External interference (static electricity)
Code 78
Description Error at test of safety relay (main circuit) at start-up
Error cause Defective electronic card A4
Code 79
Description Safety relay (main circuit) has opened
Error cause Electronics card A4 dislodged/jarred
No +48 V feed
Codes
244989-040 2013-03-04 6004330- 485, 487
Code 80
Description General communications error
Error mode
Error cause Defective CAN wiring/resistance
Displaced A4 electronics card
Speed for fork movement reduced
Code 81
Error mode
Running speed reduced
Codes
485, 487 6004330- 2013-03-04 244989-040
Code 90
Description Potentiometer R6 for fork lift/fork lower supplies
incorrect voltage (<0.3 or >7.0 V).
Error cause Defective potentiometer/wiring
Activated input without connected potentiometer
Comments
Fork controls, joystick R6

- 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 oxi-
dized.
- 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.
Codes
244989-040 2013-03-04 6004330- 485, 487
Code 91 (VR only)

Error cause 1. Defective potentiometer/wiring or activated input
without connected potentiometer
Comments
Fork rotation control, joystick R5

) is 7-7.5 VDC.
dized.
correctly adjusted.
Codes
485, 487 6004330- 2013-03-04 244989-040
Code 92
Description Potentiometer R4 for traversing movement sup-
plies incorrect voltage (<0.3 or >7.0 V).
Activated input without connected potentiometer
Comments
Fork traversing control, joystick R4

) is 7-7.5 VDC.
dized.
correctly adjusted.
Codes
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Code 93 (VR only)

Description Potentiometer R14 for extra functiuon 1/”auto-rota-
tion” or R15 för extrafunktion ”2” supplies incorrect
voltage (<0.3 or >7.0 V).
Error cause 1. Parameters 15/16 >0, no potentiometer con-
nected
2. Defective potentiometer/wiring
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:
- Depress the switch I while turning the start key.
- Use switch II to advance and switch III to back up to the param-
eter to be changed.
- Depress the switch. The display blinks.
- Change the value using switches II/III.
Codes
485, 487 6004330- 2013-03-04 244989-040
2. Check to make sure that both joysticks for the extra hydraulic func-
tion are not stuck in an actuated position.
3. Check to make sure that R14 and R15 are correctly seated in their
mounts.
dized. 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.
Codes
244989-040 2013-03-04 6004330- 485, 487
Code 94
Description Potentiometer R1 for accelerator pedal supplies
Comments
Speed control, R1

the mechanical adjustment of R1 is correct.
Codes
485, 487 6004330- 2013-03-04 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 previ-
ous 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.
Codes
244989-040 2013-03-04 6004330- 485, 487
17.3.7 Error Codes with Registration

Code 104
Error cause Emergency switch for Y1 activated
Defective wiring/valve Y1
Comments
Parking brake, Y1
1. Check to make sure switch S131 is open.

loose or oxidized.
Y1 coil.
- Measure the ohm resistance on the Y1 coil between the X37 ter-
minals. The resistance should be approx. 33 ohms.
- Check whether cable 40 is intact all the way to battery minus.
Codes
485, 487 6004330- 2013-03-04 244989-040
Code 106
Error cause Defective wiring/contactor K10
Comments
Main connector, K10, coil

loose or oxidized.
tactor K10:A2.
- Measure the ohm resistance in the K10 coil between A1 and A2.
- 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.
Codes
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Code 107
Description Main contactor K10 does not close after key start
and emergency switch is deactivated
Error cause Defective contactor K10
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 in-
tact.
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.
Codes
485, 487 6004330- 2013-03-04 244989-040
Code 108
Description Main contactor K10 does not close after key start
and emergency switch is deactivated
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 contac-
tor 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
Codes
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Code 111
Description Potentiometer R2 for brake pedal supplies incor-
rect voltage (<0.4 or >4.6 V)
Comments
Potentiometer R2, brake control

- 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 de-
pressed.
- 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 in-
tact, replace the potentiometer R2.
2. If input 505 receives the correct voltage and the error remains,
then replace the A5 electronic card.
Codes
485, 487 6004330- 2013-03-04 244989-040
Code 112
Description Error at test of brake input
Comments
Code 114 (VR only)

Description Too fast regenerative lowering of the forks.
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 er-
ror 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
1. Temporary interference may have affected the card.

Try to restart the truck.
Codes
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Code 121
Description Safety relay deactivated because of incorrect volt-
age at drive stage or communications error with
master processor

Codes
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Code 122
Description Warning temperature in steering servo
Error cause High ambient temperature
Steering binds
Defective wiring to steering motor
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.
Codes
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Code 123
Description Output voltage to steering motor does not corre-
spond to requested steering
Error cause Defective steering motor
Defective wiring to steering motor
Comments
Steering motor, M6

- Brushes and brush mounts. See the S1730 tab: "Electric steering
motor".
- Armature windings.
Codes
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Code 125
Description Steering generator error at test
Error cause Defective generator/carbon brushes
Defective wiring
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
Codes
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Code 126
Description Steering motor error at test
Error cause Fault F61 fuse
Defective steering motor/carbon brushes
Defective wiring
Comments
Steering motor, M6
1. Inspect fuse F61, 30 A, the cables 1 and 25 as well as terminal 901.

- Brushes and brush mounts. See MSM 1730.
Codes
485, 487 6004330- 2013-03-04 244989-040
Code 127
Description Communications error between steering processor
and master processor

Code 128
Description Memory cell for steering set point value contains
incorrect value

Code 130
Description Communications error between I/O processor and
master processor

Codes
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Code 131
Description Error at test of safety relay (steering) at start-up
Error cause Fault F61 fuse
Defective wiring to F61
Comments
Fuse F61, 30 A
1. Inspect fuse F61, 30 A.

2. Inspect the cables 1 and 25 as well as terminal 901.
Codes
485, 487 6004330- 2013-03-04 244989-040
Code 133
Description Error at test of safety relay (steering) at start-up
Comments

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 cause Electronics card A5 displaced/jarred
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.
electronic card.
Code 135
Comments

electronic card.
Code 136
Comments
Codes
244989-040 2013-03-04 6004330- 485, 487

electronic card.
Code 137
Description Safety relay (main circuit) has opened
Error cause Electronics card A5 displaced/jarred
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.
electronic card.
Codes
485, 487 6004330- 2013-03-04 244989-040
Code 140
Description Defective check-sum in parameter memory at
start-up
Download new program

- Try to restart the truck.
- Change a parameter and restart the truck.
- Download new firmware.
Code 141
Description Defective check-sum for applicable program
Error cause Defective download of program from PC
Comments Download new program via CAN
Change program memory

Download new firmware.
Codes
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Code 150
Description No communication with frequency inverter at start-
up
Error mode Drive regulator error and lift regulator error
15 (V)
Comments
CAN communication
1. Check to make sure the cables 117, 118, 119 and 120 are not short-
circuited 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.
Codes
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Code 151
Description No communication with drive motor’s frequency
inverter at start-up
Error mode Drive regulator error
Faulty frequency inverter
Comments
CAN communication between A5 and A1
circuited or interrupted. Also check the R101 resistor.
2. Try with a new A1 traction controller.
Codes
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Code 152
Description No communication with drive motor’s frequency
inverter during operation
Comments
2. Try with a new A1 traction controller.
Codes
485, 487 6004330- 2013-03-04 244989-040
Code 153
Description No communication with pump motor’s frequency
inverter at start-up
Error mode Lift regulator error
Comments
Codes
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Code 154
Description No communication with pump motor’s frequency
inverter during operation
Comments
Codes
485, 487 6004330- 2013-03-04 244989-040
Code 155 - 163

Comments
CAN communication
circuited or interrupted. Also check the R100 and R101 resistors.
2. Check whether the CAN bus has been correctly connected to all
other units.
electronic card.
Code 170 - 177

Description Wire guidance related fault
Codes
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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 cause Sensor S4 or S9 has received mechanical impact
Defective sensor S4 or S9
Defective wiring to S4 or S9
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.
Codes
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Code 203
Description CPU or memory error at drive motor’s frequency
inverter
Comments
1. Replace the A1 traction controller.
Code 205
Description Overheated drive motor
Error cause Motor overload
Defective thermoelectric sensor/wiring
Comments Restart possible
Temperature sensor B1 in the drive motor M1
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.
A1.
Codes
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Code 206 - 207

Description Overheated drive motor frequency inverter
Error cause Defective cooling fan
Defective motor
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 cause Motor cables incorrectly connected
Comments
Drive motor circuit
1. Check to make sure the motor cables are intact and correctly con-
nected.
2. Replace the A1 traction controller.
Codes
485, 487 6004330- 2013-03-04 244989-040
Code 209 - 210

Description Excessive voltage at drive motor frequency
inverter
Error cause Defective battery
Defective motor
Comments
1. Check whether the battery is intact, sufficiently charged and of the

correct type.
2. Check whether the travel motor is OK.
Codes
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Code 211 - 212

Description Voltage too low at drive motor’s frequency inverter
Error cause Defective wiring/fuse F62
External current load incorrectly connected
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 en-
gaged. 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.
Codes
485, 487 6004330- 2013-03-04 244989-040
Code 213 - 214

Description CAN error at drive motor’s frequency inverter
Comments
Code 223
Description CPU or memory error at pump motor’s frequency
inverter
Comments
Codes
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Code 225
Description Overheated pump motor
Error cause Motor overload
Defective thermoelectric sensor/wiring
Temperature sensor B2 in the pump motor
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.
A1.
Codes
485, 487 6004330- 2013-03-04 244989-040
Code 226 - 227

Description Overheated pump motor frequency inverter
Defective motor
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.
Codes
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Code 228
Description Excessive current at pump motor’s frequency
inverter
Error cause Motor cables incorrectly connected
Comments
Pump motor, M3
1. Check to make sure the motor cables 5, 6 and 7 are intact and cor-
rectly connected.
2. If the cabling is OK, replace A2.
Codes
485, 487 6004330- 2013-03-04 244989-040
Code 229 - 230

Description Excessive voltage at pump motor’s frequency
inverter
Poor contact at K10’s contact points
Comments
Battery circuit
1. Check whether the battery is intact, sufficiently charged and of the

correct type.
2. Inspect the K10 contactor tips.
Codes
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Code 231 - 232

Description Voltage too low at pump motor’s frequency inverter
Error cause Defective wiring/fuse F62
External current load incorrectly connected
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 en-
gaged. 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
Codes
485, 487 6004330- 2013-03-04 244989-040
Code 233 - 234

Description CAN error at pump motor’s frequency inverter
Comments
Codes
244989-040 2013-03-04 6004330- 485, 487
Codes
485, 487 6004330- 2013-03-04 244989-040
Electrical system – 5000.2
General
244989-040 2013-03-04 6004330- 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.

General
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VRE125SF
Main Display, Height pre- Height

contactor A6 selection, A7 indication, A8
RS 485
Brakes Motor
Aisle functions AC drive

freq. Inverter,
A1
Accelerate pedal
Brake pedal
Logic card A5
AC pump
freq. Inverter,
Joysticks A2
On/Off Lower Batt. Steering

valves Meas. Motor
Personal CAN-Bus
protection
Wire
guidance,
Valve traverse A3
Service key
Pulse counter Fork unit card
traverse A4
S D16
Shock sensor
Pinkods-login

General
244989-040 2013-03-04 6004330- 485, 487
VRE150
Main Display, Height pre- Height

contactor A6 selection, A7 indication, A8
RS 485
Brakes Motor
Aisle functions AC drive

freq. Inverter,
A1
Accelerate pedal
Brake pedal
Logic card A5
AC pump
freq. Inverter,
Joysticks A2
On/Off Lower Batt. Steering

valves Meas. Motor
Personal CAN-Bus
protection
Wire
Prop. Valve traverse guidance,
Prop. Valve rotation A3
Pulse counter
traverse Service key
Fork unit card
A4 S D16
Rotation pot. Shock sensor

Extra functions
Pinkods-login

Logic card, drive controller A1 and lift controller A2
485, 487 6004330- 2013-03-04 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.

244989-040 2013-03-04 6004330- 485, 487
18.2.2 Connection terminal and terminal

pillars
I = Input, O = Output
Conn. Cable Description Active Input/

A1/A2 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 I
8 -/16 CAN ID0 1: Open I
(Not connected when used 0: Sensor, -
as A1)
9 NC I
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

485, 487 6004330- 2013-03-04 244989-040

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 -35 - +55 oC
temperature
Current limit, down- 85 o
C 0 A at 125o C
regulated in case of
excess temperature of
cooling body
Current limit, down- -20 o
C 50% current limit at start-up
regulated in case of too
low temperature of
cooling body
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:
= 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.

Logic card, fork unit, A4
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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.

485, 487 6004330- 2013-03-04 244989-040
18.3.2 Connector plug

I = Input, O = Output

output
001 22 Voltage supply from battery +48 VDC I
002 NC +10 V O
003 NC 0-24 V O
004 95 Directional valve, traversing right +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 +15 V I
lift, phase 1
012 55 Pulse generator for height measurement free +15 V I
lift, phase 2
013 104 Height measurement for free lift, reference +15 V I
sensor
014 NC Spare (0-10 V or I
0-48 V)
016 NC 0-24 V O
017 94 Directional valve, traversing left +48 V O
018 NC +48 V O
019 NC +48 V O
020 150 Switch signal, for dual camera systems O
021 NC Spare (0-20 V) I
022 NC Spare I
023 NC Spare I
024 NC Spare I
025 NC Spare I

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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
030 NC Spare O
031 NC (0-24 V) O
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

485, 487 6004330- 2013-03-04 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.

Logic card, main card, A5
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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.

485, 487 6004330- 2013-03-04 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
Conn. Cable Description Active LED

(V)
101 NC Spare
102 NC Spare
103 NC Spare
104 45 Selection of direction of travel for fork direction +48 I
at creep speed
105 46 Selection of direction of travel for steering +48 I
wheel direction at creep speed
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

244989-040 2013-03-04 6004330- 485, 487
20X

(V)
201 22 Personal safety equipment, I
202 - Indication signal for lifting (See parameter +48 O
28)
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, +48 I
208 - Indication signal for truck travel (See +48 O
parameter 28)
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
30X

(V)
301 98 Height sensor, channel A 0 -(+)15 I
302 99 Height sensor, channel B 0 -(+)15 I
303 NC Spare I
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

485, 487 6004330- 2013-03-04 244989-040
40X

(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
50 V)
50X
Conn Cable Description Active LED

. (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 +0.77-3.7-6.6
point
505a 84 Potentiometer, fork rotation, set point +0.66-3.7-6.6
5061 85 Potentiometer, auto rotation/extra (1) +0.66-3.7-6.6

hydraulic function, set point
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, +0.66-3.7-6.6

set point
511 129 Steering tachometer (-) 0
a.Only used on the VRE150.

244989-040 2013-03-04 6004330- 485, 487
60X

(V)
601 70 Battery guard, voltage measurement (+) +48
602 71 Battery guard, voltage/current 0
measurement (-)
603 72 Battery guard, current measurement (+)
604 NC Spare
50 V)
70X

(V)
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 +0.5-48 O
only)

485, 487 6004330- 2013-03-04 244989-040
80X

(V)
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 0
807 24 Battery voltage, (+) 48 V after key +48 +48 V
KEY
808 23 Battery voltage, (+) 48 V after main contactor +48
809 22 Battery voltage, (+) 48 V after emergency stop +48 +48 V
ESO
810 29 Voltage meter feed sensor, (+) 15 V +15
811 30 Minus feed sensor 0
90X

(V)
901 25 Battery voltage, (+) 48 V +48
902 40 Battery voltage, minus 0
903 60 Steering motor, (+) +48
904 61 Steering motor, (-) +48

244989-040 2013-03-04 6004330- 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)

Electric system, overview
485, 487 6004330- 2013-03-04 244989-040
18.5 Electric system, overview

VRE125SF
1 8
G1 48V SHUNT WIRE

1 X1 X1 40
+ -
22
MEASURING WIRES F63 26 26 S99 191 192
1 1
E4 E3
40 40
2 2
X42 X42
MAIN CONTACTOR K10 EXTERNAL EQUIPMENT
40 LIFT HEIGHT INDICATOR A8
F62 3 +48VDC RX+ 5 5 RX+ +48VDC 3

1 ID RX- 2 2 RX- OV 4
8
4 OV
LENGTH INDICATOR A9 126 125 PRE SELECTION HEIGHT UNIT A7
23
31
70
71
72
7 RX+ 0V 6
22 ELECTRONIC CARD
INP BATT IND - CURRENT (-) 602

INP BATT IND + 601
INP BATT IND CURRENT (+) 603

INP MAIN CONTACTOR 808
804
3 RX- +48VDC 4
A5
1 TX+
OUT MAIN CONTACTOR

5 TX-
F60
21
805 + 48VDC
ELECTRONIC CARD 24 127
A16 807 INP KEY RX+ HEIGHT UNIT 409
S23 43 128
110 INP LEFT FOOT SWITCH RX- HEIGHT UNIT 410
21 X3:2 S17 S21
24 22 121
21 X3:1 809 INP +48VDC SUPPLY OUTPUTS SERIE + 405 1 SERIE +
S26 45 122
104 INP DRIVE FORK DIR CREEP SERIE - 406 2 SERIE -
46 RS 485 125
105 INP STEER WHEEL DIR CREEP TX + 407 3 RX +
40 S89 126
X3:7 GND 49
1 40 22 203 INP SEAT SWITCH TX - 408 4 RX -
119 27
X3:4 CAN H
507 POT FEED 7-7,5VDC DISPLAY A6
120 X3:3 CAN L 50
R1 501 SPEED REFERENCE VALUE
27 28 28
508 POT GND
29
X3:5 OPERATION MODE PIN 1 810 +15VDC
X3:9 OPERATION MODE PIN 2 30
811 GND
S66
58
210 INP STEER WHEEL ANGLE A
C4
59
211 INP STEER WHEEL ANGLE B 117
47 nF S65 OUT CAN +15VDC 401
57 118
209 INP STEER WHEEL REF 180 DEG
OUT CAN GND 402
119
806 OUT/INP CAN H 403 120
40 OUT/INP CAN L 404
902 GND
F61
25
901 +48VDC STEER SERVO
M6
60
903 OUT + STEER MOTOR
61
904 GND FOR STEER MOTOR
U1
62 98 U10 29
509 INP STEERING WHEEL TACHO + INP HEIGHT COUNTER > FREELIFT PULSE A 301
129 99 30
511 GND FOR TACHO INP HEIGHT COUNTER > FREELIFT PULSE B 302
S131
Y1
64
802 OUT PARKING BRAKE
51
R2 502 INP BRAKE REFERENCE VALUE
Y5:1 66
63 INP WIRE GUIDANCE OFF 304
801 OUT SUPPORT ARM BRAKE 1
30
29 30 40 22 27 28 Y6:1 Y5:2
68 803 OUT SUPPORT ARM BRAKE 2 29
Y6:2 WITHOUT WIRE GUIDANCE
82 22
R6 503 INP JOYSTICK FORK
S120
83 40
R4 504 INP JOYSTICK TRAVERSE
160
201 INP PERSONAL PROTECTION 1
202 OUT DATA COLLECT LIFT

OUT FORKS IN HOME POSITION (L, R OR MIDDLE)
208 OUT DATA COLLECT DRIVE

161
OUT LENGTH INDICATION LAMP (IN AISLE)
S61 81
204 INP WEIGHT
OUT HALF PALLET HANDLING IND LAMP
S33 100
205 INP OVERRIDE
INP HALF PALLET HANDLING MODE
162
206 INP SPEED REDUCTION
M12
107
OUT WARNING LAMP MOTION
307 OUT POWER FAN ELECTRIC PANEL

OUT FORK SELECT MOVE
OUT IN AISLE IND LAMP
S18 54
INP IN AISLE SIGNAL1
INP IN AISLE MIDDLE
OUT TRAVEL ALARM
OUT CABIN LOWER

OUT FORK LOWER
OUT CABIN LIFT

OUT FORK LIFT
H1
E10
M10
702
701
703
106
107
305
306
705
706
708
707
709
710
711
111
91
88
89
90
41
42
44
92
32
33
37
38
108
101
Y21
102
R34
H2
R32
R30
Y10
Y24
S6
S8
S4
H3
S90
Y20
R31
S5
S7
S9
S156
S178
H96
Y11
H95
H18
30 30
29 29
22 22
40 40

244989-040 2013-03-04 6004330- 485, 487
20
40 22
ELECTRONIC CARD TURRET HEAD A4
U9
55
012 INP HEIGHT COUNTER < FREELIFT PULSE A
40 56
011 INP HEIGHT COUNTER < FREELIFT PULSE B
22
001 INP +48VDC SUPPLY
Y8
40 94
029 GND OUT TRAVERSE LEFT 017
Y9
20 95
028 OUT +15VDC SUPPLY OUT TRAVERSE RIGHT 004
041 INP STEER SAFETY
RELAY
20 150
OUT SWITCH SIGNAL 020
40
015 GND
U13 20
52 INP. 15 VDC 030
009 INP TRAVERSE COUNTER PULSE A
53
008 INP TRAVERSE COUNTER PULSE B
20 22 40 8
103
010 INP FORKS HOME POS INDICATOR
S50
S93
120 104
042 OUT/INP CAN L INP HEIGHT REFERENCE 013
R109
119
027 OUT/INP CAN H
SERVICE KEY INTERFACE X41

117
1
118
2
119 FREQUENCY INVERTER PUMP A2
3
120 PUMP MOTOR
4 5 300A F3 8
M3 U U B+
R100
40
V 6 B-
V
ID 8
W 7
W 19
117 7
12 B2
118 16
4
13
119 15
10 3
120 U12
11
5
17
6
18
1 22
FREQUENCY INVERTER DRIVE A1

119
120
DRIVE MOTOR
2 160A F1 8
M1 U U B+
OUT/INP CAN L JP4:5
OUT/INP CAN H JP4:6
V 3 B-
40
WIRE GUIDANCE V
A3 JP3:1 4
W W
WITHOUT WIRE GUIDANCE 7
14
JP3:2 117
12 B1
22 118 11
JP3:4 13
4
S120 119 3
10
10 U11
40 R35 67 120 12 22 40
JP2:3 OUT ON WIRE 11
5
131 22
JP1:12 GND INP +48VDC SUPPLY JP2:11 6
13
130 40
JP1:21 OUT +5VDC GND JP2:24 1 22
132 111
JP1:7 INP ENCODER PULSE A OUT +12VDC JP2:21
112 S85 22
133 JP1:8 INP ENCODER PULSE B INP STEER WHEEL IN HOME POS JP2:9
113 40
U15
GND JP2:23
JPW1:2 INP NEAR WIRE COIL

