SM Vce+sf-040

Service Manual
VCE150A, 150AC, 125ASF, 125ACSF

C15 (serial number: 564221-919698)
Valid from serial number: 919699-
Order number: 227761-040

Issued: 2005-11-28 ITS
BT Europe AB
en
Document revisions:
Issue date
Order
number
Changes
2003-10-03
211459xxx
Completely new issue
2005-03-01
2005-10-28
Updated/new chapters: P4, 5000, 6000, 7100, 7200, 8700, 9390

227761xxx
New partnumber documentation/new name

Updated/new chapters: M2 , P1, P2, P3, P4, 0000, 0400, 2550,
3100, 3530, 3550, 5000, 6000, 7100, 7800
This manual covers following truck models:
T-code
Model
Serial number
712
C15
564221-919698
712
VCE150A/
VCE150AC
919699-
713
VCE125ASF/
VCE125ACSF
919699-
BT Europe AB
Service Manual
Approved by: K Hallman
Content
Order number
227761-040
Date
2005-11-28
Valid from serial number

919699-
T-code
712, 713
1- Content
1- Content ................................................................................................. 1-1
2- Presentation of the truck M2
(t-code 712) .............................................................................................. 2-1
2.1
Ergonomics .................................................................................... 2-1
2.2
Performance .................................................................................. 2-1
2.3
Electrical system ............................................................................ 2-2
2.3.1 Intended application of the truck ...................................... 2-2
2.3.2 Forbidden application of the truck ................................... 2-2
2.4
Truck data ...................................................................................... 2-3
2.5
Truck dimensions........................................................................... 2-6
2.6
Identification plate .......................................................................... 2-8
2.7
Capacity plate ................................................................................ 2-8
2.8
Additional plates (VNA) .................................................................. 2-9
2.9
Modification plate ........................................................................... 2-9
2.10 Identification plate, mast ................................................................ 2-9
2.11 Main components......................................................................... 2-10
2.12 Warning and information plates and symbols .............................. 2-12
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 ................................................................
3-1
3-2
3-2
3-3
3-4
3-5
3-8
3-8
3-8
3-9
3-9
4- Introduction, maintenance P1 (t-code 712) .................................... 4-1

4.1
Safety precautions for maintenance work ...................................... 4-1
4.1.1 Gas-charged accumulators ............................................. 4-3
4.2
Maintenance work to be performed by the operator....................... 4-3
4.2.1 Maintenance work that may be performed by trained service
technicians ....................................................................... 4-3
4.3
Cleaning and washing.................................................................... 4-4
4.3.1 Exterior cleaning .............................................................. 4-4
4.3.2 Cleaning the motor compartment .................................... 4-4
4.3.3 Electric components ........................................................ 4-4
4.4
Secure lifting .................................................................................. 4-5
4.5
Lifting points................................................................................... 4-6
4.5.1 Lifting the truck ................................................................ 4-6
5- Maintenance P1 (t-code 713) ........................................................... 5-1
5.1
Safety regulations with maintenance work ..................................... 5-1
Gas-charged accumulators ............................................. 5-2
BT Europe AB
Service Manual
1- 1
Content
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
5.1.1
5.2
5.3
5.4
Maintenance work that is to be carried out by the

operator ........................................................................... 5-3
5.1.2 Maintenance work that may be carried out by trained maintenance personnel
5-3
Cleaning and washing.................................................................... 5-3
5.2.1 External cleaning ............................................................. 5-3
5.2.2 Cleaning the motor compartment .................................... 5-4
5.2.3 Electrical components ..................................................... 5-4
Transporting and storing the truck ................................................. 5-5
5.3.1 Lifting the truck ................................................................ 5-5
5.3.2 Towing and transporting a defective truck ....................... 5-5
5.3.3 Storing the truck .............................................................. 5-6
Battery ............................................................................. 5-6
Hydraulic system ............................................................. 5-6
Drive unit ......................................................................... 5-6
Starting after a period of disuse ..................................................... 5-7
6- Preventive maintenance P2 (t-code 712) ........................................ 6-1

