Bt Vce150A 150Ac 125Asf 125Acsf C15 Service Manual-21623B320004.pdf -Bookmark created by https://wimanual.com 1- Content 2- Presentation of the truck - M2 (t-code 712) 2.1 Ergonomics 2.2 Performance 2.3 Electrical system 2.3.1 Intended application of the truck 2.3.2 Forbidden application of the truck 2.4 Truck data 2.5 Truck dimensions 2.6 Identification plate 2.7 Capacity plate 2.8 Additional plates (VNA) 2.9 Modification plate 2.10 Identification plate, mast 2.11 Main components 2.12 Warning and information plates and symbols 3- Presentation of the truck - M2 (t-code 713) 3.1 Intended application of the truck 3.2 Prohibited application of the truck 3.3 Truck data 3.4 Truck dimensions VCE125ASF 3.5 Identification plate 3.6 Capacity plate 3.7 Additional plates (VNA) 3.8 Modification plate 3.9 Identification plate, mast 4- Introduction, maintenance - P1 (t-code 712) 4.1 Safety precautions for maintenance work 4.1.1 Gas-charged accumulators 4.2 Maintenance work to be performed by the operator 4.2.1 Maintenance work that may be performed by trained service technicians 4.3 Cleaning and washing 4.3.1 Exterior cleaning 4.3.2 Cleaning the motor compartment 4.3.3 Electric components 4.4 Secure lifting 4.5 Lifting points 4.5.1 Lifting the truck 5- Maintenance - P1 (t-code 713) 5.1 Safety regulations with maintenance work Gas-charged accumulators 5.1.1 Maintenance work that is to be carried out by the operator 5.1.2 Maintenance work that may be carried out by trained maintenance personnel 5.2 Cleaning and washing 5.2.1 External cleaning 5.2.2 Cleaning the motor compartment 5.2.3 Electrical components 5.3 Transporting and storing the truck 5.3.1 Lifting the truck 5.3.2 Towing and transporting a defective truck 5.3.3 Storing the truck Battery Hydraulic system Drive unit 5.4 Starting after a period of disuse 6- Preventive maintenance - P2 (t- code 712) 6.1 Maintenance schedule 7- Preventive maintenance - P2 (t-code 713) 8- Oil and grease specifications - P3 (T-code 712) 9- Oil and grease specification - P3 (t-code 713) 10- Tools - P4 10.1 Super Seal contact 10.1.1 AMP connector 10.1.2 Diverse tools 11- Chassis - 0000 Truck installation 11.1 General 11.2 Tool list 11.3 Unloading the truck 11.3.1 Unloading a standing truck Drive the truck off the trailer Towing the truck off the trailer Unloading with a counterweight truck 11.3.2 Unloading a truck lying down Unloading the truck from a lorry using a counter balance truck 11.3.3 Unloading the truck using cranes 11.3.4 Erecting the truck 11.3.5 Final assembly 11.3.6 Assembly of the initial mast 11.4 Preparations for commissioning 11.5 Installation in narrow aisle 11.5.1 General 11.5.2 Rail-guided truck 11.5.3 Wire-guided truck 12- General tightening torque - 0400 12.0.1 Galvanised, non oiled bolts 12.0.2 Untreated, oiled bolts 12.1 Tightening torque 13- Electric pump motor - 1710.1 13.1 General 13.2 Disassembled pump motor 13.3 Disassembly and assembly of the pump motor 13.3.1 Disassembly 13.3.2 Assembly 13.4 Replacing the ball bearing 13.4.1 Disassembly 13.4.2 Assembly 13.5 Assembly instruction for the external temperature sensor 14- Electric pump motor - 1710.2 14.1 General 14.2 Disassembled pump motor 14.2.1 Connection 14.3 Disassembly and assembly of the pump motor 14.3.1 Disassembly 14.3.2 Assembly 14.4 Replacing the ball bearing 14.4.1 Disassembly (D side) 14.4.2 Assembly 14.4.3 Disassembly (N side) 14.4.4 Assembly (N side) 14.4.5 Carbon brushes and carbon brush-rocker New carbon brushes must always be smoothened beforehand Commutator Truing the commutator 15- Electric drive motor - 1760 15.1 General 15.2 Disassembled drive motor 15.3 Disassembly and assembly