JPW1:1 INP RIGHT COIL

JPW1:3 INP LEFT COIL

JPW1:15 OUT +12VDC
JPW2:15 OUT +12VDC

JPW1:13 SHIELD
JPW2:13 SHIELD
JPW1:5 OUT T0
JPW2:5 OUT T0
JPW1:6 OUT T1
JPW1:7 OUT T2
JPW1:8 OUT T3
JPW2:6 OUT T1
JPW2:7 OUT T2
JPW2:8 OUT T3
JPW1:14 GND
JPW2:14 GND
ORANGE
ORANGE
YELLOW
YELLOW
BROWN
BROWN
GREEN
VIOLET
GREEN
VIOLET
BLACK
BLACK
GREY
GREY
BLUE
BLUE
RED
RED
J1L:1
J1T:1
J1L:14
J1L:2
J1L:15
J1L:13
J1T:2
J1T:14
J1T:15
J1L:3
J1L:5
J1L:6
J1L:7
J1L:8
J1T:3
J1T:5
J1T:6
J1T:7
J1T:8
J1T:3
ANTENNA 1 ANTENNA 2
W1 W2

485, 487 6004330- 2013-03-04 244989-040
VRE150
1 8
G1 48V SHUNT WIRE

1 X1 X1 40
+ -
22
MEASURING WIRES F63 26 26 S99 191 192
1 1
E4 E3
40 40
2 2
X42 X42
MAIN CONTACTOR K10 EXTERNAL EQUIPMENT
40 LIFT HEIGHT INDICATOR A8
F62 3 +48VDC RX+ 5 5 RX+ +48VDC 3

1 ID RX- 2 2 RX- OV 4
8
4 OV
LENGTH INDICATOR A9 126 125 PRE SELECTION HEIGHT UNIT A7
23
31
70
71
72
7 RX+ 0V 6
INP BATT IND - CURRENT (-) 602

INP BATT IND + 601
INP BATT IND CURRENT (+) 603

ELECTRONIC CARD
INP MAIN CONTACTOR 808

804
3 RX- +48VDC 4
A5
1 TX+
OUT MAIN CONTACTOR

5 TX-
F60
805 + 48VDC
ELECTRONIC CARD 24 127
807 INP KEY RX+ HEIGHT UNIT 409
A16 S23 43 128
110 INP LEFT FOOT SWITCH RX- HEIGHT UNIT 410
21 X3:2 S17 S21 121
24 22
21 X3:1 809 INP +48VDC SUPPLY OUTPUTS SERIE + 405 1 SERIE +
S26 45 122
104 INP DRIVE FORK DIR CREEP SERIE - 406 2 SERIE -
46 RS 485 125
105 INP STEER WHEEL DIR CREEP TX + 407 3 RX +
40 S89 49 126
X3:7 GND 1 40 22 203 INP SEAT SWITCH TX - 408 4 RX -
1
119 27
X3:4 CAN H 507 POT FEED 7-7,5VDC DISPLAY A6
50
120 X3:3 CAN L R1 501 SPEED REFERENCE VALUE
27 28 28
508 POT GND
29
810 +15VDC
X3:5 OPERATION MODE PIN 1
30
811 GND
S66
58
210 INP STEER WHEEL ANGLE A
C4
59
211 INP STEER WHEEL ANGLE B 117
47 nF S65 OUT CAN +15VDC 401
57 118
209 INP STEER WHEEL REF 180 DEG
OUT CAN GND 402 119
806 OUT/INP CAN H 403 120
40 OUT/INP CAN L 404
902 GND
F61
25
901 +48VDC STEER SERVO
M6
60
903 OUT + STEER MOTOR
61
904 GND FOR STEER MOTOR
U1
62 98 U10 29
509 INP STEERING WHEEL TACHO + INP HEIGHT COUNTER > FREELIFT PULSE A 301
129 99 30
511 GND FOR TACHO INP HEIGHT COUNTER > FREELIFT PULSE B 302
S131
Y1
64
802 OUT PARKING BRAKE
51
R2 502 INP BRAKE REFERENCE VALUE
Y5:1 66
63 801 OUT SUPPORT ARM BRAKE 1 INP WIRE GUIDANCE OFF 304
30
29 30 40 22 27 28 Y6:1 Y5:2
68 803 OUT SUPPORT ARM BRAKE 2 29
Y6:2 WITHOUT WIRE GUIDANCE
82 22
R6 503 INP JOYSTICK FORK
S120
83 40
R4 504 INP JOYSTICK TRAVERSE
84
R5 505 INP JOYSTICK ROTATE
85
R14 506 INP JOYSTICK SPARE1/ AUTO ROTATE
R15
86 510 INP JOYSTICK SPARE2
160
202 OUT DATA COLLECT LIFT
OUT FORKS IN HOME POSITION (L, R OR MIDDLE)
208 OUT DATA COLLECT DRIVE

OUT LENGTH INDICATION LAMP (IN AISLE)
S61 81
204 INP WEIGHT
OUT HALF PALLET HANDLING IND LAMP
S33 100
205 INP OVERRIDE
INP HALF PALLET HANDLING MODE
206 INP SPEED REDUCTION

M12
107
OUT WARNING LAMP MOTION
307 OUT POWER FAN ELECTRIC PANEL

OUT FORK SELECT MOVE
OUT IN AISLE IND LAMP
S18 54
INP IN AISLE MIDDLE
OUT TRAVEL ALARM
OUT CABIN LOWER

OUT FORK LOWER
OUT CABIN LIFT

OUT FORK LIFT
H1
E10
M10
702
701
703
106
107
305
306
705
706
708
707
709
710
711
111
91
108
101
102
88
89
90
41
42
44
92
32
33
37
38
Y21
R34
H2
R32
R30
Y10
Y24
S6
S8
S4
H3
S90
Y20
R31
S5
S7
S9
S156
S178
H96
Y11
H95
H18
30 30
29 29
22 22
40 40

244989-040 2013-03-04 6004330- 485, 487
20
40 22
ELECTRONIC CARD TURRET HEAD A4
U9
55
012 INP HEIGHT COUNTER < FREELIFT PULSE A
40 56
011 INP HEIGHT COUNTER < FREELIFT PULSE B
Y25
22 93
001 INP +48VDC SUPPLY OUT PROPORTIONAL VALVE TRAVERSE 016
Y8
40 94
029 GND OUT TRAVERSE LEFT 017
Y9
20 95
028 OUT +15VDC SUPPLY OUT TRAVERSE RIGHT 004
Y26
73
041 INP STEER SAFETY OUT PROPORTIONAL VALVE ROTATE 003
Y27
RELAY 74
20 OUT ROTATE COUNTER CLOCKWISE 006
Y28
40 75
015 GND OUT ROTATE CLOCKWISE 005
U13
52
009 INP TRAVERSE COUNTER PULSE A
53
008 INP TRAVERSE COUNTER PULSE B
20 22 40 8
103
010 INP FORKS HOME POS INDICATOR
S50
Y16
76
OUT SPARE 1A 018
Y17
77
OUT SPARE 1B 019
S93
120 104
042 OUT/INP CAN L INP HEIGHT REFERENCE 013
R109
119 39
027 OUT/INP CAN H OUT POT FEED +10VDC 002
65 R8
INP ROTATION ANGLE 007
SERVICE KEY INTERFACE X41

117
1
118
2
119 FREQUENCY INVERTER PUMP A2
3
120 PUMP MOTOR
4 5 300A F3 8
M3 U U B+
R100
40
V 6 B-
V
ID 8
W 7
W 19
117 7
12 B2
118 16
4
13
119 15
10 3
120 U12
11 5
17
6
18
1 22
FREQUENCY INVERTER DRIVE A1

119
120
DRIVE MOTOR
2 160A F1 8
M1 U U B+
OUT/INP CAN L JP4:5
OUT/INP CAN H JP4:6
V 3 B-
40
WIRE GUIDANCE V
A3 JP3:1 4
W W
WITHOUT WIRE GUIDANCE 7
14
JP3:2 117
12 B1
22 118 11
JP3:4 13
4
S120 119 3
10
10 U11
40 R35 67 120 12 22 40
JP2:3 OUT ON WIRE 11
5
131 22
JP1:12 GND INP +48VDC SUPPLY JP2:11 6
13
130 40
JP1:21 OUT +5VDC GND JP2:24 1 22
132 111
JP1:7 INP ENCODER PULSE A OUT +12VDC JP2:21
112 S85 22
133 JP1:8 INP ENCODER PULSE B INP STEER WHEEL IN HOME POS JP2:9
113 40
U15
GND JP2:23



JPW1:15 OUT +12VDC
JPW2:15 OUT +12VDC

JPW1:13 SHIELD
JPW2:13 SHIELD
JPW1:5 OUT T0
JPW2:5 OUT T0
JPW1:6 OUT T1
JPW1:7 OUT T2
JPW1:8 OUT T3
JPW2:6 OUT T1
JPW2:7 OUT T2
JPW2:8 OUT T3
JPW1:14 GND
JPW2:14 GND
ORANGE
ORANGE
YELLOW
YELLOW
BROWN
BROWN
GREEN
VIOLET
GREEN
VIOLET
BLACK
BLACK
GREY
GREY
BLUE
BLUE
RED
RED
J1L:1
J1T:1
J1L:2
J1L:14
J1L:15
J1L:13
J1T:14
J1L:3
J1L:6
J1L:7
J1L:8
J1T:2
J1T:3
J1T:6
J1T:7
J1T:8
J1T:15
J1T:3
J1L:5
J1T:5
ANTENNA 1 ANTENNA 2
W1 W2

Symbol list and wiring diagrams
485, 487 6004330- 2013-03-04 244989-040
18.6 Symbol list and wiring diagrams
18.6.1 List of symbols

Battery
Brake coil, Brake coil,

normally released normally applied
Switch Switch
Push-button switch, Push-button switch,

Momentary switch, Momentary switch,

Push-button switch, Emergency switch off

latching,
normally open
Key switch Push-button switch,

normally open latching and
momentary
Electro-magnetic switch, Electro-magnetic switch,


244989-040 2013-03-04 6004330- 485, 487

Pressure-sensitive switch, Pressure-sensitive
normally open switch,
normally closed
Capacitive switch, Capacitive switch,

Inductive sensor, Inductive sensor,

Pulse transducer
Seat heater Temperature sensor

with thermostat
Motor, Series motor,

general armature coils,
DC
Series motor, Motor,

DC permanent magnet
Three-phase motor,
AC
Series winding Shunt winding
Converter, AC/DC Converter, DC/DC

485, 487 6004330- 2013-03-04 244989-040

Variable resistor Fixed resistor
(potentiometer)
Contactor Horn
Lamp Valve
Fuse Diode
Zener diode Light emitting diode

(LED)
Connector Multi-pin connect
Capacitor Measuring cable

244989-040
Order number
© BT Europe AB
1 + - 40
Sh. 3 Sh. 2
Date
ELECTRONIC CARD
2013-03-04
MEASURING WIRES A5
72
71
Service Manual
6004330-
70
MAIN CONTACTOR
K10
40 A1 A2 31
10A
F62
2 1 23
8
Sh. 2
T-code
485, 487

18.6.2 Electric wiring diagrams VRE125SF
249735
1/25
18- 25
18- 26
T-code
485, 487
A1
160A
F1
8
Sh. 1 7 B + +
2
U DRIVE MOTOR
40 M1
Sh. 1 3 B- - U
V
14
7
W M
3~A
B1 4
W
11
4
ELECTRONIC CARD
6004330-
10 A5
3
U11 117
Service Manual
105 Red Bl 12
5
B
+
118
13 402 OUT. CAN GND
Bk Wh 13
6
A
-
119
X30
22 120
Sh. 3 1 11 404 INP./OUT. CAN L
Date

X41
X45 X31
1 117
2013-03-04
X45 X31
2 118/BLUE 117
Sh. 7
X45 X31
3 119/RED 118/BLUE
Sh. 7
X45 X31
4 120/WHITE 119/RED
Sh. 3
R100 120/WHITE
Sh. 3
244989-040
Order number
249735

2/25
244989-040
Order number
© BT Europe AB
Date
2013-03-04
ELECTRONIC CARD
A5
10A
F60
1 21
Sh. 1 5 805 + 48VDC
X30
Service Manual
24
6004330-
807 INP. KEY

ELECTRONIC CARD
A16
S23
1 3 43
21 EMERGENCY SWITCH OFF
X3:2 +48VDC SUPPLY
S21 X30
21 24 1 2 22
X3:1 X3:6 809 + 48VDC SUPPLY OUTPUTS
X32
40 45
X3:7 GND 104 INP. DRIVE, FORK DIRECTION, CREEP
S26
X32
119 3
X3:4 CAN H X32
2 46
105 INP. DRIVE, STEER WHEEL DIRECTION, CREEP
120 1
X3:3 CAN L
X25 S89 X25
1 3 49
X3:5 OPERATION MODE PIN1
T-code
X3:9
485, 487
OPERATION MODE PIN 2

249735
3/25
22
Sh. 2 4
18- 27
18- 28
T-code
485, 487
ELECTRONIC CARD
A5
27 27
6004330-
1
50
Service Manual
2
28 28
Sh. 6 508 POT. GND
M12
Bl - +R 107

Date
X32 S18 X32

54 3 4
2013-03-04
X30
IN
22 40
Sh. 3 5 + - Sh. 3 5
HORN
H1
SEAT HEATER
X25 E10 X25
244989-040
Order number
FAN PUMPMOTOR
X35 M10 X35
M 249735
4/25

244989-040
Order number
© BT Europe AB
ELECTRONIC CARD
A5
29 29
Sh. 11 810 + 15VDC
Date
30 30
Sh. 11 811 GND
S66
2013-03-04
Br Bk 58
Wh
Bl
C4 59
S65
X30
Service Manual
6004330-
22 Br Bk 57
Sh. 4 6 209 INP. STEER WHEEL REFERENCE 180 DEG.
Bl
806
40 40
Sh. 4 6 902 GND
30A
F61
1 25
M6
Bk Red 60
61
T-code
485, 487
U1 X32
Bk Red 62

X34
129
511 GND, TACHO
249735
5/25
18- 29
18- 30
T-code
485, 487
EMERGENCY MODE
X30 S131
22 1 2
A5
Y1
40 64
DISPLAY
A6
X46
121
X46
122
RS 485
X46
125
RX + 3 407 TX+
6004330-
X46
126
RX - 4 408 TX-
Service Manual
27
Sh. 4 8
1
51
3
2
28
Sh. 4 8
LEFT ARM, INNER
Y5:1
RIGHT ARM, INNER

Date
Y5:2 X38
63
X38
2013-03-04
LEFT ARM, OUTER

Y6:1 X38
68
RIGHT ARM, OUTER
Y6:2
126
Sh. 10
244989-040
125
Sh. 10
Order number
249735
6/25

244989-040
Order number
© BT Europe AB
Date

A2
2013-03-04
300A
F3
8 5
M3
U
40 6 V M
Sh. 6 8 B- - V
W M
3~A
Service Manual
6004330-
7
8 ID W

19
7
B2
16 117
4 12 Sh. 2
15 118/BLUE
3 13 Sh. 2
U12
155 Red Bl 17 119/RED
5 10 Sh. 3 12
B
+
Bk Wh 18 120/WHITE
6 11 Sh. 3 12
T-code
A
-
485, 487

X30
22
Sh. 6 8 1
249735
7/25
18- 31
18- 32
T-code
ELECTRONIC CARD
X32 485, 487
27 A5
Sh. 6
1
X33
82
3
X32
28
Sh. 6
1
X33
83
3

6004330-
Service Manual
22
22
NOT ON COLD STORECABIN NOT ON COLD STORECABIN (WHEN USED, SEE PAGE 21)
X30
X45 S61 X75 X31
22 5 1 81
X30 X32 S33 X33

5 1 100
205 INP. OVERRIDE
Date
ELECTRONIC CARD
2013-03-04
A4
X14 X16 X49 Y8

40 94
Sh. 7 9 017 OUT. TRAVERSE LEFT
Y9
95
244989-040
Order number
249735
8/25

244989-040
Order number
© BT Europe AB
ELECTRONIC CARD
A5
X47 Y10 X47

40 88
Date
X47 Y11 X47

89
701 OUT. FORK LIFT
2013-03-04
X47 Y24 X47

90
FORK DIRECTION 1
X30 X14 S5 X15
22 Br Bl 41
S6
Service Manual
Br Bl
6004330-
STEER WHEEL DIR. RIGHT

S156
Br Bk
Bl
FORK DIRECTION 2
X14 S7 X15
Br Bl 42
S8
Br Bl
FORK DIR. LEFT
S178
X69 X69
Br Bk
X69
T-code
Bl
485, 487
FORK DIRECTION
X14 S9 X15

Br Bl 44
S4
Br Bl
249735
9/25
18- 33
18- 34
T-code
485, 487
ELECTRONIC CARD
A5
X45 S90 X45 X31

22 1 5 91
680ohm/2W
X31 X45 H90 R34 X45 X31
40 10 9 920 92
NOT ON COLDSTORE CABIN NOT
680ohm/2W ON COLDSTORE CABIN
X31 X45 H95 R30 X75 X30
- + 320 32
680ohm/2W
X31 X45 H18 R31 X75 X30
- + 330 33
6004330-
X31 X36 H2 X36 X30

- + 37
H3
Service Manual
X31 X37 X37 X31
- + 38
47ohm/50W
H96 R32
- + 109 108
X23 Y20 X23

101
710 OUT. CABIN LIFT
X23 Y21 X23

102
Date
LENGTH INDICATOR
A9
X45 X45 X46
125
3 +48V RX+ 5 Sh. 6 11
2013-03-04
1 ID
X31 X45 X45 X46
126
4 0V RX- 2 Sh. 6 11
EXTERNAL EQUIPMENT
WORKING LIGHT
10A X42 X42
F63 X30 S99 E4 E3
1 26 1 1 26 1 5 191 192
Sh. 5 13
244989-040
X31
40 2 2 40
Order number
249735

10/25
244989-040

Order number
A8
© BT Europe AB
X45 X45 X46
22 125
Sh. 10 12 3 +48V RX+ 5 Sh. 10
X45 X46
126
4 0V RX- 2 Sh. 10
X30 X45
Date

X31 A7
X32 X34
40
6 0V RX+ 7
2013-03-04
Sh. 10 12
X32 X34
ELECTRONIC CARD
4 +48V RX- 3
A5
X34
127
Service Manual
X34
6004330-
128
U10
X15 X17 X17 X15
29 Red Wh 98
Sh. 5 301 INP. HEIGHT COUNTER > FREELIFT PULSE A
A
+
X15 X17 X17 X15
30 Bk Bl 99
302 INP. HEIGHT COUNTER > FREELIFT PULSE B
Sh. 5 B
-
A4
U9
20 Red Wh 55
Sh. 12 012 INP. HEIGHT COUNTER < FREELIFT PULSE A
A
+
X14 X16 X49
Bk Bl 56
T-code
011 INP. HEIGHT COUNTER < FREELIFT PULSE B

485, 487
B
-
S93
104

Br Bl
249735
11/25
18- 35
18- 36
T-code
485, 487

A4
X30 X14 X16 X49

22 22
6004330-
X14 X16 X49

40 40
Sh. 11 13 029 GND
Service Manual
015 GND
X15 X16 X49

119/RED 119
R109 120ohm / 1W
X15 X16 X49
120/WHITE 120
20 20
Sh. 11 18 028 OUT. + 15VDC SUPPLY
Date

2013-03-04
U13
Red Bl 52
A
+
Bk Wh 53
B
-
S50
Br Bk 103
244989-040
Bl
Order number
249735
12/25

244989-040

1
Sh. 10 22
Order number
© BT Europe AB
30A
30A
30A
Date
X44 X57 5A
(Red)
2013-03-04

(Wh) (Ye) 2 4
X45 S97
22 1 5 157
Sh. 12 14
Service Manual
6004330-
15 18 750W
E1
(Bk)
TIMER
S70 A1
(Bl) Y1
E2
750W
A2
(Gn)
X31 X45
(Or)
750W
(Gn)
T-code
485, 487
(Ye) 750W

0/1/2/3
FAN M
40
Sh. 12 14
249735
13/25
18- 37
18- 38
T-code
485, 487
OPTION
WIRE GUIDANCE, PAGE 14 TO 17. WIRE GUIDANCE
A3
X30 X48
22 22
6004330-
X48
40 40
Sh. 13 18 JP2:24 GND
Service Manual
111
JP2:21 OUT. + 12VDC
S85
Br Bk 112
Bl
113
JP2:23 GND
X48
119/RED 119
Sh. 12 25 JP4:6 INP./OUT. CAN H
Date
X48
120/WHITE 120
Sh. 12 25 JP4:5 INP./OUT. CAN L
2013-03-04
JP3:1
JP3:2
JP3:4
244989-040
Order number
249735
14/25

244989-040
Order number
© BT Europe AB
Date
OPTION
WIRE GUIDANCE, PAGE 14 TO 17.
2013-03-04
WIRE GUIDANCE
A3
131
JP1:12 GND
130
JP1:21 OUT. + 5VDC
Service Manual
6004330-
ENCODER
U15
Br Gr 132
A
+
Wh Ye 133
B
-
680 ohm/2W
X30 X32 H120 R35 X32 X48
22 10 9 670 67
ELECTRONIC CARD
T-code
A5
485, 487
X32 S120 X32

5 7 66

VRSF WITHOUT WIRE GUIDANCE
249735
15/25
18- 39
18- 40
T-code
485, 487
OPTION
W1 A3
BLACK
BROWN
6004330-
RED
Service Manual
ORANGE
YELLOW
GREEN
Date
BLUE
2013-03-04
VIOLET
J1L:14 JPW1:14 GND
GREY

244989-040
Order number
249735
16/25

244989-040
Order number
© BT Europe AB
OPTION
Date
W2 A3
BLACK
J1T:1
2013-03-04
JPW2:1 INP. RIGHT COIL
BROWN
RED
Service Manual
6004330-
ORANGE
YELLOW
GREEN
BLUE
VIOLET
J1T:14 JPW2:14
GND
T-code
485, 487
GREY

2497354
17/25
18- 41
18- 42
T-code
485, 487
CAMERA SELECTOR
OPTION ELECTRONIC CARD, TURRET UNIT
A54 CAMERA ON FORKS, BT-BRAND EXCLUDING COLDSTORE CABIN A4
PAGE 18 AND 20.
150 150
SET
40 20
PAGE 19 X49
PAGE 19 X16
6004330-
PAGE 19 X14
TV-MONITOR
A49
X61 X60 X151 X55
Service Manual
210 110 110
X61 X60 X151 X55

114 114 114
OUT
X61 X60 X151 X55
115 115 115
GND OUT:3 B:2 GND
X61 X60 X151 X55

256 156 156
Date
20
Sh. 12 19
2013-03-04
40 WHEN STEREO/CD
Sh. 14 19
X52
115
Sh. 23
244989-040
X52
Order number
114
Sh. 23
249735