6.1
Maintenance schedule ................................................................... 6-1
7- Preventive maintenance P2(t-code 713) ......................................... 7-1
8- Oil and grease specifications P3(T-code 712) ............................... 8-1
9- Oil and grease specification P3 (t-code 713) ................................. 9-1
10- Tools P4 ........................................................................................
10.1 Super Seal contact.......................................................................
10.1.1 AMP connector ..............................................................
10.1.2 Diverse tools ..................................................................
10-1
10-1
10-2
10-3
11- Chassis 0000

Truck installation ................................................................................... 11-1
11.1 General ........................................................................................ 11-1
11.2 Tool list......................................................................................... 11-1
11.3 Unloading the truck ...................................................................... 11-2
11.3.1 Unloading a standing truck ............................................ 11-3
Drive the truck off the trailer .......................................... 11-3
Towing the truck off the trailer ....................................... 11-3
Unloading with a counterweight truck ............................ 11-4
11.3.2 Unloading a truck lying down ......................................... 11-5
Unloading the truck from a lorry using a counter
balance truck ................................................................. 11-6
11.3.3 Unloading the truck using cranes .................................. 11-7
11.3.4 Erecting the truck ......................................................... 11-10
11.3.5 Final assembly ............................................................. 11-14
11.3.6 Assembly of the initial mast ......................................... 11-14
11.4 Preparations for commissioning................................................. 11-15
11.5 Installation in narrow aisle.......................................................... 11-16
11.5.1 General ........................................................................ 11-16
11.5.2 Rail-guided truck .......................................................... 11-16
11.5.3 Wire-guided truck ........................................................ 11-16
12- General tightening torque 0400 ................................................... 12-1
12.0.1 Galvanised, non oiled bolts ........................................... 12-1
1- 2
Service Manual
BT Europe AB
Content
Order number
227761-040
Date
2005-11-28

919699-
12.1
BT Europe AB
T-code
712, 713
12.0.2 Untreated, oiled bolts ..................................................... 12-1

Tightening torque ......................................................................... 12-2
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 ...........
13-1
13-1
13-1
13-2
13-3
13-4
13-5
13-5
13-6
13-7
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 .......................................................................
14.4.1 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 .....................
Commutator ...................................................................
Truing the commutator ..................................................
14-1
14-1
14-1
14-1
14-2
14-3
14-4
14-4
14-5
14-5
14-5
14-6
14-6
14-6
14-7
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 ..............................................
N side ............................................................................
D side ............................................................................
15.4.1 Assembly .......................................................................
N side ............................................................................
D side ............................................................................
15.5 Assembly instruction for the external temperature sensor ...........
15-1
15-1
15-2
15-3
15-3
15-3
15-3
15-4
15-4
15-4
15-5
15-5
15-5
15-6
15-6
15-6
15-7
16- Drive unit/gear 2550 .....................................................................

16.1 General ........................................................................................
16.2 Components/data of the drive unit and gear ................................
16.2.1 Component identification ...............................................
16.2.2 Technical data ...............................................................
16.2.3 Dismantled gear ............................................................
16-1
16-1
16-1
16-2
16-4
16-4
Service Manual
1- 3
Content
T-code
712, 713

91969916.3
16.4
16.5
Date
2005-11-28
Order number
227761-040
Replacing the drive motor/drive gear ........................................... 16-5

16.3.1 Dismantling of drive unit from truck ............................... 16-5
16.3.2 Fitting the drive unit in truck ........................................... 16-5
16.3.3 Dismantling the drive motor and the gear ...................... 16-6
16.3.4 Fitting the drive motor and the gear ............................... 16-6
Oil level check/replacement ......................................................... 16-7
16.4.1 Checking/filling of oil ...................................................... 16-7
16.4.2 Oil replacement ............................................................. 16-7
Repairs ........................................................................................ 16-8
16.5.1 Replacing the drive shaft sealing ring ............................ 16-9
Dismantling .................................................................... 16-9
Assembly ....................................................................... 16-9
16.5.2 Leakage from the top cover ......................................... 16-10
16.5.3 Leakage from the lower cover ..................................... 16-10
16.5.4 Replacing the wheel bolt ............................................. 16-11
17- Travel brake system 3100 ............................................................ 17-1