of the drive motor 15.3.1 Disassembly of the drive motor Disassemble the gear wheel Disassemble the brake 15.3.2 Assembly of the drive motor Assemble the brake Assemble the gear wheel 15.4 Replacing the ball bearing N side D side 15.4.1 Assembly N side D side 15.5 Assembly instruction for the external temperature sensor 16- Drive unit 16.1 General 16.2 Components 16.2.1 Component identification 16.2.2 Technical data 16.2.3 Dismantled gear 16.3 Replacing the drive motor 16.3.1 Dismantling of drive unit from truck 16.3.2 Fitting the drive unit in truck 16.3.3 Dismantling the drive motor and the gear 16.3.4 Fitting the drive motor and the gear 16.4 Oil level check 16.4.1 Checking 16.4.2 Oil replacement 16.5 Repairs 16.5.1 Replacing the drive shaft sealing ring Dismantling Assembly 16.5.2 Leakage from the top cover 16.5.3 Leakage from the lower cover 16.5.4 Replacing the wheel bolt 17- Travel brake system - 3100 17.1 General 17.2 Operating description 17.2.1 Releasing the accelerator 17.2.2 Travel direction selector 17.2.3 Pressing down the brake pushbutton 17.2.4 Parking brake 17.2.5 Emergency braking 17.3 Electromechanical disc brake, drive motor 17.3.1 Assembling 17.3.2 Dismantling 17.3.3 Inspection 17.3.4 Assembling 17.4 Maintenance 17.4.1 Adjusting the play 17.4.2 Wear 17.4.3 Check the braking force 17.5 Multiple disc brake, support arm 17.5.1 Assembling 17.5.2 Dismantling 17.5.3 Inspection 17.5.4 Assembling 17.6 Maintenance 17.6.1 Adjusting the play 18- Drive wheel - 3530 18.1 General 18.2 Dismantling the drive wheel 18.3 Assembling the drive wheel 19- Fork 19.1 Dismantling the wheel 19.2 Assembling the wheel 300 mm wheel with brake and 350 mm wheel 19.3 Dismantling 19.3.1 300 mm wheel with brake and 350 mm wheel Dismantling the bearing Assembling bearings 21- Hydraulic system - 6000 21.1 General 21.1.1 Symbols 21.2 Cabin lifting 21.2.1 General 21.2.2 Cabin lifting - S44 closed 21.2.3 Cabin lowering - S70 closed 21.2.4 AC hydraulic unit, components 21.2.5 Hydraulic flow diagram, cabin lifting Symbol list, chassis 21.2.6 B cylinder system Hydraulic flow diagram, B cylinder system Symbol list, B cylinder system 21.3 Fork units and steering 21.3.1 General 21.3.2 Hydraulic flow diagram, DC system (t-code 712) 21.3.3 Hydraulic diagram (t-code 713) Symbol list, fork unit and steering Turret head fork unit valve (t-code 712) 21.3.4 Shuttle fork valve blocks (Tcode 713) 21.3.5 Fork rotation (t-code 712) 21.3.6 Traversing movement 21.3.7 Fork lifting 21.3.8 Fork lowering 21.3.9 Steering Steering valve 21.4 Extra hydraulic function (T-code 712) 21.4.1 Valves used for the extra hydraulic functions Electrical connection 21.4.2 Hydraulic diagram, extra hydraulic function (t-code 712) 22- Hydraulic pump - 6140 22.1 General 22.2 Replacing the hydraulic pump 22.2.1 Dismantling 22.2.2 Assembling 23- Main mast and mast - 7100 23.1 Setting the cab and mast stoppers 23.1.1 Cab stoppers 23.1.2 Setting the cab stoppers 23.1.3 Mast stoppers 24- Main lift chain system - 7120 24.1 General 24.2 Checking the chain setting 24.3 Chain inspection 24.3.1 Noise 24.3.2 Surface rust 24.3.3 Rusty links 24.3.4 Stiff links 24.3.5 Bolt rotation 24.3.6 Loose bolts 24.3.7 Outline wear 24.3.8 Stretching 24.3.9 Damage 24.3.10 Damaged discs 24.3.11 Damaged bolts 24.3.12 Dirty chain 24.4 Cleaning 24.5 Lubrication 25- Initial mast 25.1 General 25.2 Assembly 25.2.1 Mast assembly 25.2.2 Installation of belts on a new truck 25.2.3 Installing the hydraulic hose and electric cabling 25.2.4 Mast disassembly 25.3 Inspection and replacement of belts used for fork traversing 25.3.1 Inspection Inspecting the belt condition 25.3.2 Replacing the