18/25
OPTION
244989-040

A54 CAMERA ON FORKS, COLDSTORE CABIN AND TOYOTA BRAND. A4
Order number
© BT Europe AB
CAMERA ON FORKS, PAGE 19 AND 20.
150 150
SET
40 20
Date
PAGE 19 X49
2013-03-04
PAGE 19 X16
PAGE 19 X14 TV-MONITOR

R49
A50
X61 X60 120ohm/0,6W X:A50

210 210
X61 X60 X:A50
Service Manual
114 114
6004330-
OUT
X61 X60 X:A50
115 115
GND OUT:3 B:2 GND
X61 X60 X:A50

256 256
20 VOLTAGE CONVERTER
Sh. 18 A14
X30
22 22
Sh. 15 21 + INP. + 48VDC
X30
40 40
T-code
485, 487
115
- OUT. GND

114
+ OUT. + 12VDC
249735
19/25
18- 43
18- 44
T-code
485, 487
OPTION
CAMERAS ON FORKS
CAMERA ON FORKS, LEFT CAMERA SELECTOR
A51 A54
310 310
6004330-
114 114
+ 12VDC 102 IN1:2 + 12VDC
Service Manual
IN 1
115 115
GND 103 IN1:3 GND
256 256
PAGE 18
PAGE 18
VIDEO SIGNAL PAGE 18
CAMERA ON FORKS, RIGHT
A52
Date
410 410
2013-03-04
114 114
+ 12VDC 102 IN2:2 + 12VDC
IN 2
115 115
GND 103 IN2:3 GND
PAGE 18
256 256
244989-040
Order number
249735
20/25

244989-040
Order number
© BT Europe AB
OPTION
Date
ELECTRONIC CARD
A5
X30
2013-03-04
33 33
OVERRIDE EMERGENCY MODE / OVERRIDE LIFT HEIGHT
X33
S33 100
22 1
Sh. 19 23
3
7
Service Manual
6004330-
X33
165 2
Sh. 22
4
8
X34
166
Sh. 22

TBM GM-107ECO
X150
163

T-code
X150
485, 487
164

X150
40
Sh. 19 22
249735
21/25
18- 45
18- 46
T-code
485, 487

PERSONAL PROTECTION SYSTEM, PAGE 21 AND 22. GM-107ECO
7,5A 8A
F64 X150 F
1 9
X150
40
X150
ELECTRONIC CARD
A5
X150
160
6004330-
X150
Service Manual
X150
161
X150
X150
162
Date
X150
33
2013-03-04
X150
165
Sh. 21 X1:12 OUT. +24VDC
X150
166
244989-040
Order number
249735
22/25

DC/DC CONVERTER
OPTION A10
X44 STEREO/CD
22 22
Sh. 21 24 6 INP. +48V
X44
244989-040
40 40
Order number
© BT Europe AB
114 114
Sh. 18 4 OUT. +12V
115 115
Date
X51
340
2 OUT. GND (GALV SEPARATED)
2013-03-04
X51
312
1 OUT. +12V
STEREO/CD
A11
Service Manual
6004330-
312
A:7 INP. +12VDC
312
A:4 INP. +12V KEY
340
A:8 INP.GND
H4 X56
LEFT +
B:5 OUT. LEFT (+)
X56
LEFT -
B:6 OUT. LEFT (-)
H5 X56
T-code
RIGHT +
485, 487
B:3 OUT. RIGHT (+)
X56

RIGHT -
B:4 OUT. RIGHT (-)
W5
249735
23/25
18- 47
OPTION DC/DC CONVERTER
18- 48
A10 T-code
STEREO/CD ON COLDSTORE CABIN
X:A9 485, 487
22 22
Sh. 23 25 + INP. +48V
X:A9
40 40
340
- OUT. GND
312
+ OUT. +12V
6004330-
STEREO/CD
A11
Service Manual
312
A:7 INP. +12V
312
A:4 INP. KEY +12V
340
A:8 INP. GND
H4
B:5 OUT. LEFT (+)
Date
B:6 OUT. LEFT (-)

2013-03-04
H5
B:3 OUT. RIGHT (+)
B:4 OUT. (-)
W5
244989-040
Order number
249735

24/25
OPTION
244989-040
TRUCK LOG SYSTEM

TRUCK LOG SYSTEM, CONTROL UNIT
Order number
A20
© BT Europe AB
21
1 INP. +48VDC
40
2 INP. GND
Date
RED
3 INP. CAN H
2013-03-04
WHITE
4 INP. CAN L
W7
Service Manual
6004330-
TRUCK LOG SYSTEM, SHOCK SENSOR

A23
22
1 INP. +48VDC (LOGGED IN)
40
2 INP. GND
RED
3 INP. CAN H
WHITE
4 INP. CAN L
T-code
485, 487
ELECTRONIC CARD, KEYPAD

A16

40
249735
25/25
18- 49
18- 50
T-code
485, 487
1 + - 40
Sh. 3 Sh. 2
ELECTRONIC CARD
MEASURING WIRES A5
72
71
6004330-
70
Service Manual
MAIN CONTACTOR
K10
40 A1 A2 31
10A
F62
2 1 23
8
Sh. 2
Date
2013-03-04
244989-040
18.6.3 Electric wiring diagrams VRE150

Order number
246883

1/22
A1
244989-040
160A
Order number
F1
© BT Europe AB
8
Sh. 1 7 B + +
2
U DRIVE MOTOR
40 M1
Sh. 1 3 B- - U
V
Date
14
7
W M
3~A
B1
4
W
2013-03-04
11
4
ELECTRONIC CARD
10 A5
3
U11 117
Red Bl 12
5
B
+
Service Manual
6004330-
118/BLUE
13 402 OUT. CAN GND
Bk Wh 13
6
A
-
119/RED
X30
22 120/WHITE
Sh. 3 1 11 404 INP./OUT. CAN L

X41
X45 X31
1 117
X45 X31
2 BLUE 117
Sh. 7
X45 X31
3 RED 118/BLUE
Sh. 7
T-code
X45 X31
485, 487
4 WHITE 119/RED
Sh. 3
R100 120/WHITE
Sh. 3

246883
2/22
18- 51
18- 52
T-code
485, 487
ELECTRONIC CARD
A5
10A
F60
6004330-
1 21
Sh. 1 5 805 + 48VDC
X30
Service Manual
ELECTRONIC CARD 24
807 INP. KEY
A16
X30
S23
21 1 3 43
X3:2 +48VDC SUPPLY 110 INP. LEFT FOOT SWITCH
EMERGENCY SWITCH OFF
S21 X30
21 24 1 2 22
X3:1 X3:6 809 + 48VDC SUPPLY OUTPUTS
X32
40 45
X3:7 GND 104 INP. DRIVE, FORK DIRECTION, CREEP
S26
X32
RED 3
X3:4 CAN H X32
2 46
Date
105 INP. DRIVE, STEER WHEEL DIRECTION, CREEP

WHITE 1
X3:3 CAN L
X25 S89 X25
1 3 49
X3:5 203
2013-03-04
OPERATION MODE PIN 1 INP. SEAT SWITCH

244989-040
Order number
22
Sh. 2 4
246883
3/22

244989-040
Order number
© BT Europe AB
Date
ELECTRONIC CARD
A5
2013-03-04
27 27
1
50
2
28 28
Sh. 6 508 POT. GND
Service Manual
6004330-
M12
Bl - +R 107
X32 S18 X32

54 3 4
X30 IN
22 40
Sh. 3 5 + - Sh. 3 5
HORN
T-code
H1
485, 487
SEAT HEATER
X25 E10 X25

FAN PUMPMOTOR
X35 M10 X35
M
246883
4/22
18- 53
18- 54
T-code
485, 487
ELECTRONIC CARD
A5
29 29
Sh. 11 810 + 15VDC
30 30
Sh. 11 811 GND
S66
Br Bk 58

Wh
Bl
6004330-
C4 59
Service Manual
S65
X30
22 Br Bk 57
Sh. 4 6 209 INP. STEER WHEEL REFERENCE 180 DEG.
Bl
806
40 40
Sh. 4 6 902 GND
30A
F61
1 25
Date
M6
Bk Red 60
2013-03-04
61
U1 X32
Bk Red 62
X34
129
511 GND, TACHO
244989-040
Order number
246883
5/22

EMERGENCY MODE
X30 S131
22 1 2
244989-040
A5
Order number
Y1
© BT Europe AB
40 64
DISPLAY
A6
X46
121
Date
X46
122
RS 485
X46
2013-03-04
125
RX + 3 407 TX+
X46
126
RX - 4 408 TX-
27
Sh. 4 8
Service Manual
1
6004330-
51
2
28
Sh. 4 8
LEFT ARM, INNER
Y5:1
RIGHT ARM, INNER

Y5:2 X38
63
X38
LEFT ARM, OUTER
Y6:1 X38
68
RIGHT ARM, OUTER
Y6:2
T-code
485, 487
126
Sh. 10

125
Sh. 10
246883
6/22
18- 55
18- 56
T-code
485, 487

A2
300A
F3
8 5
M3
6004330-
U
40 6 V M
Sh. 6 9 B- - V
W M
Service Manual
3~A
7
8 ID W

19
B2
16 117
4 12 Sh. 2
15 118/BLUE
3 13 Sh. 2
Date
U12
Red Bl 17 119/RED
5 10 Sh. 3 12
B
+
2013-03-04
Bk Wh 18 120/WHITE
6 11 Sh. 3 12
A
-
X30
22
Sh. 6 8 1
244989-040
Order number
246883

7/22
ELECTRONIC CARD
X32
27 A5
Sh. 6
1
X33
82
3
X32
28
Sh. 6
1
X33
244989-040
83
2
Order number
© BT Europe AB
1
X33
84
3
Date
1
X33
2013-03-04
85
3
1
X33
86
Service Manual
6004330-



X30
S61 X75 X31
22 5 1 81
204
T-code
Sh. 7 9 INP. WEIGHT

485, 487
X30 X32 S33 X33

5 1 100
205 INP. OVERRIDE

246883
8/22
18- 57
18- 58
T-code
485, 487
ELECTRONIC CARD
A5
X47 Y10 X47

40 88
X47 Y11 X47

89
701 OUT. FORK LIFT
X47 Y24 X47

90
703
OUT. SELECT FORK MOVE

FORK DIRECTION 1
X30 X14 S5 X15
6004330-
22 Br Bl 41
106
Sh. 8 10 INP. IN AISLE, SIGNAL 1

S6
Service Manual
Br Bl
STEER WHEEL DIR., RIGHT
S156
Br Bk
Bl
FORK DIRECTION 2
X14 S7 X15
Br Bl 42
S8
Br Bl
Date
FORK DIR., LEFT

S178
X69 X69
Br Bk
2013-03-04
X69
Bl
FORK DIRECTION
X14 S9 X15
Br Bl 44
S4
Br Bl
244989-040
Order number
246883
9/22

ELECTRONIC CARD
A5
X45 S90 X45 X31

244989-040
22 1 5 91
Order number
© BT Europe AB
680ohm/2W
X31 X45 H90 R34 X45 X31
40 10 9 920 92
680ohm/2W
X31 X45 H95 R30 X75 X30
- + 320 32
705 OUT. FORKS IN HOME POSITION (L,R OR CENTER)
Date
680ohm/2W
X31 X45 H18 R31 X75 X30
- + 330 33
2013-03-04
X31 X36 H2 X36 X30

- + 37
H3
X31 X37 X37 X31
- + 38
47ohm/50W
H96 R32
- + 109 108
Service Manual
6004330-
X23 Y20 X23

101
710 OUT. CABIN LIFT
X23 Y21 X23

102
LENGTH INDICATOR
A9
X45 X45 X46
125
3 +48V RX+ 5 Sh. 6 11
1 ID
X31 X45 X45 X46
126
4 0V RX- 2 Sh. 6 11
EXTERNAL EQUIPMENT
WORKING LIGHT
10A X42 X42
F63 X30 S99 E4 E3
T-code
1 26 1 1 26 1 5 191 192
485, 487
Sh. 5 21
X31
40 2 2 40

246883
10/22
18- 59
18- 60
T-code
485, 487

A8
X45 X45 X46
22 125
Sh. 10 12 3 +48V RX+ 5 Sh. 10
X45 X46
126
4 0V RX- 2 Sh. 10
X30 X45
X31
A7
X32 X34
40
Sh. 10 12 6 0V RX+ 7
X32 X34
ELECTRONIC CARD
4 +48V RX- 3
A5
6004330-
X34
127
Service Manual
X34
128
U10
X15 X17 X17 X15

29 Red Wh 98
Sh. 5 301 INP. HEIGHT COUNTER > FREELIFT PULSE A
A
+
X15 X17 X17 X15
30 Bk Bl 99
Sh. 5 302 INP. HEIGHT COUNTER > FREELIFT PULSE B
B
-
Date

A4
U9
2013-03-04
20 Red Wh 55
Sh. 12 012 INP. HEIGHT COUNTER < FREELIFT PULSE A
A
+
X14 X16 X49
Bk Bl 56
011 INP. HEIGHT COUNTER < FREELIFT PULSE B
B
-
S93
104
Br Bl
244989-040
Order number
246883

11/22
244989-040
Order number
© BT Europe AB
Date

2013-03-04
A4
X30 X14 X16 X49

22 22
X14 X16 X49

40 40
Sh. 11 13 029 GND
Service Manual
6004330-
015 GND
X15 X16 X49

119/RED RED
R109 120ohm / 1W
X15 X16 X49
120/WHITE WHITE
20 20
Sh. 11 028 OUT. + 15VDC SUPPLY

U13
Red Bl 52
T-code
A
+
485, 487
Bk Wh 53
B

-
S50
Br Bk 103
Bl
246883
12/22
18- 61
18- 62
T-code
485, 487
ELECTRONIC CARD
A4
X14 X16 X49 X62 Y25 X63

40 93
Sh. 12 14 016 OUT. PROPORTIONAL VALVE TRAVERSE
X62 Y8 X63
6004330-
94
017 OUT. TRAVERSE LEFT
X62 Y9 X63
Service Manual
95
X62 Y26 X63

73
003 OUT. PROPORTIONAL VALVE ROTATE
X62 Y27 X63

74
006 OUT. ROTATE, COUNTER CLOCKWISE
X62 Y28 X63

75
005 OUT. ROTATE, CLOCKWISE
Date
X62 Y16 X63

76
018 OUT. SPARE 1A
2013-03-04
X62 Y17 X63

77
019 OUT. SPARE 1B
X64
39
002 OUT. POT. FEED + 10VDC
X64
65
R8 007 INP. ROTATION ANGLE
X64
244989-040
Order number
246883
13/22

244989-040
Order number
© BT Europe AB
OPTION
Date
WIRE GUIDANCE, PAGE 14-17 WIRE GUIDANCE

A3
X30 X48
2013-03-04
22 22
X48
40 40
Sh. 13 19 JP2:24 GND
111
JP2:21 OUT. + 12VDC
Service Manual
6004330-
S85
Br Bk 112
Bl
113
JP2:23 GND
X48
119/RED 119
Sh. 12 22 JP4:6 INP./OUT. CAN H
X48
120/WHITE 120
Sh. 12 22 JP4:5 INP./OUT. CAN L
JP3:1
T-code
485, 487
JP3:2

JP3:4
246883
14/22
18- 63
18- 64
T-code
485, 487
OPTION WIRE GUIDANCE

A3
WIRE GUIDANCE, PAGE 14-17
131
JP1:12 GND
6004330-
130
JP1:21 OUT. + 5VDC
Service Manual
ENCODER
U15
Br Gr 132
A
+
Wh Ye 133
B
-
680 ohm/2W
Date
X30 X32 H120 R35 X32 X48

22 10 9 670 67
2013-03-04
ELECTRONIC CARD
A5
X32 S120 X32

5 7 66
244989-040
VR WITHOUT WIRE GUIDANCE

Order number
246883

15/22
244989-040
Order number
© BT Europe AB
OPTION
Date
LOAD ANTENNA WIRE GUIDANCE, PAGE 14-17 WIRE GUIDANCE

W1 A3
2013-03-04
BLACK
BROWN
RED
Service Manual
6004330-
ORANGE
YELLOW
GREEN
BLUE
VIOLET
J1L:14 JPW1:14
GND
T-code
485, 487
GREY

246883
16/22
18- 65
18- 66
T-code
485, 487
OPTION
TRACTOR ANTENNA WIRE GUIDANCE, PAGE 14-17 WIRE GUIDANCE
W2 A3
BLACK

6004330-
BROWN
Service Manual
RED
ORANGE
YELLOW
GREEN
Date
BLUE
2013-03-04
VIOLET GND
J1T:14 JPW2:14
GREY

244989-040
Order number
246883
17/22

244989-040
Order number
© BT Europe AB
OPTION
CAMERA ON FORKS.
CAMERA TV-MONITOR
Date
A51 A50
X67 X61 X60 X55

110
101 A:1
2013-03-04
VIDEO SIGNAL VIDEO SIGNAL
X67 X61 X60 X55

156
SCREEN 102 A:2 SCREEN
X67 X61 X60 X55

114
+12VDC 103 B:1 +12VDC
Service Manual
6004330-
X67 X61 X60 X55

115
GND 104 B:2 GND
T-code
485, 487
WHEN STEREO/CD
X52

114
Sh. 19
X52
115
Sh. 19
246883
18/22
18- 67
18- 68
T-code
DC/DC CONVERTER
OPTION A10 485, 487
X44 STEREO/CD
22 22
Sh. 15 20 6 INP. +48VDC
X44
40 40
114 114
Sh. 18 4 OUT. +12VDC
115 115
340
2 OUT. GND (GALV. SEPARATED)
312
1 OUT. +12VDC
6004330-
STEREO/CD
Service Manual
A11
312
A:7 INP. +12VDC
312
A:4 INP. +12V KEY
340
A:8 INP. GND
H4 X56
Date
B:5 OUT. LEFT (+)
X56
B:6 OUT. LEFT (-)
2013-03-04
H5 X56
B:3 OUT. RIGHT (+)
X56
B:4 OUT. RIGHT (-)
W5
244989-040
Order number
246883

19/22
244989-040
Order number
© BT Europe AB
OPTION
Date
ELECTRONIC CARD
A5
X30
33 33
2013-03-04

OVERRIDE EMERGENCY MODE / OVERRIDE HEIGHT
X33
S33 100
22 1
Sh. 19 22
3
7
Service Manual
X33
6004330-
165 2
Sh. 21
4
8
X34
166
Sh. 21

TBM GM-107ECO
X150
163
X150
T-code
164
485, 487

X150
40
Sh. 19 21
246883
20/22
18- 69
18- 70
T-code
485, 487

GM-107ECO
7,5A 8A
F64 X150 F
1 9
X150
40
X150
ELECTRONIC CARD
A5
X150
160
6004330-

X150
Service Manual
X150
161
X150
X150
162
Date
X150
33
2013-03-04
X150
165
Sh. 20 X1:12 OUT. +24VDC
X150
166
244989-040
Order number
246883
21/22

244989-040
Order number
© BT Europe AB
TRUCK LOG SYSTEM, CONTROL UNIT
A20
21
1 INP. +48VDC
Date
40
2 INP. GND
2013-03-04
RED
3 INP. CAN H
WHITE
4 INP. CAN L
W7
Service Manual
6004330-
TRUCK LO SYSTEM, SHOCK SENSOR

A23
22
1 INP. +48VDC (LOGGED IN)
40
2 INP. GND
RED
3 INP. CAN H
WHITE
4 INP. CAN L
T-code
485, 487

ELECTRONIC CARD, KEYPAD
A16
40
246883
22/22
18- 71
18- 72
ELECTRONIC CARD
X32 T-code
27 A5
Sh. 6 485, 487
1
X33
82
3
X32
28
Sh. 6
1
X33
83
3
1
X33
84
3
1
X33
6004330-
85
506
R14 INP. JOYSTICK SPARE 1/AUTO ROTATE
Service Manual
1
X33
86
3
cabins VRE150

Date

2013-03-04

X30
S61 X31
22 5 1 81
X30 X32 S33 X33

5 1 100
205 INP. OVERRIDE
244989-040
Order number
18.6.4 Electric wiring diagrams, cold store

247602_8
ELECTRONIC CARD
244989-040
A5
Order number
© BT Europe AB
X45 S90 X45 X31
22 1 5 91
680~E/2W
X31 X45 H90 R34 X45 X31
40 10 9 920 92
680~E/2W
Date
X31 H95 R30 X30

- + 320 32
705 OUT. FORKS IN HOME POSITION (L,R OR CENTER)
680~E/2W
2013-03-04
X31 H18 R31 X30

- + 330 33
X31 X36 H2 X36 X30

- + 37
H3
X31 X37 X37 X31
- + 38
Service Manual
6004330-
47~E/50W
H96 R32
- + 109 108
X23 Y20 X23

101
710 OUT. CABIN LIFT
X23 Y21 X23

102
LENGTH INDICATOR
A9
X45 X45 X46
125
3 +48V RX+ 5 Sh. 6 11
1 ID
X31 X45 X45 X46
126
4 0V RX- 2 Sh. 6 11
T-code
485, 487
EXTERNAL EQUIPMENT
F63 X30 S99 E4 E3
1 26 1 1 26 1 5 191 192

Sh. 5 14
X31
40 2 2 40
247602_10
18- 73
18- 74
T-code
485, 487
1
Sh. 10 22
30A
30A
30A
5A
(Red)
S68
COMFORT HEATER (1500W)

(Wh) (Ye) 2 4
6004330-
X45 S97
22 1 5 157
Sh. 12 15
Service Manual
15 18 750W
E1

(Bk)
TIMER
S70
E2
(Bl) Y1 A1
750W
A2
(Gn)
X31 X45
(Or)
Date
750W
2013-03-04
(Gn)
(Ye) 750W
0/1/2/3
FAN M
40
244989-040
Sh. 13 15
Order number
247602_14

244989-040 2013-03-04 6004330- 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
A11 Stereo/CD
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

485, 487 6004330- 2013-03-04 244989-040

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, 4
10/16 A
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 7
H90 Indicator light, half pallet handling
H95 Indicator light, forks in home position 7
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

244989-040 2013-03-04 6004330- 485, 487

picture
R2 Potentiometer, brake 4
R4 Potentiometer, traversing 2
R5 (VRE150 Potentiometer, rotation 2
only)
R6 Potentiometer, fork lifting/fork lowering 2
R8 (VRE150 Potentiometer, rotation angle 6
only)
R14 (VRE150 Potentiometer, extra hydraulic function/auto rotation 2
only)
R15 (VRE150 Potentiometer, extra hydraulic function 2
only)
R49 Damping resistor, camera
(VRE125SF)
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 5
direction
S7 Magnetic switch, aisle indication 2, fork direction 5
S8 Magnetic switch, aisle indication 2, steering wheel 5
direction
S9 Magneto switch, aisle centre, fork direction 5

485, 487 6004330- 2013-03-04 244989-040

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 2
speed
S27 Micro-switch, travel direction, fork direction, foot 8
S29 Micro-switch, travel direction, steering wheel direction, 8
foot
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
U1 Tachometer, steering 2
U9 Pulse transducer, height measurement in free lift 6
range