17.1 General ........................................................................................ 17-1
17.2 Operating description................................................................... 17-1
17.2.1 Releasing the accelerator .............................................. 17-2
17.2.2 Travel direction selector ................................................ 17-2
17.2.3 Pressing down the brake pushbutton ............................ 17-2
17.2.4 Parking brake ................................................................ 17-2
17.2.5 Emergency braking ........................................................ 17-2
17.3 Electromechanical disc brake, drive motor .................................. 17-4
17.3.1 Assembling .................................................................... 17-4
17.3.2 Dismantling .................................................................... 17-5
17.3.3 Inspection ...................................................................... 17-5
17.3.4 Assembling .................................................................... 17-5
17.4 Maintenance ................................................................................ 17-5
17.4.1 Adjusting the play .......................................................... 17-6
17.4.2 Wear .............................................................................. 17-6
17.4.3 Check the braking force ................................................. 17-7
17.5 Multiple disc brake, support arm .................................................. 17-7
17.5.1 Assembling .................................................................... 17-8
17.5.2 Dismantling .................................................................... 17-9
17.5.3 Inspection .................................................................... 17-10
17.5.4 Assembling .................................................................. 17-10
17.6 Maintenance .............................................................................. 17-10
17.6.1 Adjusting the play ........................................................ 17-11
1- 4
18- Drive wheel 3530 ..........................................................................

18.1 General ........................................................................................
18.2 Dismantling the drive wheel .........................................................
18.3 Assembling the drive wheel .........................................................
18-1
18-1
18-1
18-1
19- Fork/support arm wheel 3550 ......................................................

19.1 Dismantling the wheel ..................................................................
19.2 Assembling the wheel ..................................................................
300 mm wheel with brake and 350 mm wheel ..............
19.3 Dismantling/assembling the wheel bearings ................................
19.3.1 300 mm wheel with brake and 350 mm wheel ..............
Dismantling the bearing .................................................
Assembling bearings .....................................................
19-1
19-1
19-3
19-3
19-4
19-4
19-4
19-5
Service Manual
BT Europe AB
Content
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
20- Electrical system 5000 ................................................................. 20-1

20.1 General ........................................................................................ 20-1
20.1.1 Terminology ................................................................... 20-3
20.1.2 Truck firmware applications ........................................... 20-3
20.1.3 Communication .............................................................. 20-3
CAN communication ...................................................... 20-3
AUX serial interface ....................................................... 20-4
20.2 Main Computer Unit, MCU (A5) ................................................... 20-4
20.2.1 General .......................................................................... 20-5
The MCU has the following functions: ........................... 20-6
20.2.2 Voltage feed .................................................................. 20-6
20.2.3 Battery negative ............................................................. 20-6
20.2.4 Electric connectors ........................................................ 20-6
20.2.5 Internal status monitoring .............................................. 20-6
20.2.6 External inputs and outputs ........................................... 20-7
X130 connector ............................................................. 20-7
X131 connector ............................................................. 20-9
X132 connector ........................................................... 20-11
20.2.7 Installing a new card in the truck ................................. 20-12
20.2.8 Programming the MCU ................................................ 20-12
20.3 Fork computer unit, FCU (A4) .................................................... 20-13
20.3.1 General ........................................................................ 20-13
The FCU has the following functions: .......................... 20-13
20.3.2 Voltage feed ................................................................ 20-14
20.3.3 Battery negative ........................................................... 20-14
20.3.4 Electric connectors ...................................................... 20-14
20.3.5 External inputs and outputs ......................................... 20-15
Connector .................................................................... 20-15
20.3.6 Installing a new card in the truck ................................. 20-17
20.3.7 Programming ............................................................... 20-17
20.4 Integrated Control Panel, ICP (A16)........................................... 20-18
20.4.1 General ........................................................................ 20-18
The ICP has the following functions: ........................... 20-19
20.4.2 ICP modules ................................................................ 20-20
Left section .................................................................. 20-21
Right section ................................................................ 20-21
Display/keypad section (Std. version) ......................... 20-21
Logic card .................................................................... 20-21
20.4.3 Voltage feed ................................................................ 20-21
20.4.4 Battery negative ........................................................... 20-22
20.4.5 External inputs and outputs ......................................... 20-22
X100 connector ........................................................... 20-22
X101 connector ........................................................... 20-23
X102 connector ........................................................... 20-24
X103 connector ........................................................... 20-25
X104 connector ........................................................... 20-25
X106 connector ........................................................... 20-26
X107 connector ........................................................... 20-26
20.4.6 Installing a new ICP in the truck .................................. 20-26
20.4.7 Programming ............................................................... 20-26
20.5 AC regulators, ACTL (A1), ACTR (A31) and ACH (A2).............. 20-27
20.5.1 General ........................................................................ 20-27
20.5.2 Connection terminal and terminal pillars ..................... 20-28
20.5.3 Technical data ............................................................. 20-29
20.5.4 Installing a new frequency converter in the truck ........ 20-29
20.5.5 Programming ............................................................... 20-29
BT Europe AB
Service Manual
1- 5
Content
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
20.5.6 Maintenance ................................................................ 20-30