belt Disassembly of the belt Installing the belt 25.3.3 Checking belt tensioning Belt tension meter 213973 �Span� measurement of the traversing arm Tension measurement of the traversing belt Tension measurement of the drive belt 25.4 Friction plate adjustment 26- Shuttle fork unit - 7800 (t-code 713) 26.1 Assembling shuttle forks 26.2 Maintenance 26.2.1 Maintenance schedule 26.2.2 Lubrication Oil and grease specification 26.2.3 Adjustment of chains Adjustment of fork chains 26.3 Replacement of shuttle fork unit 27- Wire guidance equipment - 8200 27.1 General 27.2 Generator 27.2.1 Technical data 28- Control 28.1 General 28.2 Connection 28.2.1 Specifications 28.3 Truck software management on the PC 28.3.1 Downloading the software package via the network 28.4 Connecting to the truck 28.4.1 Connecting to the truck 28.4.2 Menu window tree 28.4.3 Disconnection 28.5 Menus 28.5.1 File menu �Open package� �Save truck report� �Save output window to file� �Save parameter setup to file� �Update parameter setup in truck� �Save height pre-selection setup to file� �Update height pre-selection from file� 28.5.2 View menu �Read configuration� �Update� �Run� �Abort communication� 28.5.3 Tools menu �Log In� �Log In Production mode� �Log Out� �Read error log� �Erase error log� �Set hour meters� �Set all parameters to default� �Download package� 28.5.4 Option menu �Program settings� 28.6 �Download package�, Function for firmware downloading 28.6.1 Normal firmware download Errors encountered during downloading 28.6.2 �Emergency download� 28.7 Using the menu tree to verify 28.7.1 �Software� 28.7.2 �Parameters� 28.7.3 Diagnostics �Digital IO� �Analog IO� Example: Diagnostics procedure for the Initial lift function 28.8 Installation 28.8.1 Installation of TruckCom SE on a PC Downloading TruckCom SE via the Internet Installing 28.8.2 Necessary changes in Windows XP and Windows 2000 for TruckCom SE Changes in Windows� Control Panel 28.8.3 In case of communication errors with the CAN 28.8.4 To uninstall 29- Height pre-selection - 9390 29.1 General 29.2 Parameters 29.2.1 MCU parameters Parameter 159 29.3 Programming 29.3.1 Programming a level �Collection level� �Leaving level� �Order picking level� Erasing programmed levels Changing the programmed level 29.3.2 Operation General Collecting a load Depositing a load Order picking SM.VCE+SF_5000.pdf 20- Electrical system - 5000 20.1 General 20.1.1 Terminology 20.1.2 Truck firmware applications 20.1.3 Communication CAN communication AUX serial interface 20.2 Main Computer Unit, MCU (A5) 20.2.1 General The MCU has the following functions: 20.2.2 Voltage feed 20.2.3 Battery negative 20.2.4 Electric connectors 20.2.5 Internal status monitoring 20.2.6 External inputs and outputs X130 connector X131 connector X132 connector 20.2.7 Installing a new card in the truck 20.2.8 Programming the MCU 20.3 Fork computer unit, FCU (A4) 20.3.1 General The FCU has the following functions: 20.3.2 Voltage feed 20.3.3 Battery negative 20.3.4 Electric connectors 20.3.5 External inputs and outputs Connector 20.3.6 Installing a new card in the truck 20.3.7 Programming 20.4 Integrated Control Panel, ICP (A16) 20.4.1 General The ICP has the following functions: 20.4.2 ICP modules Left section Right section Display Logic card 20.4.3 Voltage feed 20.4.4 Battery negative 20.4.5 External inputs and outputs X100 connector X101 connector X102 connector X103 connector X104 connector X106 connector X107 connector 20.4.6 Installing a new ICP in the truck 20.4.7 Programming 20.5 AC regulators, ACTL (A1), ACTR (A31) and ACH (A2) 20.5.1 General 20.5.2 Connection terminal and terminal pillars 20.5.3 Technical data 