244989-040 2013-03-04 6004330- 485, 487

picture
U10 Pulse transducer, height measurement above free lift 7
range
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
X23 Connector
X25 Terminal, seat 3
X30 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 7

485, 487 6004330- 2013-03-04 244989-040

picture
X42 Terminal, Aux at electric panel 4
X44 Terminal, at tiller arm bracket
X45 Terminal, roof pillar 1
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
X61 Terminal, for camera at A4 6
X62 (VRE150 Terminal, fork unit valve block 6
only)
X63 (VRE150 Terminal, fork unit valve block 6
only)
X64 (VRE150 Terminal, for rotary potentiometer 6
only)
X65 (VRE150 Terminal, for traversing pulse transducer 6
only)
X67 (VRE150 Terminal, for camera, on fork unit 6
only)
X69 Connector to photocell
X75 Connector splice between roof harness and
instrument harness
X150 Terminal for PPS
X151 Connector between monitor and camera switch
(VRE125SF)
Y1 Magnet, parking brake 4

244989-040 2013-03-04 6004330- 485, 487

picture
Y8 Solenoid valve, traversing left 6
Y9 Solenoid valve, traversing right 6
Y10 Solenoid valve, lowering 4
Y11 Solenoid valve, lifting 4
Y16 (VRE150 Solenoid valve, extra hydraulic function 1A
only)
Y17 (VRE150 Solenoid valve, extra hydraulic function 1B
only)
Y20 Valve, cabin lifting
Y21 Valve, cabin lowering
Y24 Solenoid valve, fork movement 4
Y25 (VRE150 Proportional valve, traversing 6
only)
Y26 (VRE150 Proportional valve, rotation 6
only)
Y27 (VRE150 Solenoid valve, counter-clockwise rotation 6
only)
Y28 (VRE150 Solenoid valve, clockwise rotation 6
only)

485, 487 6004330- 2013-03-04 244989-040
18.6.6 Component location

Picture 1
A16 A6
X45
S21
Picture 2
A7 R15
R14
R12 R13
R11
U1 S18
S26
S33
S120
X11

244989-040 2013-03-04 6004330- 485, 487
Picture 3

485, 487 6004330- 2013-03-04 244989-040
Picture 4
M6
X23
S66
X38 S65
X48
X14
S 66
S131
X32 X33
X47 X15
X34 X 660 Y1
X46
X31 F63 F62
X30
X42 F61
F60
A5 M12 F1 A1 F3 A2
K10
R1
H1
R2
S23
M10
X35
S66 S65 M6 M1 Y1 M3 Y10

B1 B2 Y11
U11 U12 Y24

244989-040 2013-03-04 6004330- 485, 487
Picture 5 (VRE125SF)

485, 487 6004330- 2013-03-04 244989-040
Picture 5 (VRE150)

244989-040 2013-03-04 6004330- 485, 487

485, 487 6004330- 2013-03-04 244989-040
Picture 6 (VRE150)

244989-040 2013-03-04 6004330- 485, 487
U10
X41
S61
R100
S90
A50
H18, H95, S99
H2 E3 E4
A8 A9
G1
X1
A51
Y5:1 Y6:1
Y5:2 Y6:2

485, 487 6004330- 2013-03-04 244989-040
Picture 7 (VRE150)
U10
X41
S61
R100
S90 H2 E3 E4
H18, H95, S99
A50
A8 A9
A51
G1
Y5:1 Y6:1
Y5:2 Y6:2
X1

244989-040 2013-03-04 6004330- 485, 487
Picture 8
S27
S29
S23

Function description
485, 487 6004330- 2013-03-04 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.
Designation Diode number

Designation of the input/output The diode number/name that
on the card as it appears in the shows the active input/output on
wiring diagram the card

244989-040 2013-03-04 6004330- 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 R4-
R6, R14-R15.

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.

485, 487 6004330- 2013-03-04 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.
.

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.

DRIVE, FORK DIR CREEP 104
DRIVE, STEERING WHEEL DIR 105
CREEP
The display shows the travel direction.

244989-040 2013-03-04 6004330- 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.

PARKING BRAKE 802

485, 487 6004330- 2013-03-04 244989-040
18.7.5 Travel speeds

Outside narrow aisles and with forks in the "home
position"
- Fork height <1.2 m = speed reduced to
max 9.0 km/h (2.5 m/s).
- Fork height >1.2 m but <3.0 m = speed reduced to max 4.0 km/h
(1.11 m/s).
If a steering manoeuvre is >10o = speed is reduced to
max 2.5 km/h (0.7 m/s).
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 <1.2 m =
speed reduced to max 12.0 km/h (3.33 m/s).
- Driving in the direction of the forks, fork height <1.8 m = speed
- Fork height >1.2/1.8 m but <6.9 m gives variable speed reduction
(OPTIPACE), which is dependent on requirements for stability
and braking.
max 2.5 km/h (0.7 m/s).

244989-040 2013-03-04 6004330- 485, 487
Truck without support arm brakes:

- Fork height <3.0 m but <6.9 m gives variable speed reduction
and braking.
max 2.5 km/h (0.7 m/s).
- m = speed reduced to
max 9.0 km/h (2.5 m/s).
and braking.
max 2.5 km/h (0.7 m/s).

485, 487 6004330- 2013-03-04 244989-040
Wire-guided truck
- Fork height <3.5m = speed reduced to
max 9.0 km/h (2.5 m/s).
and braking.

244989-040 2013-03-04 6004330- 485, 487
18.7.6 Steering
When the steering wheel is turned, power is fed from tachometer U1 to
A5/509 which progressively powers steering motor M6. Thus, the faster
the steering wheel is turned, the faster the steering motor will rotate.
This progressive functionality also means that as the truck travel speed
increases, the steering speed will decrease. The drive motor speed is
measured using the sensor U11.
When the steering wheel is turned, the steering wheel sensor S65 is
actuated and a voltage is supplied to A5/209. The opposite travel
direction is indicated in the display. The electronics automatically
shows the correct travel direction since switch S65 provides a signal
under 180° of 360 possible. In order for the electronics to know the
direction of the steering wheel and show the travel direction, sensor
S65 must pass one of the reference points. The function is initiated
when the operator turns the steering wheel. This must be done during
the initial start-up and after servicing.
LEDs 209, 210 and 211 are lit depending on whether the sensor is
actuated or not.


Sensors S65 and S66 have their own adjustment instructions,

see C-code 5850.
Steering wheel indicator

When the operator turns the steering wheel, the sensor S66 provides a
signal to A5/210 and 211 that indicate the travel direction on the display.
In order for the electronics to know the direction of the steering wheel
and show the travel direction, sensor S65 must pass one of the
reference points. The function is initiated when the operator turns the
steering wheel. This must be done during the initial start-up and after
servicing. When the travel direction is changed using the controls, the
arrows in the display switch.
LEDs 209, 210 and 211 are lit depending on whether the sensor is
actuated or not.

485, 487 6004330- 2013-03-04 244989-040
Wire-guided narrow aisle

When entering a rail-guided narrow aisle, the truck must be set straight
beforehand. The steering angle should be less than 15°.
When the truck enters a narrow aisle, S5/S7 or
S6/S8 are activated by magnets in he floor, or if photocells are used
S156/ S178. A voltage of +48 V is supplied at A5/106 and 107.
Manual steering is disconnected when the truck is set straight and
steering is taken over by the S66 sensor which signals the A5 power
steering unit about correction of the angle of deviation in relation to the
straight-ahead position.
LED 209 lights depending on whether or not the sensor has triggered.


Wire guidance
Wire guidance is separately described in C code 4500 Automatic
steering systems and C code 8200 Wire guidance equipment. Please
note that if wire guidance is not installed, a jumper should be connected
instead of S120. Input A5/304 must be high (+48 V) when wire
guidance is not installed.
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18.7.7 Braking
Braking can be achieved in different ways:
Auto braking
When the operator releases the accelerator pedal, the drive motor will
brake the truck automatically to the desired speed. The automatic
brake function and deceleration rate can be set using the parameters.
Plug braking (electric)

When the operator changes the travel direction using the controls, the
drive motor acts as a generator/brake to return current to the battery.
The braking force can be controlled using the accelerator pedal. The
A5 logic card receives information from A1 that plug braking is in
progress and accordingly changes the status of A1.
Foot brake
When the operator depresses the brake pedal, the potentiometer R2 is
actuated. The voltage then rises from 1.7 to 4.1 V on input A5/502 to
provide a braking force of 0–100%.
Braking of the truck is done by a reversing the drive motor down to 85%
of the pedal regulation.
When the pedal is pressed fully down, the parking brake is also applied
and output 802 goes low.
Support arm brakes

If the truck has brakes in the support arm wheels, the support arm
wheel brakes are applied when the brake pedal is pressed down
approx. 60%.
A voltage of 0–48 V is then supplied on outputs A5/801 and 803.
When the pedal is pressed down to approx. 90%, the parking brake is
also applied and output 802 goes low.
LEDs 801 and 803 shine progressively brighter as
braking power increases.

Parking brake
When the truck has come to a standstill and the brake pedal is
depressed, the parking brake is applied and output 802 goes low.
If the operator stands up from the seat for more than three seconds, A5
cuts power to Y1, output 802 goes low, thus applying the parking brake.
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18.7.8 End of aisle retardation

When entering a narrow aisle, no automatic speed reduction should
take place.
When exiting a narrow aisle, at a predefined distance from the end of
the aisle (approx. 7 metres) and on the condition that the travel speed
when passing this point exceeds half speed, the truck must interrupt its
travel and start to slow down.
When the truck passes the retardation point, a buzzer
is heard for about 2 seconds.
Slowdown is achieve by reversing the motors.
When the truck has reach a low speed, speed reduction is deactivated.
To continue exiting the aisle, the accelerator pedal must be depressed
anew.
The maximum speed when exiting a narrow aisle is half speed.
If the travel speed equals half speed or less, the truck will pass the
"slowing down point" without slowing down.
Bistable magneto switches, S4 and S9, are fitted on the truck.
Permanent magnets are installed in the narrow aisle floor.
18.7.9 Fork lifting

When the operator operates the hydraulic lever R6, A5 receives a
voltage of 3.7–6.6 V on input A5/503, the directional valve Y11 opens,
+48 V is supplied on output A5/702, and A5 transmits a signal to the
transistor regulator A2. The pump motor M3 then starts and supplies oil
to the lifting cylinders.
If the battery control has detected a remaining battery capacity level of
20% or less, the lifting speed will be reduced.
The lifting speed is reduced when transiting from free lift to main lift.
This can be programmed with parameter 19.
The speed of M3 is measured using sensor U12.
Fork lifting can be programmed with an electric lift stop when the pump
motor stops. The maximum height is set with parameter 29.

FORKLIFT 701
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18.7.10 Height indicator

The height measurement feature measures the lifting height from the
lowest (floor) level to the highest fork position.
Measurement starts when the height reference switch S93 (after first
key-on) passes the magnet installed on the mast. The pulse transducer
U9 sends pulses to A4. Information is sent via the CAN to A5, which
indicates the current height on the display A8.
Each time S93 passes the magnets, height measurement is calibrated
to the value set in parameter 54.
When the forks reach the main lift range, the pulse transducer U9
stops, and U10 starts sending pulses to A5. A5 adds the U10 pulse
count to the height that was calculated using the pulses received from
U9.
LEDs 301 and 302 are lit depending on whether or not the sensor is
actuated.

HEIGHT COUNTER 301
HEIGHT COUNTER 302
18.7.11 Lift height limitation

The forks stop when the pre-programmed height limits (2 levels) are
reached, parameter 17 and 18.
If the forks should be lifted above these heights, depress switch S33.
This sends a signal to A5 and the movement continues.
This movement must start within fifteen seconds.
LEDs 301 and 302 are lit depending on whether or not the sensor is
actuated.

HEIGHT COUNTER 301
HEIGHT COUNTER 302
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18.7.12 Height preselector

Height measurement takes place according to the height indication
description.
The current lift height is displayed on both the A7 and A8 displays.
The forks stop at the first pre-programmed height when A5 via the pulse
transducer U9 or U10 has received the correct height information.
Stopping is performed by A5 controlling the pump motor speed using
A2 and the fork lifting/fork lowering valves.
The operator picks up or sets down the load manually. When the
operator once again depresses the hydraulic lift/lowering control, the
forks continue to the next pre-programmed level.
See chapter 9390.

HEIGHT COUNTER 301
HEIGHT COUNTER 302
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18.7.13 Fork lowering

When the operator operates the hydraulic lever R6, a voltage of 3.7–-
0.66 V is applied on A5/503, the directional valve Y10 opens, +48 V is
supplied on output A5/702, and A5 signals the transistor regulator A2.
The pump motor M3 starts operating at a maximum speed
corresponding to the potentiometer value received from R6.
Before the lowering movement starts, the lifting cycle is used for a brief
moment to build torque in M3. The torque in M3 is used to brake the
hydraulic pump.
The operator can control the lowering speed by adjusting the lever
angle of R6, thus varying the braking torque.
The braking torque generates a current that is returned to the battery,
so-called regenerative lowering.
When transiting from the main lift range to the free-lift range, the
lowering speed is automatically reduced by an increase in the M3
braking torque. When the forks are in the free-lift range and U9 starts
counting down, the braking torque is reduced and the lowering speed
increases.
Close to the fork bottom position, the braking torque increases to
reduce the lowering speed and achieve smooth stopping.
The speed of M3 is measured using sensor U12.
The LED is dimly lit in the neutral position and lit at full intensity when
maximum lowering speed starts.

FORK LOWER 702
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18.7.14 Sideshift/traversing of forks

(VRE125SF)
When the operator operates the hydraulic lever R4, a voltage (left =
3.7–0.66 V or right = 3.7–6.6 V) is applied on A5/504, the directional
valve opens Y24, +48 V is applied on output A5/703, and a signal is
sent to the frequency converter A2. Pump motor M3 starts.

Information about desired traversing movement is sent via the CAN to

A4.
A4 supplies a voltage of +48 V on output A4/017 for traversing to the left
and to open directional valve Y8 or to A4/004 for traversing to the right
and to open directional valve Y9.
The traversing speed is dependent on the rpm, M3, and the voltage
received from R4. The traversing speed is measured using sensor U13
and the speed of M3 is measured using sensor U12.
Close to the traversing end stops and the centre position, the speed is
braked to achieve smooth stopping. The stopping ramp is adjustable
using parameter 50.
Braking of the fork movement using the ramp function is also used for
stopping during the movement or when changing directions. This can
be adjusted with parameter 57.
Parameter Function
44 Stroke (pre-set at the factory)
45 Stroke for half pallet (pre-set at the factory)
50 Braking ramp at end stop and centre position
55 Traversing speed
57 Braking ramp in case of change of direction or
stopping
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18.7.15 Sideshift/traversing of forks (VRE150)

When the operator operates the hydraulic lever R4, a voltage (left =
3.7–0.66 V or right = 3.7–6.6 V) is applied on A5/504, the routing valve
opens Y24, +48 V is applied on output A5/703, and a signal is sent to
the lift controller A2. Pump motor M3 starts.

Information about desired traversing movement is sent via the CAN to

A4.
A4 supplies a voltage of +48 V on output A4/017 for traversing to the left
and to open directional valve Y8 or to A4/004 for traversing to the right
and to open directional valve Y9.
A4/016 supplies a PWM voltage of 0-24 V, depending on the voltage
received from R4,
and to the proportional valve Y25 to control the traversing speed.
The pump motor M3 operates at a fixed rpm measured using the
sensor U12.
Close to the traversing end stops, the speed is reduced to achieve
smooth stopping. The distance and hardness of the deceleration can
be adjusted using the parameters.
Parameter Function
44 Stroke (pre-set at the factory)
45 Stroke for half pallet (pre-set at the factory)
50 Braking distance at end stop
55 Traversing speed
57 Braking ramp
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18.7.16 Fork rotation (VRE150)

When the operator operates the hydraulic lever R5, a voltage
(clockwise rotation = 3.7–6.6 V or counter-clockwise rotation = 3.7–
0.66 V) is applied on A5/505, the routing valve opens Y24, +48 V is
applied on output A5/703, and a signal is sent to the lift controller A2.
Pump motor M3 starts.

Information about desired rotation movement is sent via the CAN to A4.
A4 supplies a voltage of +48 V on output A4/005 for clockwise rotation
and to open directional valve Y28 or to A4/006 for counter-clockwise
rotation and to open directional valve Y27.
A4/003 supplies a PWM voltage of 0-24 V, depending on the voltage
received from R5,
and to the proportional valve Y26 to control the traversing speed.
The rotation speed is measuring using the potentiometer R8.
The pump motor M3 rotates at a fixed speed measured with sensor
U12.
Close to the end stops of the rotation movement, the speed is braked to
achieve smooth stopping. The distance and hardness of the
deceleration can be adjusted using the parameters.
Parameter Function
51 Braking distance at end stop
56 Rotation speed
58 Braking ramp
18.7.17 Simultaneous traversing and rotation

movement (VRE150)
Manually
When the operator operates the hydraulic levers R4 and R5
simultaneously, adjustment of the traversing movement changes from
rpm control to adjustment of the proportional valve control.
The rpm of M3 becomes fixed and higher than for rotation only, and A4/
016 supplies a PWM voltage of 0–24 V to proportional valve Y25, which
subsequently controls the traversing speed.
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Auto-rotation
When the operator operates the hydraulic lever R14, a voltage is
applied on A5/506, the routing valve opens Y24, +48 V is supplied on
output A5/703, and a signal is sent to the lift controller A2. Pump motor
M3 starts.
Note:
The auto rotation function follows the traversing direction.

Information about desired auto rotation movement is sent via the CAN
to A4.
The rotation angle and speed is measured with potentiometer R8.
The traversing speed is measured with sensor U13.
The pump motor M3 rotates at a fixed speed measured with sensor
U12.
Parameter Function
53 Left/right symmetry for selected rotation angle
according to parameter 59
59 Activation and setting of the rotation angle at
which traversing should start.
60 Maximum lift height up to which auto rotation is
permitted
61 Activation and angle adjustment of auto rotation
90°
66 Start speed for rotation movement prior to
starting traversing
Auto rotation to the right (traversing to the right/

counter-clockwise rotation)
A4 supplies a voltage of +48 V on outputs A4/004 and A4/006 to open
the directional valves Y9 and Y27.
A4/016 and A4/003 supply a PWM voltage of 0–24 V, in relation to the
voltage received from R14, to proportional valves Y25 and Y26 to
control the traversing and rotation speeds.
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Auto rotation to the left (traversing to the left/

clockwise rotation)
A4 supplies a voltage of +48 V on outputs A4/017 and A4/005 to open
the directional valves Y8 and Y28.
A4/016 and A4/003 supply a PWM voltage of 0–24 V, in relation to the
voltage received from R14, to proportional valves Y25 and Y26 to
control the traversing and rotation speeds.
Auto rotation with stopping straight ahead 90°

If the hydraulic lever R14 is operated 1/3 of the maximum stroke
(forwards/backwards), auto rotation stops with the forks stopping
straight ahead and with traversing halfway.
More than 1/3 actuation of the lever results in 180° auto rotation.
Any deviation from this angle can be adjusted using parameter 61.
18.7.18 Extra hydraulic function (VRE150)

When the operator operates hydraulic lever R14/R15, a voltage (3.7–
6.7 V or 3.7–0.66 V) is applied on A5/510. The routing valve opens Y24,
+48 V is applied on output A5/703 and a signal is sent to the lift
controller A2. The pump motor M3 then starts and supplies oil to the
extra function.
A4 supplies a voltage of +48 V on output A4/018/019 to open the
directional valve Y16/Y17.
Note:
If the auto rotation function is used, only R15 can be used for the extra
hydraulic function.