20.5.7 Safety .......................................................................... 20-30
20.5.8 Cleaning ...................................................................... 20-30
20.6 DC regulator, DCHI (A32) .......................................................... 20-31
20.6.1 General description ..................................................... 20-31
20.6.2 Connection terminal and terminal pillars ..................... 20-32
20.6.3 Technical data ............................................................. 20-33
20.6.4 Installing a new transistor panel .................................. 20-33
20.7 Parameters ................................................................................ 20-34
20.7.1 Diagnostics and troubleshooting ................................. 20-34
Displaying errors codes and error logging ................... 20-34
Error codes, troubleshooting ....................................... 20-35
Resetting errors ........................................................... 20-35
20.7.2 Maintenance ................................................................ 20-36
20.7.3 Safety .......................................................................... 20-36
20.7.4 Cleaning ...................................................................... 20-36
20.7.5 Hand-held terminal 1307 ............................................. 20-37
20.7.6 Using the hand-held terminal ....................................... 20-39
20.7.7 Viewing and adjusting parameters .............................. 20-40
Using the MORE INFO PROGRAM MODE ................. 20-40
20.7.8 SPECIAL PROGRAM MODE ...................................... 20-41
20.7.9 Using the TEST mode ................................................. 20-41
20.7.10 Using the DIAGNOSTICS MODE ................................ 20-42
20.7.11 SPECIAL DIAGNOSTICS MODE ................................ 20-42
20.8 Electrical system, overview ........................................................ 20-43
T-code 712 .................................................................. 20-44
T-code 713 .................................................................. 20-47
20.9 List of symbols and electric circuit diagrams .............................. 20-48
20.9.1 List of symbols ............................................................. 20-48
20.9.2 Electrical wiring diagrams (T-code 712) ...................... 20-50
20.9.3 Electrical wiring diagrams (T-code 713) ...................... 20-80
20.10 Component list ......................................................................... 20-109
20.10.1 Placement of components ......................................... 20-116
Picture 1 .................................................................... 20-116
Picture 2 .................................................................... 20-117
Picture 3 .................................................................... 20-118
Picture 4 .................................................................... 20-119
Picture 5 .................................................................... 20-120
Picture 6 .................................................................... 20-121
Picture 7 .................................................................... 20-122
Picture 8 .................................................................... 20-123
Picture 9 .................................................................... 20-124
20.10.2 Cabling contacts ........................................................ 20-125
20.11 Functional description, General ............................................... 20-127
20.12 Functional description, starting, driving, steering and braking . 20-128
20.12.1 Battery connected, truck switched off ........................ 20-128
20.12.2 Log-in / Start-up ......................................................... 20-129
Log-in ......................................................................... 20-129
Start-up process ........................................................ 20-130
Warnings during start-up ........................................... 20-131
Critical faults during start-up ...................................... 20-132
20.12.3 Log-out / Switch-off .................................................... 20-133
Log-out ...................................................................... 20-133
20.12.4 Presence verification ................................................. 20-134
Open cabin gates ...................................................... 20-134
1- 6
Service Manual
BT Europe AB
Content
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
Closed cabin gates .................................................... 20-134