20.5.4 Installing a new frequency converter in the truck 20.5.5 Programming 20.5.6 Maintenance 20.5.7 Safety 20.5.8 Cleaning 20.6 DC regulator, DCHI (A32) 20.6.1 General description 20.6.2 Connection terminal and terminal pillars 20.6.3 Technical data 20.6.4 Installing a new transistor panel 20.7 Parameters 20.7.1 Diagnostics and troubleshooting Displaying errors codes and error logging Error codes, troubleshooting Resetting errors 20.7.2 Maintenance 20.7.3 Safety 20.7.4 Cleaning 20.7.5 Hand-held terminal 1307 20.7.6 Using the hand-held terminal 20.7.7 Viewing and adjusting parameters Using the MORE INFO PROGRAM MODE 20.7.8 SPECIAL PROGRAM MODE 20.7.9 Using the TEST mode 20.7.10 Using the DIAGNOSTICS MODE 20.7.11 SPECIAL DIAGNOSTICS MODE 20.8 Electrical system, overview T-code 712 T-code 713 20.9 List of symbols and electric circuit diagrams 20.9.1 List of symbols 20.9.2 Electrical wiring diagrams (T-code 712) 20.9.3 Electrical wiring diagrams (T-code 713) 20.10 Component list 20.10.1 Placement of components Picture 1 Picture 2 Picture 3 Picture 4 Picture 5 Picture 6 Picture 7 Picture 8 Picture 9 20.10.2 Cabling contacts 20.11 Functional description, General 20.12 Functional description, starting, driving, steering and braking 20.12.1 Battery connected, truck switched off 20.12.2 Log-in Log-in Start-up process Warnings during start-up Critical faults during start-up 20.12.3 Log-out Log-out 20.12.4 Presence verification Open cabin gates Closed cabin gates 20.12.5 Selecting the drive direction Forward travel Reverse travel Motor control (ACTL, ACTR) 20.12.6 Emergency driving mode 20.12.7 Travel speeds Optipace Other travel speed reductions Travel speeds outside narrow aisles with forks in the "home position" Travel speeds for trucks in rail-guided narrow aisles Travel speeds for trucks in wire-guided narrow aisles 20.12.8 Steering Safety monitoring Steering wheel Free driving mode Rail-guided narrow aisle mode Wire-guidance mode 20.12.9 Braking Safety monitoring Automatic braking Reversing Braking with the brake button (S48) Right dead man's handle released (S101) End-of-aisle braking Personal protection system (PPS) Emergency switch-off (ESO) Parking brake 20.13 Electrical description of the hydraulic functions 20.13.1 Allowed combined functions 20.13.2 Monitoring and functional limitations Monitoring Safety limitations 20.13.3 Slack chain guard 20.13.4 Height measurement Safety monitoring 20.13.5 Cabin lifting Safety monitoring 20.13.6 Special height (lift limiter function) 20.13.7 Cabin lowering Safety monitoring 20.13.8 Special function with cab lifting 20.14 Turret head unit (T-code 712) Safety monitoring Automatic switching of the turret head fork unit's functions Fork lifting Measuring the load weight Side shifting Fork rotation 20.14.1 Auto rotation 20.14.2 Miscellaneous electrical functions Warning lamp Personal protection system (PPS) 20.14.3 Narrow aisle ID system 20.14.4 Alternative �narrow aisle system� Narrow aisle type 20.15 Shuttle fork unit (t-code 713) 20.15.1 Traversing of the forks Functional description 20.15.2 Fork lifting Lifting Lowering Measuring the load weight 20.16 Wire guidance 20.16.1 General 20.16.2 Wire guidance components MCU Antennas, W1 and W2 Installing a new antenna Steering angle sensor R7 Activation switch Narrow aisle mode Narrow aisle type 20.16.3 Functional description Run mode 20.17 Display 20.17.1 Normal mode 20.17.2 Information mode 20.18 Calibration Turret Head (t-code 712) 20.18.1 Calibration mode Calibration of the ICP controls - �CONTROLS� Calibration of steering - �STEERING� Calibration of wire guidance - �WIRE� Calibration of the turret head fork