Parameter Function
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18.7.19 Weight calculation

• Collect load on forks.
• Lift the forks up from floor.
• Press the weight calculation button.
• ---- is displayed in the hour counter display.
• Lift the load.
The weight of the load is now displayed in increments of 50 kg with a
margin of ±25 kg. After 10 seconds, the display reverts to the hour
counter. For calibration, see parameter 37.
Display and programming
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18.8 Display and programming

It is possible to view the machine-specific register, but not to re-
programme it. However, you can re-programme the operator-specific
parameters and the clock. The parameters are described in the table.
If the operator has not logged out with the 0 key, the truck will
automatically perform the log-out operation after a specified time.
C
18.8.1 Keypad
A B D E
Follow the instructions below to check the operator and machine-
specific register:
• Enter the operator code and then depress the green I key on the
keypad. This will power up the logic card and the travel direction
F G H I J K selector will be set to the fork direction.
The following functions will scroll across the display:
• Time of day CL
• Parameters P
• Serial number software Pn
• Operating times H
• Error codes E
Release the travel direction selector at the desired item.
Use the lift/lowering lever to increase/decrease the value.
The travel direction selector is used for the different adjustment modes.
The display shows the following functions:
- (C) Time of day
- (D) parameters, serial number of firmware, operating hours and
error codes
The "No." of the address register is displayed on the left side, while the
"value" is displayed on the right side.
Display and programming
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Clock
When the clock can be set, the hours will blink in the display, and after
depressing the travel direction selector, the minutes will blink.
• Use the lift/lowering lever to increase/decrease the value.
• Use the travel direction selector to switch between hours and
minutes.
Function Value
hours 09 = 9 hours
minutes 35 = 35 minutes
Terminate programming and store the set value by pressing the red
button 0.
Note:
Changed driving characteristics.
The handling characteristics of the truck will change if you change
any of the truck-specific parameters.
Do not change any parameters without possessing the necessary
know-how.
Driver parameters 1-8

Do as follows to reprogram the operator parameters if this is permitted:
selector will be set to the fork direction.
• Release the travel direction selector when “P” is displayed. The
operator number will be shown in the display (E).
• Use the lift/lowering lever to scroll to the parameter to be changed.
• Depress the travel direction selector (the parameter number blinks).
• Depress the travel direction selector to confirm the value. (The
parameter number stops blinking.)
To change other parameters, scroll to the desired parameter with the
lift/lowering lever and then repeat the operation “Depress the travel
direction selector (the parameter number blinks)”.
button 0.
Common operator parameters can only be reprogrammed using a
service instrument.
Setting all parameters
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18.9 Setting all

parameters
Keypad
Alternatively, a PC/PDA running the TruckCom application can be
used.
selector will be set to the fork direction.
The following functions will scroll across the display:
• Time of day CL
• Parameters P
• Serial number software Pn
• Operating times H
• Error codes E
Release the travel direction selector at the desired item.
Use the lift/lowering lever to increase/decrease the value.
The travel direction selector is used for the different adjustment modes.
The display shows the following functions:
- (C) Time of day
- (D) parameters, serial number of firmware, operating hours and
error codes
The "No." of the address register is displayed on the left side, while
the "value" is displayed on the right side.
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Clock
When clock setting is selected, the hours will blink in the display, and
after depressing the travel direction selector, the minutes will blink.
• Use the travel direction selector to switch between hours and
minutes.
Function Value
hours 09 = 9 hours
minutes 35 = 35 minutes
button 0.
Note:
Changed driving characteristics.
The handling characteristics of the truck will change if you change
any of the truck-specific parameters.
Do not change any parameters without possessing the necessary
know-how.
Parameters
• Release the travel direction selector when “P” is displayed. The
operator number will be shown in the display (E).
• Use the lift/lowering lever to scroll to the parameter to be changed.
• Depress the travel direction selector (the parameter number blinks).
• Depress the travel direction selector to confirm the value. (The
parameter number stops blinking.)
To change other parameters, scroll to the desired parameter with the
lift/lowering lever and then repeat the operation “Depress the travel
direction selector (the parameter number blinks)”.
button 0.
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No. Type of Min.- Std. Remarks

parameter max. value
01 Steering sensitivity 1-6 3 1 = Several wheel turns
5 = Few wheel turns
6 = No progression (Less sensitive at
higher speeds)
In steps of 1
02 Drive motor, max. 10-100 100 In increments of 5
speed in drive wheel
direction, %
03 Drive motor, 10-100 100 In percent of max. acceleration In steps of
acceleration, % 5
The lower the number is that is entered,
the longer the time the truck will need to
reach max. speed
04 Drive motor, speed 0-100 50 Percentage of speed retardation.
deceleration, % 0 = no deceleration
100 = max. deceleration
05 Drive motor, 35-100 80 Percentage of max. deceleration
deceleration when In increments of 5
reversing, %
06 Max. speed in drive 10-100 100 In increments of 5
wheel direction in
narrow aisle, %
07 Drive motor, max. 10-100 100 In increments of 5
speed in fork
direction, %
08 Max. speed in fork 10-100 100 In increments of 5
wheel direction in
narrow aisle, %
11 Drive motor, speed 5-100 100 As a percentage of max. travel speed
reduction, % In increments of 1
12 Reduced narrow 5-100 80 As a percentage of max. narrow aisle
aisle speed, % speed
Max. permissible travel speed in narrow
aisle mode when input 206 is activated
In increments of 1
13 Half speed, % 10-100 100 Percentage of max. half speed
In increments of 5
14 Creep speed, % 10-100 100 Percentage of max. crawl speed
In increments of 5
15 Optipace height in 0-3.0 3.0 Break point for Optipace speed 9 km/h.
narrow aisle, % In increments of 0.05
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16 Final speed, end of 0-1 0 The truck speed after completed
aisle deceleration
deceleration 0 = 0 km/h
1 = 2.5 km/h
17 Lift height limiter 0-13.5 13.5 0 = not connected
level 1, m > 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 0-13.5 13.5 0 = not connected
level 2, m > 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, 0-4.5 See the Top side of fork to floor when inner guide is
m table at top.
below 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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23 Travel alert; truck 0-3 0 0: No alert
moving 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 In increments of 0.05
Electric stop at max. lift height
30 I/O Box 2-1 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
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33 Wire guidance 0-29 23 Buzzer alert and deceleration/stop when
warning 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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37 Calibration weight 100- 1000 • Set this parameter to the weight with
for weight 5000 which the truck will be calibrated.
measurement, kg
• 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, 1-4 3 1 = Ignition, open
key 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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42 Time, month 1-12 In increments of 1
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, 1000- Set to Factory parameter (pre-set at factory)
traversing 2500 current In increments of 2
movement, mm Note:
If the fork unit is changed to another one
with a different travel length, this parameter
should be adjusted.
45 Travel length, half 500- 900 Factory parameter (pre-set at factory)
pallet handling, mm 2500 In increments of 2
46 Speed reduction, 0-1 1 Speed reduction dependent on current lift
traversing height.
movement Limit height = 5.0, 7.0 and 9.0 m
0: Not engaged
1: Active
47 Pump motor speed, 0-90 34 This parameter adjusts the pump motor
(VRE150) rotation speed during fork rotation.
In increments of 2
48 Pump motor speed, 0-90 46 This parameter adjusts the pump motor
(VRE150) traversing and speed during traversing movement and
combined movement during combined fork movement. The
higher the parameter value, the higher the
pump motor speed.
In increments of 2
49 Max. pump motor 0-90 24 This parameter adjusts the pump motor
(VRE125 speed, shuttle fork max. speed during traversing movement.
SF) unit The higher the parameter value, the higher
the pump motor speed.
In increments of 2
50 Braking ramp, 0-4 4 This parameter adjust the distance
(VRE125 traversing between the braking point and the end stop
SF) movement 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 Braking length, 0-4 4 Distance control, end position-end position
(VRE150) traversing In increments of 1
movement end stop
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51 Braking length, 0-4 4 This parameter adjusts the distance
(VRE150) rotation movement between the rotation movement end stop
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 Rotation angle 0-20 0 This parameter calibrates the symmetry for
(VRE150) symmetry, the rotation angle, left/right position,
angle centring for selected with parameter 59.
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 400-800 500 The calibration height for height
free-lift, mm 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, 60-100 100 As a percentage of max. travel speed
traversing In increments of 5
movement, %
244989-040 2013-03-04 6004330- 485, 487

56 Max. speed, rotation 60-100 100 As a percentage of max. travel speed
(VRE150) movement, % 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 Braking ramp, 0-4 0 Time for switch-off of the proportional
(VRE150) rotation movement valve.
In increments of 1
59 Start of traversing 0-50 0 This parameter determines the rotation angle
(VRE150) movement during at which starting of traversing movement is
auto rotation, ° permitted when auto rotation is active.
(degrees) 0: Auto-rotation not connected
>0: Angle at which traversing may start
In increments of 2
60 Max. permitted lift 1-12 2 In increments of 1
(VRE150) height for auto
rotation, m
61 Auto rotation to 0-10 0 0: Auto-rotation to middle, not connected
(VRE150) straight ahead >0: 0 = Auto-rotation to middle, connected
position
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°.
485, 487 6004330- 2013-03-04 244989-040

62 Extra hydraulic 10-100 10 Max. pump motor speed extra hydraulic
(VRE150) function 1, pump function, pot 1
motor speed, % In increments of 5
63 Extra hydraulic 10-100 20 Max. pump motor speed extra hydraulic
motor speed, % In increments of 2
64 Extra hydraulic 0-100 0 Max. pump motor torque, extra hydraulic
motor torque, % 0: No extra function
In increments of 5
65 Extra hydraulic 0-100 0 Max. pump motor torque, extra hydraulic
motor torque, % 0: No extra function
In increments of 5
66 Auto rotation start 0-255 50 Start speed for rotation in auto rotation
(VRE150) mode
A higher parameter value provides a higher
rotation speed until traversing movement
starts.
In increments of 1
67 Camera switching 0-255 0 0: Not fitted
unit >0: Fitted
In increments of 1
68-70 Not used
18.9.1 Parameter 19
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
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Lifting height Coarse setting

Free lift height
10000 3.74
485, 487 6004330- 2013-03-04 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.
244989-040 2013-03-04 6004330- 485, 487
Value Function Battery (Ah)

1
2
3
4
5
6
7
8
9
10
11 Less discharged 900

12 730, 700, 580 CSM
13 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 over-
discharge of the batteries, resulting in battery destruction.
485, 487 6004330- 2013-03-04 244989-040
18.9.3 Parameter 38
Following completed calibration, this parameter is automatically reset
to zero.
Calibration of travel speed and brake

potentiometers
• 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.
• 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.
• 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.
244989-040 2013-03-04 6004330- 485, 487
• Keep the travel direction/fork direction selector depressed for two

seconds
Warning codes
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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.
Error codes
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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 The main contactor opens.
switch off Parking brakes are activated.
activated
Steering error The steering safety relay is triggered.
The drive motor reverses to standstill.
Driving The main contactor opens.
regulator error Lift transistor regulator error
Steering is possible.
The parking brake is applied during braking
Lift transistor Hydraulics are stopped.
regulator error 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: K10 Y1 is Reversing Steering Function on

Function opens activate with M1 not A5 stops
d possible
Emergency X X -- --
switch off
Key X X -- X --
Error codes
485, 487 6004330- 2013-03-04 244989-040
Action: K10 Y1 is Reversing Steering Function on

Function opens activate with M1 not A5 stops
d possible
Steering X X
error
Error in A1 X -- --
Error in A2 X (+ solenoid
valves off)
Error in A5 X X -- X --
Error codes
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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 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
Error codes
485, 487 6004330- 2013-03-04 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
Remarks Cool and check motor/gear
Error codes
244989-040 2013-03-04 6004330- 485, 487
Code 12
Description Error in steering angle measurement detected
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.
Error codes
485, 487 6004330- 2013-03-04 244989-040
Code 13
Description No or too few pulses from the height measurement
during fork lifting or fork lowering
Error cause Defective reference switch
Defective sensor/wiring harness
Incorrect oil quality
Defective A4 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
Error codes
244989-040 2013-03-04 6004330- 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.
Error codes
485, 487 6004330- 2013-03-04 244989-040
Code 14
Description Seat switch actuated for more than 20 min. without
operating the truck
Error cause Jumpered switch
Defective switch/wiring harness
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
Error codes
244989-040 2013-03-04 6004330- 485, 487
Code 15
Description Safety switch actuated for more than 20 min.
without operating the truck
Error cause Jumpered switch
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
Error codes
485, 487 6004330- 2013-03-04 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
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.
Error codes
244989-040 2013-03-04 6004330- 485, 487
Code 17
Description Voltage from the brake pedal potentiometer R2
outside the calibrated value at start-up (+/-0.2 V).
Error cause Pedal actuated during start-up
Incorrect calibration
Brake control, R2
1. Check that the brake pedal is not stuck in the depressed position.
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.
Error codes
485, 487 6004330- 2013-03-04 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.
Error codes
244989-040 2013-03-04 6004330- 485, 487
Code 21
Description Potentiometer R6 used for fork lifting/lowering
supplies incorrect voltage at start-up (+/-0.6V).
Error cause Joystick actuated during start-up
Fork control, joystick R6

ELECTRONIC CARD
27 X32 A5
Pg. 6
1
X33 82
2
X32 3
28
Pg. 6
83
504 INP. JOYSTICK TRAVERSE
84 505 INP. JOYSTICK ROTATE
1. Check that the joystick for fork operation is not stuck in the actuated
position.
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.
Error codes
485, 487 6004330- 2013-03-04 244989-040
Code 22
Description Potentiometer R4 used for traversing movement
supplies incorrect voltage at key start-up (+/-0.6V).
Error cause Joystick actuated during start-up
Remarks
Traversing, joystick R4
ELECTRONIC CARD
27 X32 A5
Pg. 6
82
503 INP. JOYSTICK FORK
28 X32
Pg. 6
1
X33 83
R4 2
1. Check that the joystick for the traversing function has not seized in
the actuated position.
3. Calibrate the traversing control.
position.
calibrated.
Error codes
244989-040 2013-03-04 6004330- 485, 487
Code 23 (VRE150 only)

incorrect voltage at key start-up. (+/-0.6V)
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

ELECTRONIC CARD
27 X32 A5
Pg. 6
82
28 X32
Pg. 6
83
R5
X33 84 505 INP. JOYSTICK ROTATE
2
3
1. Check that the joystick for the fork rotation movement has not
seized in the actuated position.
3. Calibrate the rotation control.
position.
calibrated.
Error codes
485, 487 6004330- 2013-03-04 244989-040

Description Potentiometer R14 or R15 for the extra function “auto
rotation” and “2” supplies incorrect voltage at key
start-up. (+/-0.6V)
Error cause 1. Joystick not in neutral position during start-up
2. Defective potentiometer/bracket/wiring harness
3. Incorrect calibration.
Extra hydraulic function, joystick R14 and joystick

R15
ELECTRONIC CARD
27 X32 A5
Pg. 6
82
28 X32
Pg. 6
83
1
X33 85
2
3
1
X33 86
R15 510
2
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
Error codes
244989-040 2013-03-04 6004330- 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
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.
Error codes
485, 487 6004330- 2013-03-04 244989-040
Code 26
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.
Error codes
244989-040 2013-03-04 6004330- 485, 487
Code 27
Description Incorrect battery measurement
Error mode Battery display flashes
Error cause Poor contact in the battery measurement cables
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.
Error codes
485, 487 6004330- 2013-03-04 244989-040
Code 28
Description Emergency stop switch off is activated
Error mode Emergency switch-off connector has triggered
Error cause Operator action
Remarks Reset S21 and switch S17 off/on
Emergency stop switch, S21

ELECTRONIC CARD
A5
10A
F60 21
Pg. 1 5 1 805 X + 48VDC
24 X30 24
Pg. 14 807 X INP. KEY
43
110 X INP. LEFT FOOT SWITCH
A16
S21
21 X30
24 X30 22 809 X + 48VDC SUPPLY OUTPUTS
21 1 2
45 104 X INP. DRIVE, FORK DIR, CREEP
22
Pg. 2 4
46 105 X INP. DRIVE, STEER WHEEL DIR, CREEP
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.
Error codes
244989-040 2013-03-04 6004330- 485, 487
Code 29
Description Service time (S) is zero
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.
Error codes
485, 487 6004330- 2013-03-04 244989-040
Code 31
Description Phase error, pulse counter for traversing movement
Error cause Wiring fault
Sensor error
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.
Error codes
244989-040 2013-03-04 6004330- 485, 487
3. If nothing else can rectify the problem, replace the A4 logic card.
Error codes
485, 487 6004330- 2013-03-04 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
Remarks
Error codes
244989-040 2013-03-04 6004330- 485, 487
Code 35
Description Incorrect signal from one of the two aisle
transmitters
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.
Error codes
485, 487 6004330- 2013-03-04 244989-040
Code 36
Description Wire guidance learning did not succeed
Error cause
Remarks Perform wire guidance “learning” once again
Code 37
Description Wire guidance limit values exceeded
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 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 cause Cable break
Defective personnel protection system
Remarks The emergency brakes are applied
Error codes
244989-040 2013-03-04 6004330- 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
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.
A1.
A1.
- Check that the contact pins in the connections are not loose or
oxidised.
Error codes
485, 487 6004330- 2013-03-04 244989-040
Code 41
Description Warning temperature in the drive motor frequency
converter
Error cause High temperature in the frequency converter
Defective fan
Remarks
1. Check that the ventilation is OK.

2. Inspect the fan M12 at the controllers.
Code 42
Description Current calibration error in the drive motor
frequency converter
Error cause Defective frequency converter
Remarks
1. Replace the drive controller A1.
Error codes
244989-040 2013-03-04 6004330- 485, 487
Code 45
Description Warning temperature for the lifting motor
Error cause High temperature in the lifting motor
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.
A1.
Error codes
485, 487 6004330- 2013-03-04 244989-040
Code 46
Description Warning temperature in the pump motor frequency
converter
Error cause High temperature in the frequency converter
Defective fan
Remarks
1. Check that the ventilation is OK.

2. Inspect the fan M12 at the motor controllers.
Code 47
Description Current calibration error in the pump motor
frequency converter
Remarks
1. Replace the lift transistor regulator A2.
Error codes
244989-040 2013-03-04 6004330- 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
Error cause Defective cabling/valve Y20
Remarks
Hydraulic valve Y20 engages cab tilting

- 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.
2. Replace A5 if the error remains.
Error codes
485, 487 6004330- 2013-03-04 244989-040
Code 51
Remarks
Hydraulic valve Y21 engages cab lowering

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
Error codes
244989-040 2013-03-04 6004330- 485, 487
Code 52
Error cause Defective wiring harness/valve Y10
Remarks
Hydraulic valve Y11 engages fork lifting

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
Error codes
485, 487 6004330- 2013-03-04 244989-040
Code 53
Remarks
Hydraulic valve Y24 , reversing valve

oxidised.
X47.
- Measure the coil resistance of Y24 between the yellow and black
Error codes
244989-040 2013-03-04 6004330- 485, 487
Code 61
Error cause Defective wiring harness/valve Y10
Remarks
Hydraulic valve Y10 engages fork lowering

oxidised.
X47.
- Measure the coil resistance of Y10 between the white and black
Error codes
485, 487 6004330- 2013-03-04 244989-040
Code 62
Description Output 801 and/or 803 short-circuited/interrupted
Error cause Defective cabling/brake magnet Y5:1/Y5:2 and/or Y6:1/Y6:2
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

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.
Y6.
Resistance = 50 ohms.
Error codes
244989-040 2013-03-04 6004330- 485, 487
- Check whether cable 40 from X38 to battery minus is intact.


Error cause 1. Defective cabling/coil to Y25
Remarks
Y25, proportional valve for fork traversing

oxidised.
the X63 connector.
Y25. Resistance approx. 50 ohms.
Error codes
485, 487 6004330- 2013-03-04 244989-040

Remarks
Y26, proportional valve for fork rotation

oxidised.
the X63 connector.
Error codes
244989-040 2013-03-04 6004330- 485, 487
Code 66
Error cause Defective cabling to Y9
Short-circuit/interruption in routing valve Y9
Remarks
Y9, valve for traversing to the right

oxidised.
the X63 connector.
Error codes
485, 487 6004330- 2013-03-04 244989-040
Code 67
Error cause Defective cabling to Y8
Short-circuit/interruption in directional valve Y8
Remarks
Y8, valve for traversing to the left

oxidised.
the X63 connector.
Error codes
244989-040 2013-03-04 6004330- 485, 487

Remarks
Y28, valve for clockwise rotation

oxidised.
the X63 connector.
Error codes
485, 487 6004330- 2013-03-04 244989-040

Remarks
Y27, valve for counter-clockwise rotation

oxidised.
the X63 connector.
Error codes
244989-040 2013-03-04 6004330- 485, 487

Error cause 1. Defective cabling/coil to routing valve Y16
Remarks
Y16, valve, spare 1A

oxidised.
the X63 connector.
Error codes
485, 487 6004330- 2013-03-04 244989-040

Error cause 1. Defective cabling/coil to routing valve Y17
Remarks
Y17, valve spare 1B

oxidised.
the X63 connector.
Error codes
244989-040 2013-03-04 6004330- 485, 487
Code 76
Description Incorrect checksum in the parameter memory at
start-up
Error cause Interference in logic card A
Remarks Restart can reset error
Download new program.
Code 77
Description Communication error between the I/O processor
Code 78
Description Error encountered during test of safety relay (main
circuit) at start-up
Error cause Defective A4 logic card
Code 79
Description Safety relay (main circuit) is open
Error cause The A4 logic card has been subjected to
mechanical impact (blows, knocks)
+48 V power supply missing
Error codes
485, 487 6004330- 2013-03-04 244989-040
Code 80
Description General communication error.
No communication with the A5 logic card
Error mode
External CAN unit has been incorrectly connected
Interference in logic card A
Overmodulated A5 electronic 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
Interference in logic card A
Overmodulated A5 electronic card
Travel speed is reduced
Error codes
244989-040 2013-03-04 6004330- 485, 487
Code 90
Description Potentiometer R6 for fork lift/fork lower supplies
Error cause Defective potentiometer/wiring harness
Input activated without connected potentiometer
Remarks
Fork control, joystick R6

ELECTRONIC CARD
27 X32 A5
Pg. 6
1
X33 82
2
X32 3
Pg. 6 28
83
85 506 INP. JOYSTICK SPARE 1/AUTO ROTATE
86 510
202 X OUT. DATA COLLECT, LIFT
208 X OUT. DATA COLLECT, DRIVE
81 204 X INP. WEIGHT
100 205 X INP. OVERRIDE

- 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
2. If the voltage on input 503 is correct and the error remains, replace
the A5 electronic card.
Error codes
485, 487 6004330- 2013-03-04 244989-040

incorrect voltage (<0.3 or >7.0 V)
Error cause 1. Defective potentiometer/wiring harness or input
activated without the potentiometer having been
connected
Remarks
Fork rotation control, joystick R5

ELECTRONIC CARD
A5
82
83
27 X32
Pg. 6
1
X33 84 505 INP. JOYSTICK ROTATE
R5 2
X32 3
Pg. 6 28
86 510

VDC.
Error codes
244989-040 2013-03-04 6004330- 485, 487
Error codes
485, 487 6004330- 2013-03-04 244989-040
Code 92
Description Potentiometer R4 for traversing movement
supplies incorrect voltage (<0.3 or >7.0 V).
Input activated without connected potentiometer
Remarks
Fork traversing control, joystick R4

ELECTRONIC CARD
A5
82
27 X32
Pg. 6
1
X33 83
X32 3
Pg. 6 28
86 510

VDC.
Error codes
244989-040 2013-03-04 6004330- 485, 487

Description The potentiometer R14 for extra function 1/”auto
rotation” or R15 for extra function 2 supplies
Error cause 1. Parameter 15/16 >0, no potentiometer connected
2. Defective potentiometer/wiring harness
Remarks
Extra hydraulic function, joysticks R14 and R15

ELECTRONIC CARD
A5
82
83
27 X32
Pg. 6
1
X33 85
28 X32 R14 506 INP. JOYSTICK SPARE 1/AUTO ROTATE
Pg. 6 2
3
1
X33 86
R15 510
2
3
1. If no valve is connected, parameter 15/16 must be set to 0.

Check parameter 16 as follows and see also chapter “Parameter
Error codes
485, 487 6004330- 2013-03-04 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
Remarks
Speed control, R1

Check that the contact pin in contact X19 is not loose or oxidised.
R1 has been correctly mechanically adjusted.
Error codes
244989-040 2013-03-04 6004330- 485, 487
18.11.5 Error codes with registration

Code 104
Error cause Emergency drive switch for Y1 activated
Defective wiring harness/valve Y1
Remarks
Parking brake, Y1
1. Check that switch S131 is open.

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.
Error codes
485, 487 6004330- 2013-03-04 244989-040
Code 106
Error cause Defective wiring harness/contactor K10
Remarks
Main contactor, K10, coil
ELECTRONIC CARD
A5
1
Pg.3 72
603 INP. BATT. INDI.CURRENT -(+)
71 602 INP. BATT. INDI.-, CURRENT -(-)
70
MAIN CONTACTOR 601 INP. BATT. INDI.+
K10
40 31
Pg.2 A1 A2
804 X OUT. MAIN CONTACTOR
10A
F62 23
2 1
8
Pg.2

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.
Error codes
244989-040 2013-03-04 6004330- 485, 487
Code 107
Description The main contactor K10 does not close at key-on
and the emergency switch off not active
Remarks
Main contactor, K10, contactor points
ELECTRONIC CARD
A5
1
Pg.3 72
70
K10
40 31
Pg.2 A1 A2
10A
F62 23
2 1
8
Pg.2
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.
Error codes
485, 487 6004330- 2013-03-04 244989-040
Code 108
Description The main contactor does not open at key-off and
the emergency stop switch not active
Remarks
Main contactor, K10, contactor points
ELECTRONIC CARD
A5
1
Pg.3 72
70
K10
40 31
Pg.2 A1 A2
10A
F62 23
2 1
8
Pg.2
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.
Error codes
244989-040 2013-03-04 6004330- 485, 487
Code 109
Description Keypad relay does not open.
Error cause 1. Short-circuited cable
2. Defective keypad
Remarks
ELECTRONIC CARD
A5
21 805 +48VDC
X30 24 807 INP. KEY
43 110 INP. LEFT FOOT SWITCH

S21
24 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
48
107 INP. DRIVE, STEER WHEEL DIR
49 203 INP. SEAT SWITC
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.
Error codes
485, 487 6004330- 2013-03-04 244989-040
Code 111
Description Potentiometer R2 for brake pedal supplies incorrect
voltage (<0.4 or >4.6 V).
Remarks
Potentiometer R2, brake control

- 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 <0.4 VDC, a 7-7.5 V voltage is missing; if the
voltage is >4.6 VDC, 0 V is missing. If the cables are intact,
replace potentiometer R2.
Error codes
244989-040 2013-03-04 6004330- 485, 487
Code 112
Description Error detected during brake input test
Remarks

Description Too quick regenerative lowering of the forks.
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 cause Interference in A5 electronic card
1. Temporary interference could have affected the card.

Error codes
485, 487 6004330- 2013-03-04 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 codes
244989-040 2013-03-04 6004330- 485, 487
Code 122
Description Warning temperature in steering servo
Error cause High ambient temperature
Jammed steering
Defective wiring harness to steering motor
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.
- Brushes and brush holders, see MSM 1730.
- Armature windings
5. If the error remains, replace the A5 card.
Error codes
485, 487 6004330- 2013-03-04 244989-040
Code 123
Description The output voltage to the steering motor does not
correspond to requested steering command
Error cause Defective steering motor
Defective wiring harness to steering motor
Remarks
Steering motor, M6

2. Inspect the steering motor
- Regarding the brushes and brush holders, see tab S1730
“Electric steering motor”.
Error codes
244989-040 2013-03-04 6004330- 485, 487
Code 125
Description Steering generator error during test
Error cause Defective generator/brushes
Defective wiring harness
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”.
Error codes
485, 487 6004330- 2013-03-04 244989-040
Code 126
Description Steering motor error during test
Error cause Defective fuse F61
Defective steering motor/brushes
Defective wiring harness
Remarks
Steering motor, M6
1. Inspect the fuse F61, 30A, and cables 1 and 25 as well as contact
901.
- Brushes and brush holders, see MSM 1730.
Error codes
244989-040 2013-03-04 6004330- 485, 487
Code 127
Description Communication error between the steering
processor and master processor

Code 128
Description Memory cell for steering set point contains an
incorrect value

Code 130
Description Communication error between the I/O processor

Error codes
485, 487 6004330- 2013-03-04 244989-040
Code 131
Description Error encountered during test of safety relay
(steering) at start-up
Error cause Defective fuse F61
Defective wiring harness to F61
Remarks
Fuse F61, 30 A
1. Inspect the fuse F61, 30 A.

2. Inspect cables 1 and 25 as well as contact 901.
Error codes
244989-040 2013-03-04 6004330- 485, 487
Code 133
Description Error encountered during test of safety relay
(steering) at start-up
Remarks

2. If in spite of repeated start attempts the error remains; replace the
A5 card.
Code 134
Description Safety relay (steering) is open
Error cause The A5 electronic card has been subjected to
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.
A5 card.
Code 135
Remarks

A5 card.
Error codes
485, 487 6004330- 2013-03-04 244989-040
Code 136
Remarks

A5 card.
Code 137
Description Safety relay (main circuit) is open
Error cause The A5 electronic card has been subjected to
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.
A5 card.
Error codes
244989-040 2013-03-04 6004330- 485, 487
Code 140
Description Incorrect checksum in the parameter memory at
start-up
Change a parameter and restart the truck.
Download new program.

- Try to restart the truck.
- Change a parameter and restart the truck.
- Download new software.
Code 141
Description Incorrect checksum for the current software
Error cause Incorrectly downloaded software from the PC
Remarks Download new program via CAN
Change program memory

Download new software.
Error codes
485, 487 6004330- 2013-03-04 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
Remarks
CAN communication
1. Check that cables 117, 118, 119 and 120 have not been short-
circuited 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.
Error codes
244989-040 2013-03-04 6004330- 485, 487
Code 151
Description No communication with the drive motor frequency
converter at start-up
Remarks
circuited and that they are not disconnected. Also inspect the
resistor R101.
Error codes
485, 487 6004330- 2013-03-04 244989-040
Code 152
Description No communication with the drive motor frequency
converter during truck operation
Remarks
resistor R101.
Error codes
244989-040 2013-03-04 6004330- 485, 487
Code 153
Description No communication with the pump motor frequency
converter at start-up
Error mode Lift transistor regulator error
Remarks
resistor R101.
Error codes
485, 487 6004330- 2013-03-04 244989-040
Code 154
Description No communication with the pump motor frequency
converter during truck operation
Remarks
resistor R101.
Error codes
244989-040 2013-03-04 6004330- 485, 487
Code 155 - 163

Description General communication error
Interference in A5 electronic card
Remarks
CAN communication
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.
A5 card.
Error codes
485, 487 6004330- 2013-03-04 244989-040
Code 170 - 177

Description Error related to wire guidance
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 cause Sensors S4 or S9 have been subjected to
Defective sensor S4 or S9
Defective cabling to S4 or S9
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.
Error codes
244989-040 2013-03-04 6004330- 485, 487
Code 203
Description CPU or memory error in the drive motor frequency
converter
Remarks
1. Replace driving regulator A1.
Code 205
Description Temperature in drive motor too high
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.
Error codes
485, 487 6004330- 2013-03-04 244989-040
oxidised.
Code 206 - 207

Description Temperature in the drive motor frequency
converter too high
Defective motor

2. Inspect the drive motor and its cabling.
Code 208
Description Current in the drive motor frequency converter too
high
Error cause Motor cables incorrectly connected.
Remarks
Drive motor circuit
1. Check that the motor cables are intact and that they have been
Error codes
244989-040 2013-03-04 6004330- 485, 487
correctly connected.
2. Replace the drive controller, A1.
Error codes
485, 487 6004330- 2013-03-04 244989-040
Code 209 - 210

Description Voltage in the drive motor frequency converter too
high
Defective motor
Remarks
1. Check that the battery is intact, sufficiently charged and of the right
model.
2. Check that the drive motor is OK.
Error codes
244989-040 2013-03-04 6004330- 485, 487
Code 211 - 212

Description Voltage in the drive motor frequency converter too
low
Error cause Defective cabling/fuse F62
External electric consuming components incorrect
connected
Remarks
Main contactor, K10
ELECTRONIC CARD
A5
1
Pg.3 72
70
K10
40 31
Pg.2 A1 A2
10A
F62 23
2 1
8
Pg.2
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.
Error codes
485, 487 6004330- 2013-03-04 244989-040
Code 213 - 214

Description CAN error in the drive motor frequency converter
Remarks
Code 223
Description CPU or memory error in the pump motor frequency
converter
Remarks
Error codes
244989-040 2013-03-04 6004330- 485, 487
Code 225
Description Temperature in pump motor too high
Error cause Motor overloaded
Defective wiring harness/temperature sensor
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.
A1.
oxidised.
Error codes
485, 487 6004330- 2013-03-04 244989-040
Code 226 - 227

Description Temperature in the pump motor frequency
converter too high
Defective motor
Pump motor circuit

2. Inspect the motor cables 5, 6 and 7 as well as the pump motor M3.
Error codes
244989-040 2013-03-04 6004330- 485, 487
Code 228
Description Current in the pump motor frequency converter too
high
Error cause Motor cables incorrectly connected.
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.
Error codes
485, 487 6004330- 2013-03-04 244989-040
Code 229 - 230

Description Voltage in the pump motor frequency converter too
high
Poor contact in the K10 contact points
Remarks
Battery circuit
1. Check that the battery is intact, sufficiently charged and of the right
model.
2. Inspect the K10 contact points.
Error codes
244989-040 2013-03-04 6004330- 485, 487
Code 231 - 232

Description Voltage in the pump motor frequency converter too
low
Error cause Defective cabling/fuse F62
External electric consuming components incorrect
connected
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.
Error codes
485, 487 6004330- 2013-03-04 244989-040
Code 233 - 234

Description CAN error in the pump motor frequency converter
Remarks
resistor R101.
Truck log system, code lock
244989-040 2013-03-04 6004330- 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
Symbol Designation/function
A16 Keypad
A20 TLS, CU
A23 TLS, shock sensor
X3, X30 Connector
Truck log system, code lock
485, 487 6004330- 2013-03-04 244989-040
Symbol Designation/function
X48-X49 Connector
W7 Antenna
W7
A20
X30
X48, X49 A16
X3
A23
X48
A23
X49
A23
A20
I/O module
244989-040 2013-03-04 6004330- 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 CAN
I/O module
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Hydraulic system — 6000
General
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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 generat-
ed 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.

Hydraulic schematics
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19.2 Hydraulic schematics
19.2.1 Symbols
The table gives explanations to symbols that can be used in the hydrau-
lic schematics.

Single-acting hydraulic cylin- Single-acting hydraulic
der cylinder, air drained
Double-acting hydraulic cylin- Filter

der with damper (reduction)
Reservoir (tank) Non-return valve
Non-return valve, spring Gate valve

loaded (valve for broken (emergency lowering)
hoses)
Directional control valve Directional control valve

2/2, two ports, 3/2, two ports,
two distinct positions, two distinct positions,
electro-magnetic controlled electro-magnetic controlled
Directional control valve Servo-valve,
4/3, four ports, electro-magnetic controlled
three distinct positions,
electro-magnetic controlled

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Servo-valve, Servo-valve,
electro-magnetic controlled electro-magnetic controlled
Pressure sensor, normally Pressure regulator valve

open
Pressure relief valve Pressure relief valve
Electric motor and one pump Hydraulic motor with fixed

M with fixed displacement, two displacement,
directions of flow two directions of flow
Enclosure of two or more Pilot (control) line

functions contained in one
unit
Working line Working lines cross over
Working line with junction

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19.2.2 Hydraulic schematics (VR SF)

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19.2.3 Component description (VR SF)

Pos. Description Function Remark
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 move-
ment
1 Pressure relief valve Open by overload System pressure
2 Non-return valve
3 Emergency lowering Emergency lowering of forks
valve
4 Pressure relief valve Open by overload 50 bar
5 Loadholding valve Traverse 80 bar
6 Shock/pressure limit Open by overload 45 bar
valve
7 Hydraulic motor Overhead movement
8 Non-return valve Safety valve Gives a controlled lower-
ing speed in case of a bro-
ken hose
9 Cylinders Main lift
10 Cylinder Free lift
11 Cylinder Cab tilt Cold store cab
13 Pressure regulating 80 bar
valve

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19.2.4 Hydraulic schematics (VR)

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19.2.5 Component description (VR)

Pos. Description Function Remark
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 System pressure
2 Non-return valve
3 Emergency lower- Emergency lowering of forks
ing valve
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 low-
ering 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
14 Pressure regulating 80 bar
valve

Hydraulic components, positioning
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19.3 Hydraulic components,

positioning
19.3.1 Overview
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 Hydraulic motor,
valve block,
rotate cylinders

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VR SF

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VR
6
5
7
4
3
1
2

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19.3.2 Hydraulic unit
3
G 2
H
5
4
P 6
T
Y11 Y24
Y10

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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 Opens when selecting
fork movement
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

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19.3.3 Hydraulic components in the fork unit

(VR SF)

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Y8 Directional valve,
traverse left
traverse right
1 Loadholding valve, Loadholding pressure
traverse left = 80 bar
2 Loadholding valve, Loadholding pressure
traverse = 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
R Tank port Return to tank

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19.3.4 Hydraulic components in the fork unit

(VR)
Y26 1
Y28 Y27
A
B
A1
P
Y8
T A(X)
Y25
B1 B(X)
Y9 2 3
Y16 Y17

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traverse left
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, Opening pressure:
rotate Arm length < 900 mm = 220 bar
Arm length > 900 mm = 200 bar
2 Overcentre valve, Opening pressure:
traverse 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
T Tank port Return to tank

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19.3.5 Cab tilt function (cold store cab)

Y20 Directional valve, cab tilt
Y21 Directional valve, cab lower-
ing
1 Pressure relief valve Opening pressure = 90 bar
2 Pressure regulating valve 80 bar

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Hydraulic pump — 6140
General
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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.

Replacing the hydraulic pump
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3 20.2 Replacing the hydraulic pump

6
7 20.2.1 Dismantling
• Disconnect the battery plug.
12
• Drop the forks to the lowest position to reduce pressure in the hoses
4 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.

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• 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.

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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).
• Replace both mountings (15) on the pump motor (8).
• 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).
• Unscrew the lifting eye.
• Connect the hydraulic hoses (13 and 14) on the valve block's under-
side 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.

Hydraulic connections — 6230
General
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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,
Dimension ø Tightening Tightening angle

[mm] torque [Nm] [°]
6 23 30-45
10 30 30-45
12 50 30-45
15 60 30-45
18 70 30-45
20 80 30-45

Tightening torque for hydraulic connections
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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 cor-
rect torque.
21.2.4 Connections screwed into aluminium
Designation with cut- Dimension Torque [Nm]

ting edge
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

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21.2.5 Connections screwed into steel

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Pressure class L
Designation Dimen- Torque Designation with Dimen- Torque

with cutting sion [Nm] EOLASTIC sion [Nm]
edge sealing ring
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

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Pressure class S
Designation Dimen- Torque Designation with Dimen- Torque

with cutting sion [Nm] EOLASTIC seal- sion [Nm]
edge ing ring
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

Quick connection
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21.3 Quick connection
21.3.1 Assembling
1. Fit the assembly stop (1) on the male fitting and ensure that the dis-
mantling 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.

Quick connection
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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.

Quick connection
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Main lift chain system — 7120
General
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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 eve-
ry 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 stretch-
ing. 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 lubri-
cated.

Chain inspection
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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.
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.

Chain inspection
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22.3.7 Outline wear
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”.

Chain inspection
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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 Nominal Minimum Pitch P Nominal chain Maximum permitted

chain disc height disc height (mm) length for 20/30/ chain length for 20/
H2 ( mm) H3 (mm) 50 discs (mm) 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.

Cleaning
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22.3.10 Damaged discs

If a disc has broken on the chain, this can be due to overloading or cor-
rosion.
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.
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 chap-
ter “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.

Lubrication
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22.5 Lubrication
Mineral and synthetic oils can be used to relubricate Rexnord chains.
NOTE!
Lubricant must not contain substances such as molybdenum disul-
phide, 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 Viscosity Recommended Products*
temperature class
> - 40°C VG 15 Klüberoil 4UH 1-15, Klüber
Lubrication
< - 30°C
> - 30°C VG 68 Klüberoil 4UH 1-68N, Klüber
Lubrication
< + 5°C
Anticorit LBO 160 TT, Fuchs
DEA
> + 5°C VG 150 Klüberoil 4UH 1-150N, Klüber
Lubrication
< + 45°C
Anticorit LBO 160, Fuchs DEA
Rexoil, Rexnord Kette
>+ 45°C VG 220 Klüberoil 4UH 1-220N, Klüber
Lubrication
<+ 80°C
* Equivalent products from another manufacturer may be used.
NOTE!
Do not use a special rust protective agent to prevent
rust on the lift chains.
These agents impair the lubrication of the chains. Regular lubrication
is the best method to prevent rust attack.

Turret Head Fork Apparatus – 7700 (VR, VRE150)
General description
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23- Turret Head Fork Apparatus –

7700 (VR, VRE150)
23.1 General description

The hydraulics in the turret head fork apparatus are regulated by the
device's electronic card. The manoeuvre commands from the operator
control are sent electronically from the truck's main electronic card via
the mast cabling to the turret head fork apparatus' electronic card.
All adjustment of the apparatus' performance and movement range are
made by means of the electronic control, see parameters C-code 5000.
Mechanical adjustment of the turret head fork apparatus is described in
this instruction.
Side shift takes place by means of a hydraulic motor and geared trans-
mission. Turning of the forks takes place by means of two single acting
cylinders and a chain.
There is also a valve block with proportional valves on the apparatus for
flow regulation of the side-shift and turning speeds, directional control
valves for selection of the direction of movement and load holding
valves for the side-shift and turning movement.
The load holding valves prevent the forks from moving out of position
when braking and cornering. See C-code 6000
The apparatus' home position, forks right/left and side-shift right/left are
registered by an inductive sensor for side-shift and a potentiometer for
turning.
At the turret head fork apparatus' 0-reference point the side-shift is fully
left and the forks are turned fully to the right (as illustrated).

General description
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23.1.1 Main Components

General description
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Table 1:
Pos. Description Comments
1 Framework
2 Arm
3 Yoke beam
4 Roller Mast
5 Roller Lateral guide
6 Support roller Horizontal load
7 Support roller Vertical load
8 Valve block See C-code 6000
9 Turning cylinders See C-code 6670
10 Turning chain
11 Potentiometer Turning angle
12 Hydraulic motor See C-code 1820
13 Pulse generator Side-shift range
14 Transmission axle
15 Gear rack
16 Electronic card
17 Forks

General description
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23.1.2 Fork turning
Turning cylinders (9) and chain (10) turn the apparatus' yoke beam,
which is journalled at the top and bottom using bearing bushings. Turn-
ing of the forks takes place by means of the directional control valves
Y27 and Y28, which determine the direction, and the proportional valve
Y26, which determines the turning speed. When turning, the load hold-
ing valves (6) receive a pilot pressure and the opening pressure is
reduced to approx. 20%. The load holding valves prevent the forks from
moving out of position when braking.
The load holding valves also act as surge dampening valves with pres-
sure surges.
The turret head fork apparatus' turning angle is measured by means of
a potentiometer (11) fitted to the apparatus' turning axle.
When the forks approach the home position, approx. 10-20° before
depending on the parameter setting and the current speed, the turning
speed is reduced by the proportional valve throttling the oil flow. Also
see C-code 5000 for the electrical function.

Inspection and maintenance
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23.1.3 Side-shift movement
The side-shift movement is performed by a hydraulic motor (12) acting

directly on the transmission axle (14), which via a cog wheel, drives the
apparatus' on the gear racks. The side-shift movement takes place by
means of the directional control valves Y8 and Y9, which determine the
direction, and the proportional valve Y25, which determines the side-
shift speed.
The load holding valves (5) hold the load in position.
The movement is monitored by the pulse generator (13) mounted on
the transmission axle.
Approx. 100-200 mm before the apparatus reaches the end position,
the speed is reduced automatically (depending on the parameter).
When the turret head fork apparatus has reached its end position an
inductive sensor (S50) is actuated, this sends a signal to the A4 card
that the side-shift movement has reached the home position.
23.2 Inspection and maintenance

Inspection and maintenance as set out below, are carried out at inter-
vals of 250 hours, however at least once a year.
Also see Preventive maintenance, section P2.

Inspection and maintenance
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23.2.1 External inspection

• Note visible deformation and damage to be rectified:
• Forks Wear must not exceed 10% of the original fork thickness, the
original thickness is nominally 40 mm. Cracks that can be seen with
the naked eye are not permitted.
23.2.2 Inspection
• Check the turning chain with regard to wear and its fitting.
• Pipes, hoses and couplings.
• The mounting and tightness of turning cylinders and hydraulic motor.
• The turret head fork apparatus' mounting on the mast.
• All screws/bolt joint.
• Cable chain and cables.
• The turning and side-shift stop.
• All functions on the turret head fork apparatus, operating check.
23.2.3 Maintenance
• Clean and lubricate the support roller's contact surfaces.
• Lubricate the turret head chain
• Lubricate the cog axle/gear racks.
• Lubricate the turning bearing to the yoke beam.
See section P2, for a specification of the lubricant.

Adjustment of turret head fork apparatus
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23.3 Adjustment of turret head fork

apparatus
23.3.1 Fork carriage, end position rotation

The fork carriage's end position for rotation is adjusted as follows:
• Turn the forks fully to the right and check that the stop angle is 90o.
• If necessary, finely adjust the length of the stop bolt (1), so that a 90o
angle is obtained.
• Check that the damper (2) is not worn. A new damper should be
compressed approx. 15% (3 mm) when the yoke beam rests against
the stop bolt.
• Repeat the procedure with the forks turned fully to the left.
23.3.2 Setting tooth flank play

It is important with regard to the turret head fork apparatus' operation
that the play between the gear racks and cog axle (drive shaft) is set
correctly. There are four adjustable support rollers for setting the tooth
flank play
1. Set the fork unit in the centre of the stroke length with the forks
pointing straight forwards.
2. Dismantle the cover (2) over the valve block and pulse generator
bearing.
3. Lock the transmission axle by using a simple tool (see section
3.2.1). Fit the tool with a bolt (M10) in the transmission axle's
threaded hole and secure the tool against the apparatus' bar using
the bolts in the tool.

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4. Start by setting the lower rollers . The play is measured using an in-
dicator gauge with a magnetic base and with the measurement tip
against the top part of the arm.
Press the arm to the side (side-shift movement) and read off the
amount of play on the indicator gauge.
5. The play should be 0.1-0.2 mm. If the play is more or less the rollers
should be adjusted.
6. Use an allen key (14 mm) to adjust the rollers' eccentric axles.
7. Loosen the nuts and turn the eccentric axles so that the support
roller's are unloaded. The cog axle now rests on the lower gear
rack.
8. Turn the axles until the rollers come into contact with the support
surface. Continuing to turn you can adjust the tooth flank play,
check using the indicator gauge. Both rollers should be adjusted
equally.
9. When adjusting the upper rollers the eccentric axles are turned so
that the cog axle runs into the upper gear rack and it is then turned
back so that a tolerance of 0.1 - 0.2 mm is obtained. Check using
an indicator gauge.
10. When adjusted correctly, the axles should be adjusted equally and
the column should stand at 90° to the frame on the horizontal
plane.
11. Tighten the nuts on eccentric axles to 220 Nm (22 kpm). Test the
apparatus.
12. As little tooth flank play as possible is desirable, but with too hard a
contact the apparatus and truck will "shake" with side-shift.
13. Lock the locking nuts with the locking strip.
The support roller (14) takes up the load horizontally.

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Tools
Material consumption
- Flat bar 60 x 8 x 310 mm (x 1)
- Nuts M10 (x 1)
- Bolts M8 x 30 (x 2)
- Bolts M10 x 30 (x 1)
- Washers diameter 10.5 mm (x 1)
Manufacture
- Bend the flat bar according to the measurements in the diagram.
- Drill a 11 mm diameter hole.
- Weld the nut on the inside of the tool (spacer).
Centre with the 11 mm diameter hole.
- Drill out the nut using an 11 mm bit.
- Drill and tap the hole M8 as set out in the diagram.