unit functions - �FORKS� Calibration of weight indication - �WEIGHT� Calibration of B cylinder pressure - �PRESSURE� 20.19 Calibration Shuttle fork (t-code 713) 20.19.1 Calibration of Shuttle fork Calibration of weight indication - �WEIGHT� Learn status codes - FCU 20.20 Parameters 20.20.1 Accessing parameters Operator parameters (service key not inserted) 20.20.2 Operator parameters (operators 1-10) Parameter 1 Parameter 2 Parameter 3 Parameter 4 Parameter 5 Parameter 6 Parameter 7 Parameter 10 20.20.3 Truck parameters 20.20.4 MCU parameters Basic parameters Parameter 101 Parameter 102 Parameter 103 Parameter 104 Parameter 105 Parameter 106 Parameter 107 Parameter 108 Parameter 109 Parameter 110 Parameter 111 Parameter 112 Parameter 113 Parameter 114 Parameter 115 Parameter 116 Parameter 117 Parameter 118 Parameter 119 - 125 Parameter 126 Parameter 127 Parameter 128 Parameter 129 Parameter 130 Parameter 131 Parameter 132 Parameter 133 Parameter 134 Parameter 135 Parameter 136 Parameter 137 Parameter 138 Parameter 139 Parameter 140 Parameter 141 Parameter 142 Parameter 143 Parameter 144 Parameter 145 Parameter 146 Parameter 147 Parameter 148 Parameter 149 Parameter 150 Parameter 151 Parameter 152 Parameter 153 Parameter 154 - 156 Parameter 157 Parameter 158 Parameter 159 Parameter 160 Parameter 161 Parameter 162 Parameter 163 20.20.5 Wire guidance parameters: Parameter 165 Parameter 166 Parameter 167 Parameter 168 Parameter 169 Parameter 170 Parameter 171 Learned calibration values, steering Parameter 186 Parameter 187 Parameter 188 Parameter 189 Parameter 190 Parameter 191 Parameter 192 Parameter 193 Parameter 194 Learned calibration data, wire guidance 20.20.6 FCU parameters (t-code 712) Basic parameters, turret head fork unit Parameter 400 Parameter 401 Parameter 402 Parameter 403 Parameter 404 Parameter 405 Parameter 406 Parameter 407 Parameter 408 Parameter 409 Parameter 410 Parameter 411 Parameter 412 Parameter 413 Parameter 414 Parameter 415 Parameter 416 Parameter 417 Parameter 418 Parameter 419 Parameter 420 Parameter 421 Parameter 422 Parameter 423 Parameter 424 Parameter 425 Parameter 426 Parameter 427 Parameter 428 Learned calibration data, turret head fork unit Parameter 450 Parameter 451 Parameter 452 Parameter 453 Parameter 454 Parameter 455 Parameter 456 Parameter 457 Parameter 458 Parameter 459 Parameter 460 Parameter 461 Parameter 462 Parameter 463 Parameter 464 Parameter 465 Parameter 466 Parameter 467 Parameter 468 Parameter 469 Parameter 470 Parameter 471 Parameter 472 Parameter 473 Parameter 474 Parameter 475 Parameter 476 Parameter 477 20.21 Parameters Shuttle fork (t-code 713) 20.21.1 Service Parameters (t-code 713) 20.21.2 Learned data (t-code 713) 20.21.3 ICP parameters Parameter 500 Parameter 501 Parameter 502 - 505 Parameter 507 Parameter 508 Parameter 509 Parameter 510 Parameter 530 - 539 Parameter 540 - 549 20.22 Warning and error codes 20.22.1 Error handling Error grouping Error recording 20.22.2 Safety logics 20.23 Warning and error codes 20.23.1 ICP, code group 1 ICP warning codes ICP error codes 20.23.2 MCU, code group 2 MCU warning codes MCU error codes 20.23.3 Drive system, code group 3 Drive system - warning codes Drive system - error codes 20.23.4 Cabin lift system, code group 4 Cabin lift system - warning codes 20.23.5 Steering system, code group 5 Steering system - warning codes 20.23.6 Initial lift and turret head fork unit systems, code group 6 (t-code 712) Initial lift and turret head fork unit systems - warning codes 20.23.7 Shuttle Fork system (including FCU cautions) - code group 6 (t-code 713) . 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