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23.3.3 Adjusting the apparatus' lateral play

on the mast guide
• Lift the turret head fork apparatus to half way up the free lift height.
• Run out the forks as far as possible to one side.
• Check the lateral guide rollers' play against the mast beam at the
points A1 and A2 using the feeler gauges.
• The apparatus' lateral play on the mast's inner guide should be 0.2
mm in the centre of the free lift range.
The play is adjusted by shimming the lateral guide rollers.
• Shims (B) are available in the sizes 0.5 mm, 0.8 mm and 1.0 mm.
• Remove all the shims behind the upper lateral guide rollers. Meas-
ure the total shim thickness.
• Calculate which shim thickness must be added or replaced to give
the correct play.
• Fit the shims. Distribute shim thickness so equally as possible be-
tween the right and left sides.
NOTE!
Note which shim thicknesses should be fitted behind the right and left
lateral guide rollers.
• Fit identical shim thicknesses behind the right resp. left lower lateral
guide rollers.

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23.3.4 Potentiometer for the turning

movement
• Dismantle the guard over turning chain.
• Turn the forks fully anticlockwise (1).
Check that the stop angle is 90o as set out paragraph 3.1.
Adjust if necessary.
• Check the potentiometer's supply voltage, 10 V, between connec-
tions 1 and 3.
• Check the potentiometer's voltage between connections 2 and 3.
Nominal value 0.5 V. Tolerance range plus/minus 0.2 V.
• Turn the forks fully clockwise (2).
Check that the stop angle is 90o as set out paragraph 3.1.
Adjust if necessary.
• Check the potentiometer's voltage between connections 2 and 3.
The value must not exceed 9.8 V.
• If the voltage value clockwise exceeds 9.8 V despite the minimum
tolerance anticlockwise (0.3V) being used, the potentiometer is
probably faulty.

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23.3.5 Inductive sensor for the home

position, side-shift
• In order to gain the correct reading distance on the sensor, the dis-
tance should be adjusted to 2 mm plus/minus 1 mm (measurement
A).
• Side-shift the arm against the mechanical stop in one of the home
positions. Adjust the sensor so that the correct reading distance is
obtained.
• Side-shift the arm to the mechanical stop at the other home position.
Adjust the bolt so that the correct reading distance is obtained.

Replacing components
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23.4 Replacing components
23.4.1 Turning chain

• Turning cylinders have a self-adjustment of approx. 5 mm, before
the piston bottoms in the cylinder housing.
• When the forks are turned to the home position, check the slack on
the turning chain.
• If the chain is slack, can be pressed in/pulled out by hand, it is worn
and should be replaced.
• Dismantling the chain lock.
• Loosen the hose couplings on the retracted cylinder and pull out the
piston 5-10 mm
• Fit the new chain and chain lock.
NOTE!
Use assembly paste Molycote G-rapid when assembling the chain
lock in the piston's end piece.
• Turn to the home position anticlockwise and check the turning po-
tentiometer's voltage according to paragraph 3.4.
• Adjust if necessary.

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23.4.2 Turning bearing

Dismantling
• Dismantle the forks from the fork yoke.
• Disconnect the rotary potentiometer's contact from the cables.
• Dismantle turning chain (1).
• Dismantle the potentiometer' drive fork (2).
• Loosen the turning axle's locking screw (3) and dismantle the turn-
ing axle (4).
• Lift off the fork yoke from the apparatus arm.

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Replacing bearings
• Press the bushings (5) out of the yoke.

• Heat the axial bearing washer (6) to 180-200oC so the adhesive re-
leases.
• Clean any residue adhesive from the axial bearing washer seating
on the yoke.
• Clean grease and dirt from the bushing's seating on the yoke
• Lubricate the outside of the bushings to facilitate insertion.
• Press the new bearing bushings (5) into the yoke.
NOTE!
Exercise care when inserting so that the bushings are pressed
straight into the yoke hole.
• Spray cleaning agent Loctite 7063 on the axial bearing washer (6)
and the yoke to give clean and grease free surfaces.
• Apply the adhesive Loctite 638 on the axial bearing washer (6) and
located in position.
NOTE!
The parts must be completely clean and free of grease for the adhe-
sive to bond.
Do not apply too much adhesive on the axial bearing washer. Make
sure no adhesive comes on the bushing's bearing surfaces.
Be careful to centre the bearing washer.

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• Place the bonded joint under pressure using a clamp for 5-10 min-
utes.
NOTE!
It takes between 3-6 hours before the bonded joint has hardened and
the bearing can be loaded.
Assembly
• Lift the fork yoke onto the apparatus arm.
• Fit a new spacer (7).
• Fit the turning axle (4) with a new seal (8).
NOTE!
The hole in the axle must be centred with the hole for the locking
screw in the apparatus arm.
• Fit the locking screw (3) with Loctite 243
• Fit the potentiometer's drive fork (2).
• Fit the turning chain (1).
NOTE!
Use assembly paste Molycote G-rapid when assembling the chain
lock in the piston's end piece.
• Connect the rotary potentiometer's contact to the cables.
• Assemble the forks on the fork yoke.
• Lubricate the turning bearing using the specified lubricant as set out
in section P2.

Shuttle fork unit – 7800 (VR SF, VRE125SF)
Maintenance
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24- Shuttle fork unit – 7800 (VR SF,

VRE125SF)
At the delivery the fork unit is lubricated and the chains are streched.
After a short use (30-40 hours) should the fork unit be lubricated and
the chains adjusted.
24.1 Maintenance
This section contains all the check points required in order to keep the
equipment in good condition, and shall be carried out periodically.
This periodical maintenance work is to be executed according to the
check-list.
Proper completion of this work is to be documented in the maintenance
log with a signature and date. Defects are to be entered in to the main-
tenance log.
The maintenance logs and inspection document are to be stored in
such a manner that they are easily accessible at any time.
Defects or damage is to be repaired immediately.
Damaged components/ parts should only be replaced with original
components.
If parts other than original are installed, any claim of warranty will be
automatically rejected.
In addition to this, the owner is liable for all damage on property or per-
sons which results from this action.

Maintenance
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24.1.1 Maintenance schedule

The service life of each item in the equipment is predicted and all items
are to be checked before they affect the efficiency of the equipment.
This leads to different maintenance intervals for each item and the
check list is unique for each maintenance occasion.
I: Inspect, adjust and replace if necessary. T: Tighten. C: Clean. L: Lubricate.

M: Measure and adjust if necessary.
Pos. Work to be performed
no. Interval in hours - can vary depending Initially 500 1000 2000 3000
on application 250 h
Interval in months - can vary 3m 6m 12 m 24 m 36 m
depending on application
7800 Reach carriage
7800.1 Lubricate the drive chain LA LA
7800.2 Lubricate shuttle fork chain LA LA
7800.3 Lubricate the gear rods on the guide LF LF
7800.4 Lubricate contact surfaces on guide rollers LF LF
7800.5 Check the adjustment of the guide chain I I
7800.6 Check the adjustment of the shuttle fork I I
chain
7800.7 Check the reach carriage play +/- 2mm I I
7800.8 Check the mounting and wear on the chain I I
wheel
7800.9 Inspect line components and the hydraulic I
motor for leakage
NOTE: 500 h is based on average loads of 700-800 kg. For higher aver-
age loads, the interval should be changed to 250 h.
The letters A-F indicate the lubricant type to be used. See the separate
table.

Maintenance
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7800.1
7800.1
7800.2
7800.2 7800.2
7800.3
7800.4
Maintenance
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24.1.2 Lubrication
Oil and grease specification
Pos. Lubricant Ambient Viscosity Use Recommended
tempera- class products*
ture
A Chain Lubri- > - 40°C VG 150 Chains Klüberoil 4UH 1-15,
cation Klüber Lubrication
< - 30°C
> - 30°C VG 68 Chains Klüberoil 4UH 1-68N,
Klüber Lubrication
< + 5°C
Anticorit LBO 160 TT,
Fuchs DEA
> + 5°C VG 150 Chains Klüberoil 4UH 1-150N,
Klüber Lubrication
< +45°C
Anticorit LBO 160,
Fuchs DEA
Rexoil, Rexnord Kette
>+ 45°C VG 220 Chains Klüberoil 4UH 1-220N,
Klüber Lubrication
<+ 80°C
F Grease > - 40°C EP2 Mast girders Q8 Rubens LT
< - 15°C
> -15°C EP2 Mast girders Q8 Rembrandt EP2
< +45°C

Maintenance
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24.1.3 Adjustment of chains

2
• Adjustment of drive motor chain

• Manoeuvre the fork (1) in the direction of the arrow to its outermost
position.
• Adjust the drive motor chain tension using nut (2). Correct tension
has been achieved when the chain can be deflected 10 mm while
applying a force of 10 kg at the midpoint of the upper chain run.
• Do not overtension the drive motor chain as this will result in exces-
sive and rapid wear of the bearing and plastic rollers.
Adjustment of fork chains

• Manoeuvre the forks (1) to one of the outermost positions.
• Adjust the chain tension using screw (3). Correct chain tension has
been achieved when the chain deflects 13 mm +/- 1 mm) while ap-
plying a force of 5 kg at a point just by the middle guide.
• Do not overtension the fork chain as this will result in excessive and
rapid wear of the bearing and plastic rollers.
• Repeat the above procedure on the other fork chain by manoeuvring
the fork to the other outermost position.

Maintenance
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BF K468170-353
Fig. 1 Adjustment of chains

Maintenance
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Replacement of shuttle fork unit
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24.2 Replacement of shuttle fork unit

Unscrew the shuttle fork from the fork carriage. Loosen the eight socket
head cap screws (MC6S; M12x90, hardness 12:9)
D

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B B B
C
A B
Install the sensor layer by inserting the axle at the bottom of the sleeve
and then retracting the axle 20 mm. (A)
Prior to assembly, apply a light coat of oil onto the tensioning unit and
the surfaces between the tensioning unit and the axle as well as the
surfaces between the tensioning unit and the sleeve (B).
NOTE
Do not use oil that contains MoS2 on the tensioning unit and the sur-
faces betwen the tensioning unit and axle and between the tensioning
unit and the sleeve.
Tighten the screws in the tensioning unit diagonally to a torque of 17
Nm. (C)

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Install the forks in the fork carriage using 8 socket head cap screws
MC6S (M12x90, hardness12:9) lubricated with MoS2 installation paste.
Tightening torque 140 Nm. (D)

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485, 487 6004330- 2013-03-04 244989-040

Charger BTCM — 8340
General
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25- Charger BTCM — 8340
25.1 General
This is a technical description of charger BTCM.
BTCM is a computer controlled Wa-charger intended for open lead–
acid batteries. Wa- charger means that the charging current is high
when the charging starts and decreases as the battery voltage increas-
es. The computer monitors the charging process and ensures that the
battery receives the correct charge independent of the charging depth,
temperature or age. The computer registers the charging effect and
limits it if necessary by shutting down temporarily. Voltage, current,
charged Ah (ampere hours), charging time, etc. are shown on a display.
Statistics from the charging process are saved.
25.2 Installation
• Ensure the charger is placed in a dry area.
• Ensure the charger’s ventilation is not covered.
• Hang small chargers on the wall.

Function and use
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• Place large chargers on the floor.

• Check the intended mains supply on the charger’s rating plate.
NOTE! The charger’s transformer has a relatively high starting cur-
rent, slow rupture fuse should be used.
Inside the enclosure there are switching options for a high or low mains
voltage and high or low charging current. These should only be
switched by skilled personnel while the battery and mains supply are
disconnected.
25.3 Function and use
25.3.1 Charging process

• Connect the charger to the battery.
• Switch the main power switch to position 1.
The display shows the program version (e.g. 1.21) for a few seconds
while the computer checks the counter-voltage, mains voltage, the
charger’s temperature, etc. Charging starts and the status of the charg-
er is indicated by three LEDs. The display indicates the charging cur-
rent and the yellow LED comes on. At certain periods the computer
stops charging and collects measurement data, which is then used to
calculated the correct charge. The fan is started or stopped depending
on the temperature.
Abnormalities during charging are registered, the red LED flashes and
an error message is given. Important information on the charging proc-
ess is saved in the event of a power cut. When the mains supply is
reconnected charging continues from the right level.
The charger calculates when the battery is fully charged based on the
collected measurement data. Charging is stopped and the green LED
comes on.
When the battery voltage has dropped to the set value (normally
2.17þV/cell) a maintenance charge pulse starts and runs for two min-
utes. The period between two pulses is never shorter than 30þminutes
irrespective of the battery voltage.
Collected measurement data is saved in non-volatile memory. This
data can be read on the display at any time by using the keyboard.
NOTE! Old values are overwritten when a new charging process is
started.
25.3.2 Shut-off conditions

The most important requirement with a charger’s operation is that it is
shut-off when the battery has the correct charge. BTCM has parallel
running shut-off programs, which monitor that the right ampere hours
are charged and that the right voltage has been reached.

Function and use
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25.3.3 Delayed start and charging

There are two features to delay the start of the charger.
The first is programmable from 0 - 31 seconds and is activated each
time the charger is started.The remaining time is shown on the display.
In the event of a power cut this feature prevents several chargers start-
ing at the same time and causing fuses to blow.
The other is programmable from 0 - 7 hours and is only activated by a
new charging process. The remaining time is shown on the display;
approx. 5 seconds each minute the remaining time is shown in hours
and minutes while other times are shown in seconds. This feature
allows batteries to be charged during the part of the day when the low-
est tariff is charged.
25.3.4 Extra charging

This feature restarts the charger again after a set number of hours (at
least six hours after the start of a new charging process). The extra
charge works as if a battery change has taken place and is intended to
give a fresher battery after a weekend. For example, the battery is put
on charge on a Friday at 5.00 pm and the extra charge starts after 56
hours (standard value) at 1.00 am on Monday morning. The function
shuts off automatically when the battery is fully charged.
25.3.5 Equalisation charge

This feature charges 20% of the programmed battery capacity at the
earliest six hours after the ordinary charge is finished. The equalisation
charge can only run for five hours and can only take place once per pro-
gram. This function is deleted after the equalisation charge and it must
be reprogrammed when an equalisation charge is required. The equal-
isation charge is only used a few times a year to counteract unequal cell
voltage and sulphation.
25.3.6 Current and voltage characteristics

The charger’s direct voltage varies with the load and is
2.0 - 2.1 V/cell at 100% current and 2.55 - 2.65 V/cell at 25% current.
The voltage varies due to the mains supply and temperature.
25.3.7 Safety shut-off

The computer switches off the main switch if anything abnormal should
occur to prevent damage to the battery and other components.
Temporary shutdown occurs with:
• Incorrect mains voltage.
• Too high charging effect.
• Too high temperature.

Display and keyboard
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Definitive shutdown and maintenance charging is engaged when the

following occurs:
• Recharged capacity is too high.
• Charging with a voltage over 2.37 V/cell, for more than 6 hours, with-
out approved measurement values. Eight hours is permitted with the
function “Cold storage charging” (charging of cold batteries).
Shutdown takes place and maintenance charging is disconnected
when:
• The battery is incorrect.
• The charging current’s instantaneous value is higher than double
the rated current.
• The battery has been disconnected without the main power switch
being switched off.
If the computer does not work, charging is interrupted by a separate
overall time circuit after 12 hours without contactor coupling.
25.4 Display and keyboard

25.1 General
The panel of the charger is equipped with, a display, keyboard and
three LEDs, amongst others.
• The LEDs indicate the charging phase in progress and faults.
• The display shows different measurement values and collected da-
ta. During charging the display shows the normal charging current
and during measurement and rest periods it shows the battery volt-
age.
• The keyboard is used to control the displayed information and to
program the computer.

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Reading analog measurement values

Analog measurement values during the present charge can be read off
on the display. The significance of the codes are shown in the table
below.
• Press* code *:
Code The display shows

10 The voltage on the charger’s output(V)
11 Total charging time during main and post charging
(hh.mm)
12 Recharged ampere hours (Ah)
13 Charge time with voltage under 2.37 V/cell (hh.mm)
14 Charge time with voltage over 2.37 V/cell (hh.mm)
15 Charging current (A)
16 Mains voltage (VAC)
17 Air temperature around the motherboard (°C)
18 Temperature of one of the wound units
(transformers in V2-V3, chokes in general) (°C)
19 Temperature of the diode heatsinks (°C)

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Error indication and error messages

When the red LED flashes, an error has occurred and the display
shows the error code.
• Press the # - key to read one or more error codes in order of priority:
Code Error message
E01 The wrong code has been entered
E02 The entered value is too large.
E21 The connected battery has too high counter voltage
(over 2,4 V/cell)
E22 The connected battery has too low counter voltage
(under 1,8 V/cell)
E23 Overcurrent (more than double the rated current)
E25 Too low current (less than 1% of the rated current)
E26 The secondary fuse has tripped
E30 High temperature
E43 Charged capacity > programmed capacity × recharging
factor
E52 Phase missing on 3 phase charger
E61 Keyboard fault (key pressed > 20 seconds)
E62 Communication fault with the printer
E67 Battery acknowledgement fault
E70 Data in the motherboard’s EE-prom is not valid
E72 Fault with the motherboard’s EE-prom
E76 Fault with the computer board’s EE-prom
E77 The contents of the EE-proms on the computer board and
motherboard do not correspond

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Reading statistics from the previous charging proc-

ess
The statistic remain until a new charging process is started or until the
battery is changed. The statistics are saved in a register with a three
digit number in the interval 290 - 500. The most important are shown in
the following table.
• Press* register number *:
Register Function (resolution, unit)

290 Voltage before starting (10 mV/cell).
291 Starting current (% of the charger’s rated current).
320 Final voltage (10 mV/cell).
321 Final current (% of the charger’s rated current)
340 Calculated discharge capacity (Ah)
360 Total recharged capacity (not maintenance charging)
including the recharge factor (Ah)
Reading long-term statistics

BTCM saves statistics of how the battery and charger have been used
over a long period. The recharging factor has been deducted from
these statistics.
Battery utilisation can be read off from five registers. Depending on the
discharge depth, each charge is saved in one of these registers.
The limits shown in the table are the default settings, however, these
can be changed.
• Press* register number * :
Register Number of cycles with utilised capacity

610 0 - 30% of the programmed battery capacity
620 31- 50% of the programmed battery capacity
650 over 90% of the programmed battery capacity
660 Total recharged Ah
670 Total recharged Ah × 65535
760 Number of charges with shutdowns due to long time
over 2.37 V/cell

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Saving parameters in general.

Parameters that the program uses and that can be modified by the user
are saved in parameter memory (EE-prom). This type of memory main-
tains information when the voltage is switch off, but permits the con-
tents to be changed.
The charger contains two EE-proms. Important information is stored in
both and they are monitored by special program functions that warn if
there are deviations. If a fault occurs in one of the memory chips, the
program automatically overwrites from the other memory.
If an intended change is made when, e.g. programming, the program
approves this, but warns that the changes have only been entered in
one of the memory chips. (E.77).
• Perform an overwrite of data with code 22, when all changes have
been entered.
• Press * 22 * 2451 *.
2451 is a security code to prevent unintentional changes to data. If
charging is in progress, the contactor breaks during the actual copying
process.
Reading parameters
The program and the incorporated circuitboards have the same design
irrespective of the charger’s rated voltage or current. The setting of the
actual values takes place through the parameters for the battery and
charger being stored in the parameter memories (EE-prom). These val-
ues are entered during the unit’s pre-delivery test.
NOTE!
There are further parameters which are set at the factory and that are
not described here. The default valves are those entered with the
function’s basic programming. The significance of the register is
shown in the following table.
• Press * register *
Battery specific parameters
Register Function (resolution, unit) Default

value
200 Battery capacity (Ah) 0
210 Recharging factor (%) 15
230 Number of cells 0
220 Current loading the battery during charg- 0
ing (100 mA)
224 Cold storage operation, 0 = no, 1 = yes 0

244989-040 2013-03-04 6004330- 485, 487
Register Function (resolution, unit) Default

value
215 Starting voltage for maintenance charg- 217
ing pulse (10 mV/cell)
204 Under statistical limit ((25 + (y×5))%) 1
y=a value bewteen1 and 15
e.g. ((25 + (2×5))%)=35%
205 Statistical interval ((z×2)%) 10
z=optional value for required interval t.
ex. ((10×2)%)=20%
Charger specific parameters
Register Function Default-

value
232 Charger’s rated current (A) 0
240 Mains voltage code (see separate 9
table)
213 Extra charging, 0 = no, 1 = yes 1
225 Time for extra charging (hours) 56
217 Equalisation charging, 0 = no, 1 = yes 0
216 Pause until equalisation charging 10
(hours)
221 Delayed start (seconds) 0
226 Delayed charging (hours) 0
242 Fan installed, 0 = no, 1 = yes 1
Mains voltage codes
Design of the charger

Main voltage 1 phase 3 phase
220 0 8
380 1 9
500 2 10
127 3 11
346 4 12

485, 487 6004330- 2013-03-04 244989-040
Other functions
Register Function Default-

value
233 Automatic print-out of statistics, 0 = no, 0
1 = yes
234 Print-out of charging, 0 = no, 1 = yes 0
235 Print-out interval (minutes) 5
203 Print-out language (depends on the 0
program version)
Changing of parameters
Parameter values can be changed if necessary. For example, the
charger is programmed for 250 Ah batteries, but you require 300þAh.
• Press * 200 * (the display shows 250).
• Press, within10 seconds, * 2451 * 300 *.
• Do not forget to overwrite (* 22 * 2451 *) when all changes have
been made.

Service and maintenance
244989-040 2013-03-04 6004330- 485, 487
25.2 Service and maintenance

25.1 Basic programming, code 30
The function automatically reprograms all values to their default setting.
• Press * 30 * 2451 *.
After basic programming the battery capacity, number of cells and the
charger’s rated current should be programmed. If necessary the mains
voltage code is changed.
25.1.1 Resetting the statistics, code 31

The function resets the long-term statistics.
• Press * 31 * 2451 *.
25.1.2 Calibrating measurement values

General
The electronic components in BTCM have a certain margin of error.
Instead of calibrating the margins of error using variable resistors or
potentiometers, the computer saves the BTCM trimming constants in
the parameter memory (EE-prom). These trimming constants are cal-
culated with help of the trimming functions and are activated from the
keyboard.
Calibration takes place by measuring the value to be calibrated using
an accurate instrument. Using the calibrating function you tell the com-
puter the real value. The computer calculates a trimming constant
which is then saved in the parameter memory and is used to compen-
sate a measured value.
The trimming constants are saved in the same way as parameters. Cal-
ibration therefore gives the error message E77. When the calibration is
completed, writeover the data to the other memory chip.

485, 487 6004330- 2013-03-04 244989-040
Calibrating the current’s zero value and tempera-

ture, code 21
NOTE!
The battery must not be connected. The charger should be cold.
• Ensure the temperature of the charger and its components are the
same as the ambient temperature.
• Measure the ambient temperature.
• Press * 21 * 2451 * temperature °C*
(E.g., if the ambient temperature is19°C, press * 21 * 2451 * 19 *).
The current indication is reset when calibrating. The temperature for
the transformer, choke and diodes is set that same as the ambient tem-
perature.
Calibrating the battery current’s measurement val-

ue, code 20
• Connect the charger to the battery
• Measure the voltage across the battery’s terminals.
• Wait until the battery’s voltage has stabilised.
• Press * 20 * 2451 * voltage and the first decimal*.
(E.g., the voltage was measured to 56.4 V. Press * 20 * 2451 * 564 *).
Calibrating the charging current, code 25

• Ensure the charger gives at least 50% of the rated current.
• Measure the current using a clip-on ammeter intended for direct cur-
rent.
• Press * 25 * 2451 * current and the first decimal *.
(E.g., the current was measured to 68.5 A. Press * 25 * 2451 * 685 *).
Calibrating the mains voltage indication, code 26

• Measure the voltage between two phases. (With single phase be-
tween the phase and zero).
• Press * 26 * 2451 * voltage*.
(E.g., the voltage was measured to 396 V. Press * 26 * 2451 * 396 *).
25.1.3 Modifying the charging characteristics

If the charge gives too high or too low current at the start of charging,
the charging characteristics can be modified by moving the coupling
strip. The strip is placed to the right of the transformer. There is one or
three strips depending on the type of charger. There is a sign by the
strip explaining how it can be connected.

244989-040 2013-03-04 6004330- 485, 487
25.1.4 Printing to a printer

25.1.1 General
BTCM is fully equipped to print to a Micropower diagnostic printer
(MDP). Connect the printer to the computer board via the display’s
socket.
Printing data from EE-prom

• Press* 8 * 1 *, to print statistics from the previous charging process.
• Press * 8 * 2 *, to print the long-term statistics.
• Press * 8 * 3 *, to print the parameters.
Automatic print-out of statistics

Program value 1 in register 233.
• Press * 233 *.
• Press (within 10 seconds) * 2451* 1 *.
been made.
The printer prints out the statistics after each charging process.
Automatic logging of the charging process

Program value 1 in register 234.
• Press * 234 * 1 *.
• Press (within 10 seconds) * 2451* 1 *.
been made.
The printer prints out the data from the charge in progress at the set
interval (normally 5 minutes, see Other functions).

Trouble shooting
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25.2 Trouble shooting

25.1 General
If an error occurs during charging this normally results in one or more
error messages. There are some errors that the computer does not
report as errors, e.g. a fault in the electronics. Here follows a compila-
tion of errors and suitable actions.
25.1.1 Error messages, analysis and actions

25.1.1 E.22 = low counter voltage.
The connected battery has too low counter voltage.
• Check the battery and its connections.
E.30 = high temperature

• Check the fan.
• Check that the ventilation openings are not blocked.
• Check that the mains voltage setting is correct.
• Check that the ambient temperature is not too high.
E.25 = low current

• Check that there is no play on the battery connector and the battery
terminals.
• Check that the battery is not sulphated.
• Check the contactors.
• Check the thermal fuses.
• Check for faults on the motherboard.
E.52 = phase fault

• Check the fuse on the mains supply.
• Check that a phase is not missing.
• Check for play on the mains terminal.
• Check for a break on the diodes.
• Check that the correct mains voltage code has been programmed

Trouble shooting
244989-040 2013-03-04 6004330- 485, 487
E.70 = incorrect information in the motherboard’s

EE-prom
• Reprogram and calibrate if necessary.
• Writeover the data.
• Shut off the charger and start again.
• Check to see if the error message has disappeared.
E.72 = error with the motherboard’s EE-prom

• Check the EE-prom.
• Check the computer board.
E.76 = Error with the computer board’s EE-prom

• Check that the computer board’s EE-prom is not missing or incor-
rect.
• Check that an older type of display card or printer has not been con-
nected.
E.77 = the data in the computer board and mother-

board’s EE-proms is valid but not the same
• Check that the data has been overwritten.
• Check that the computer board does not come from another unit.
Faults without indication

If the charger does not work, check that the computer board and the
display card and correctly installed and connected.
If the mains fuse trips when charger is switched on, compare the size of
the fuse with the charger’s rated data.
• Check the fuses and connections.
• Check the diodes.
• Check the insulation between the phases and the charger’s case.

Service actions
485, 487 6004330- 2013-03-04 244989-040
25.2 Service actions

25.1 General
Service may only be carried out by authorised, skilled personnel.
• Disconnect the charger from the mains supply and the battery when
servicing with the charger open.
• Ensure all cover plates are replaced and that the charger’s covers
are shut and locked, after servicing.
25.1.1 Switching to timer charging

In the event of a fault with the charger whereby it cannot be computer
controlled you can temporarily switch to timer charging.
• Switch the service plug (J5), which is situated above the mother-
board’s control transformer.
• Set J5 in its right-hand position.
• Set the power switch to position 1.
Charging will start immediately and will continue during the set time,
normally 12 hours. The time can be set between 5 and 13 hours using
the potentiometer (P2). There are markings for 6 and 12 hours. In the
service mode the fan runs continuously.
• When the fault has been rectified, return J5 to its ”normal position”
and P2 is set to 12 hours.
25.1.2 Replacing the display card

• Insert the LEDs in the corresponding holes before the card is
screwed in position.

Preventive maintenance
244989-040 2013-03-04 6004330- 485, 487
25.1.3 Replacing the computer board

• Loosen the motherboard’s catches on the upper and lower guides.
• Pull out the computer board.
• Check that the new computer board has the right design and right
program version.
• Fit the new computer board.
If the computer board’s EE-prom is unprogrammed, it will be updated
when the charger starts. If it is programmed, the error message E.77 is
displayed. Carry out an overwrite using codeþ22 (* 22 * 2451 *).
25.1.4 Replacing the motherboard

• Remove the motherboard.
• Remove the bottom grille (applies to wall models).
• Disconnect all connections.
NOTE!
Take care with the thermo-wires.
• Loosen the five nuts and lift out the motherboard from the charger.
• Fit the new motherboard.
• Connect the computer board.
• Carry out complete basic programming, calibration and reset the
statistics.
25.1.5 Replacing the diodes

There are two types of diode 40HF40, with the red connection and
which is used on the charger’s positive-cooler. And 40HFR40, with the
blue connection and which is used on the charger’s negative cooler.
Some types have mixed couplings, i.e. both types are fitted in the same
cooler. If these types are not available, you can use another diode that
can withstand at least 40 A, 400 V, and has1/4”-threads.
• Secure the diode so that the body rests against the heatsink (check
using feeler gauges).
• Only use hand pressure. (Recommended tightening torque is
2.5þNm).
25.2 Preventive maintenance

In normal environments the charger requires no maintenance. In dusty
buildings regular cleaning is recommended so cooling and thereby the
charger’s efficiency is not affected. Cleaning should only be carried out
by authorised personnel.

Preventive maintenance
485, 487 6004330- 2013-03-04 244989-040

Position sensors — 9390
Height Indication and Height Pre-Set
244989-040 2013-03-04 6004330- 485, 487
26- Position sensors — 9390
26.1 Height Indication and Height Pre-

Set
26.1.1 General
This chapter is about height indication and height pre-set.
The height indication system comprises two pulse sensors/generators
which measure impulses on a wire and relay them to the truck's elec-
tronic card. The main electronic card then relays the signals to a display
panel showing the height of the forks.
The height pre-set receives impulses from the height indication system.
On the height pre-set, you can program the height at which the forks will
stop to pick-up and drop-off cargo.

Components for Height Indication/Height Pre-Set
485, 487 6004330- 2013-03-04 244989-040
26.2 Components for Height Indication/

Height Pre-Set

Height Indication
244989-040 2013-03-04 6004330- 485, 487
26.3 Height Indication

Height measurement measures the lifting height from the lowest (floor
level) to the highest fork position, both within free-lift and main lift areas.
At "first start" (key on), the height measurement system comes on-line
when the fork apparatus reaches approx. 500 mm and the height refer-
ence switch S93 passes the magnet mounted on the frame. As long as
the key is on, the fork height is measured continuously from floor to
maximum height.
Each time S93 passes the magnet, height measurement is calibrated to
the value set by parameter 54.
Within the free lift area, the pulse generator U9 sends pulses to the fork
unit's electronic card A4, which relays the information via CAN to the
truck's main card A5. A5 shows via RS 485 the current height on dis-
play A8.
When the forks reach the main lift area, the pulse generator U9 stops
and pulse generator U10, on the frame, begins sending pulses to A5.
A5 adds U10’s pulse count to the height calculated by the pulses from
U9.
The pulse generators have two channels A and B, which relay signals
with 90° content relationship. This gives A5 information on whether the
forks are moving up or down. LEDs 301 and 302 light/blink on A5.

HEIGHT COUNTER 301
HEIGHT COUNTER 302
For connection, see Wiring Diagram, chapter 5000.

For programming the free lift height, see Setting Parameters, chapter
5000.
The steel wire should be wrapped one turn around the metering wheel
and stretched taut so it does not slip.

Height Indication
485, 487 6004330- 2013-03-04 244989-040
26.4 Height Indication

Standard equipment for the truck includes a height indication system,
which shows the current height of the forks.
The display window A shows the fork height based on information from
the height measurement system.

Display A8
244989-040 2013-03-04 6004330- 485, 487
26.5 Display A8
The picture shows the rear side of the height indication display, and the
table explains the terminal numbers for contacts where I means input.
5 4
3 2 1
Terminal Connection Function

Number
1
2 I RX (-) receives data
3 I +48 V
4 I Negative
5 I RX (+) receives data
26.6 Height Pre-Set

Using the height pre-set, you can lift and lower the forks to a maximum
of 99 different pre-programmed levels within the main lift area.
Lifting and lowering movements are stopped at the desired level based
on information from the height meter. Drop-off and pick-up of cargo
takes place manually.
Program the right levels for pick-up and drop-off on the keypad. The
display window shows the chosen level and any error codes.

Function
485, 487 6004330- 2013-03-04 244989-040
26.7 Function
Height measurements are made in accordance with the description
above.
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 operator picks up or deposits the load manually. When the opera-
tor again presses the hydraulic lever to lift/lower, the forks continue to
the next pre-programmed level.
See the chapter "Programming."

Display A7
244989-040 2013-03-04 6004330- 485, 487
26.8 Display A7
The diagram shows the rear of the display for preset height and the
table describes the contactor’s terminal number where I stands for
Input and O stands for output.
7 6 5
4 3 2 1
Terminal Connector Function

Number
1 O TX (+) transmits data
2
4 I + 48V
5 O TX (-) transmits data
6 I Minus

Display A7
485, 487 6004330- 2013-03-04 244989-040
26.8.1 Description of the display symbols

Symbol Function
Numerical push-buttons for setting height
levels
9
To control the required height level while
driving
INFO
STOP
Deletes incorrectly entered height levels in auto-
matic mode, stops programming and removes stops
due to error
Save “LEAVE level” when programming
Save “COLLECT level” when programming
LOAD
Push-button to indicate that there is a load on the
forks when starting
Push-button to access programming routines
PROG
Display to indicate height levels and error codes

Assembly of height preset
244989-040 2013-03-04 6004330- 485, 487
26.9 Assembly of height preset

• Undo the 11 screws holding the lower panel in place and remove it.
• Remove the plastic plugs and remove the plastic console from the
cavity for the height preset.
• Screw the height preset in place.
• Connect the contactor.
• Screw the lower panel back in place with the 11 screws.
26.10 Programming
Press the PROG button briefly to enter the programming mode. The
LED in the button comes on and the display shows PL00 when the pro-
gramming routine has been started. You can now program new lifting
heights, modify or delete programmed values.
26.10.1 Programming a level

26.10.1 Collection level
• Enter programming mode and state the required level (e.g. 1+5=
level 15). The numbers are shown on the display.
• Lift the forks to the required level and press the button COLLECT.
The LED flashes.
Leaving level
• Pick up the load and wait three seconds. Lift the forks just enough so
that the pallet can be removed from the rack. Ensure that there is
sufficient space for safe handling.
• Now press the LEAVE button and both LEDs for collecting and leav-
ing will start to flash.
• Press the PROG button until both LEDs go out and the display indi-
cates PL00, to save the information.
• Repeat from “LEAVE “ level to program more levels.
• Press STOP to return to display mode.

Automatic operations
485, 487 6004330- 2013-03-04 244989-040
26.10.2 Erasing programmed levels

Lower the forks to the free lift zone when deleting lifting heights.
• Enter the programming mode and state the required level (e.g. 1+5=
level 15). The numbers are shown on the display.
• Press the COLLECT button (the LED flashes) and then press the
LEAVE button (both LEDs start to flash).
• Press the PROG button until both LEDs (COLLECT and LEAVE)
stop flashing and the display shows PL00 to erase the memory.
• Press the STOP button to return to the display mode.
26.11 Automatic operations

There are two different automatic operating modes. One where the
forks are raised/lowered to the required level without a load and the oth-
er, with a load.
26.11.1 Collect load

• State the required height level using buttons 0-9, (e.g. 1+2= level
12). The display will show LE12.
• Raise/lower the forks until they are automatically stopped by the
electronics. If the wrong direction is chosen no “raise/lower move-
ment” will take place. The electronics expect the correct direction to
be selected.
• When the forks stop and the LED, COLLECT comes on, the forks
can be manoeuvred under the load.
• Raise the forks until they are automatically stopped by the electron-
ics and the LED, LEAVE, comes on.
• Move the load from the rack. When the work cycle has been com-
pleted the LEDs will go out.

Automatic operations
244989-040 2013-03-04 6004330- 485, 487
26.11.2 Leaving a load

• Press the load button (the LED now comes on).
• State the required height level using buttons 0-9,
(e.g. 5=level 5. The display will show LE05).
• Raise/lower the forks until they are automatically stopped by the
electronics. If the wrong direction is chosen no “raise/lower move-
ment” will take place. The electronics expect the correct direction to
be selected.
• When the forks stop and the LED, LEAVE comes on, the forks can
be slid out from under the load.
• Lower the forks until they are automatically stopped by the electron-
ics and the LED, COLLECT comes on.
• Remove the forks from the rack. When the work cycle has been
completed the LEDs will go out.
26.11.3 Control
• Press the button INFO to check the required “collect/leave level”.
The value will be shown for three seconds on the display.

Parameters
485, 487 6004330- 2013-03-04 244989-040
26.12 Parameters
There are a number of parameters that can be modified in the preset
height program.
• Press the button PROG for three seconds to start programming rou-
tines. The LED comes on and the display shows P_ _ _ .
• Enter code 852 using the numerical keys and the display will now
show P_.
• State the required parameter 1-9 and then press the LOAD button.
The display shows the factory settings. These can be changed to
any of the max/min. values shown in the table “Programming param-
eters”.
NOTE!
If a value outside the max/min. range is programmed in, this will be re-
placed by the max/min. factory setting.
• Press the STOP button to complete programming.
26.12.1 P1
Select the unit of measurement you wish to use (metres or inches).
Press the PROG button to save the unit you selected. The display
shows P_ .
26.12.2 P2
If the distance between lifting heights is equal on all levels, you can
make a common program:
• State parameter 2 and press the LOAD button. The display shows P
00 and you now enter the number of levels. Press the LOAD button
and the display shows P000.
• Enter the “collect height” for the first level, in steps of 10 mm. Press
the LOAD button, the display shows P000.
• The next value to be entered is the distance between the collect and
leave levels, in steps of 10 mm. Press the LOAD button, the display
shows P000.
• The last value to be entered is the distance between each level in
steps of 10 mm. Press the PROG button to save the programmed
values. The display shows P_.

Parameters
244989-040 2013-03-04 6004330- 485, 487
26.12.3 P3
Programming the crawling speed for braking distances:
• State parameter 3 and press the LOAD button. The display shows
the previously programmed value for the crawling speed lower. En-
ter the new value using the numerical keys. The permitted max/min.
values are shown in the table “Programming parameters”.
• Press the LOAD button to change the crawling speed lift. The dis-
play shows the value for the crawling speed. Enter the new value us-
ing the numerical keys.
• Press the PROG button to save the new values. The display shows
P_.
26.12.4 P4
Programming the crawling distance when lifting and lowering.
• State parameter 4 and press LOAD button. The display shows the
previous value for crawling distance lower. Enter the new value us-
ing the numerical keys. The permitted max/min. values are shown in
table “Programming parameters”.
• Press the LOAD button to change the crawling distance lift. The dis-
play shows the value for the crawling distance. Enter the new value
using the numerical keys.
P_.
26.12.5 P5
Programming the tolerance for the “stop levels”.
• State parameter 5 and press LOAD button. The display shows the
previous value for tolerance. Enter the new value using the numeri-
cal keys. The permitted max/min. values are shown in table “Pro-
gramming parameters”.
P_.

Parameters
485, 487 6004330- 2013-03-04 244989-040
26.12.6 P7
Programming the largest and smallest permitted programming distance
between the levels collect and leave.
• State parameter 7. The display shows the previously programmed
value for the minimum distance. Enter the new value using the nu-
merical keys, (e.g. 030 = 30 mm). The permitted max/min. values
are shown in table “Programming parameters”.
• Press the LOAD button. The display shows the previously pro-
grammed value for the maximum distance. Enter the new value us-
ing the numerical keys (e.g. 150 = 150 mm).
P_.
26.12.7 P8
Reset all the parameters to the factory settings.
no value.
• Press the PROG button until the display stops showing PP. Turn the
ignition key on and off to start the new program.
26.12.8 P9
• Programming the “leave/collect level’s” braking distance.
the braking distance for lower. Enter the new value using the numer-
ical keys, (e.g. 050 = 500 mm).
• Press the LOAD button. The display shows the braking distance for
lift.
• Enter the new value using the numerical keys, (e.g. 030 = 300 mm).
• Press the PROG button to save. The display shows P_.

Programming parameters
244989-040 2013-03-04 6004330- 485, 487
26.13 Programming parameters

Parameter Max/min Factory Unit Function
Number value value
P1 001 m - 10 mm Unit of measurement
002 inch - 10ths
of an inch
P2 Programming of several levels at
equal collect/leave distances.
1 - 99 Number of levels
0 - 999 10 mm Distance first “ collect level”
0 - 255 10 mm Distance collect-leave
0 - 999 10 mm Distance between “leave levels”
P3 % of max Crawling speed before stop
0 - 127 030 speed Lower
0 - 127 010 Lift
P4 mm Crawling speed before stop
010 Lower
005 Lift
P5 0 - 255 010 mm Permitted error tolerance in stop
position
P7 0 - 255 030 mm Min/max distance between leave/col-
0 - 255 150 lect
P8 Resetting of all values to factory set-
tings
P9 Braking distance before stop
0 - 255 050 10 mm Lower
0 - 255 030 10 mm Lift

Programming parameters
485, 487 6004330- 2013-03-04 244989-040
Position Function
A Leave level
B Collect level
C Main lifting zone
H2 Free lifting zone

Error codes
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26.14 Error codes

Error code Remarks
Err 1 Requested height level not programmed or incor-
rect
Err 2 Forks have stopped outside the tolerance zone
(P5)
Err 9 Incorrect value entered when programming
Err flashing Fault in communication between height preset
and truck computer
• Four lines appear first. This shows that there has been no communi-
cation between the height preset and the main electronics. The lines
will disappear when communication is restored between the units.
• Four dots appear on the display when the forks are in the free lift
zone.
• If the dots are flashing it is an indication that the reference switch
was activated when the truck was started (e.g. the forks were above
the free lift zone). If the dots continue to flash after the forks have
been lowered a fault may have occurred in the wiring harness or the
height reference switch.

Error codes
485, 487 6004330- 2013-03-04 244989-040

Error codes
244989-040 2013-03-04 6004330- 485, 487

© BT Europe AB
SE-595 81 Mjölby
Sweden
www.bt-industries.com

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Service manual en

Veflex VR, VR SF, VRE150, VRE125SF

Order number: 244989-020

Publishing Order Amendments

This manual contains information on the following trucks:

T-Code Model Serial number

© BT Europe AB Service manual Veflex VR, VR SF, VRE150, VRE125SF

1- Technical data ..................................................................................... 2-1

2- Maintenance ........................................................................................ 3-1

3- Tools ..................................................................................................... 4-1

4- Chassis – 0000 ..................................................................................... 5-1

5- Frame, mounted components — 0400 ............................................... 6-1

6- Driver Protection — 0840 .................................................................... 7-1

7- Electric Pump Motor — 1710 .............................................................. 8-1

© BT Europe AB Service Manual Veflex VR, VR SF, VRE150, VRE125SF 1

8- Electric Steering Motor — 1730 .......................................................... 9-1

9- Electric Drive Motor — 1760 ............................................................. 10-1

10- Mechanical Drive Gear Unit — 2550 .............................................. 11-1

11- Travel brake system — 3100 .......................................................... 12-1

2 Service Manual Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB

11.7.3 Checking the braking force .......................................... 12-10

12- Drive wheel — 3530 ......................................................................... 13-1

13- Fork/support arm wheel – 3550 ...................................................... 14-1

14- Electric steering wheel/lever — 4310 ............................................. 15-1

15- Steering angle sensor — 4350 ....................................................... 16-1

16- Automatic steering system — 4500 ............................................... 17-1

© BT Europe AB Service Manual Veflex VR, VR SF, VRE150, VRE125SF 3

17- Electrical System — 5000.1 ............................................................ 18-1

4 Service Manual Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB

17.1.10 Parameter 11 ............................................................. 18-114

© BT Europe AB Service Manual Veflex VR, VR SF, VRE150, VRE125SF 5

17.3.4 Warning Codes without Registration ......................... 18-130

18- Electrical system – 5000.2 .............................................................. 19-1

6 Service Manual Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB

18.10 Warning codes ......................................................................... 19-130

19- Hydraulic system — 6000 ............................................................... 20-1

20- Hydraulic pump — 6140 .................................................................. 21-1

21- Hydraulic connections — 6230 ...................................................... 22-1

22- Main lift chain system — 7120 ........................................................ 23-1

© BT Europe AB Service Manual Veflex VR, VR SF, VRE150, VRE125SF 7

22.3.5 Bolt rotation ................................................................... 23-2

25- Charger BTCM — 8340 .................................................................... 26-1

8 Service Manual Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB

25.1.4 Printing to a printer ...................................................... 26-13

26- Position sensors — 9390 ................................................................ 27-1

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10 Service Manual Veflex VR, VR SF, VRE150, VRE125SF © BT Europe AB

< -15° C: SAE 75W SAE 75W

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2.1 Introduction and safety,

2.2 Safety regulations during

© BT Europe AB Service Manual Veflex VR, VR SF, VRE150, VRE125SF 2- 1

• Unless otherwise indicated in this service handbook, always discon-

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2.2.1 Tilting the cab up on a cold store truck

2.2.2 Tilting the cab down on a cold store