20.12.5 Selecting the drive direction / Driving ........................ 20-134
Forward travel ............................................................ 20-135
Reverse travel ........................................................... 20-135
Motor control (ACTL, ACTR) ..................................... 20-135
20.12.6 Emergency driving mode ........................................... 20-136
20.12.7 Travel speeds ............................................................ 20-137
Optipace .................................................................... 20-137
Other travel speed reductions ................................... 20-137
Travel speeds outside narrow aisles with forks in the "home
position" ..................................................................... 20-139
Travel speeds for trucks in rail-guided narrow aisles 20-140
Travel speeds for trucks in wire-guided narrow aisles 20-142
20.12.8 Steering ..................................................................... 20-142
Safety monitoring ....................................................... 20-143
Steering wheel ........................................................... 20-144
Free driving mode ...................................................... 20-145
Rail-guided narrow aisle mode .................................. 20-146
Wire-guidance mode ................................................. 20-146
20.12.9 Braking ...................................................................... 20-147
Automatic braking ...................................................... 20-148
Reversing/Motor braking ........................................... 20-148
Braking with the brake button (S48) .......................... 20-149
Right dead man's handle released (S101) ................ 20-149
End-of-aisle braking/End-of-aisle stopping (options) . 20-150
Personal protection system (PPS) ............................. 20-151
Emergency switch-off (ESO) ..................................... 20-151
Parking brake ............................................................ 20-152
20.13 Electrical description of the hydraulic functions........................ 20-152
20.13.1 Allowed combined functions ...................................... 20-153
20.13.2 Monitoring and functional limitations ......................... 20-154
Monitoring .................................................................. 20-154
Safety limitations ....................................................... 20-154
20.13.3 Slack chain guard ...................................................... 20-156
20.13.4 Height measurement ................................................. 20-156
20.13.5 Cabin lifting ................................................................ 20-158
20.13.6 Special height (lift limiter function) ............................. 20-160
20.13.7 Cabin lowering ........................................................... 20-161
20.13.8 Special function with cab lifting/lowering and forks set
straight ahead
20-163
20.14 Turret head unit (T-code 712) .................................................. 20-164
Automatic switching of the turret head fork unit's functions ...
20-166
Fork lifting/lowering .................................................... 20-166
Measuring the load weight ......................................... 20-169
Side shifting/traversing of the forks ........................... 20-170
Fork rotation .............................................................. 20-172
20.14.1 Auto rotation .............................................................. 20-174
20.14.2 Miscellaneous electrical functions ............................. 20-176
Warning lamp ............................................................ 20-176
Personal protection system (PPS) ............................. 20-176
BT Europe AB
Service Manual
1- 7
Content
T-code
712, 713

919699-
20.15
20.16
20.17
20.18
20.19
20.20
1- 8
Date
2005-11-28
Order number
227761-040
20.14.3 Narrow aisle ID system ..............................................

20.14.4 Alternative narrow aisle system ..............................
Narrow aisle type .......................................................
Shuttle fork unit (t-code 713) ....................................................
20.15.1 Traversing of the forks ...............................................
Functional description ................................................
20.15.2 Fork lifting/lowering ....................................................
Lifting .........................................................................
Lowering ....................................................................
Measuring the load weight .........................................
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 ..................................................................
Display .....................................................................................
20.17.1 Normal mode .............................................................
20.17.2 Information mode .......................................................
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 ....
Calibration Shuttle fork (t-code 713) ........................................
20.19.1 Calibration of Shuttle fork ..........................................
Calibration of weight indication - WEIGHT ..............
Learn status codes FCU .........................................
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 ...........................................................
Service Manual
20-177
20-178
20-178
20-180
20-180
20-180
20-182
20-182
20-183
20-184
20-185
20-185
20-185
20-185
20-185
20-187
20-187
20-188
20-188
20-188
20-190
20-190
20-192
20-192
20-195
20-197
20-197
20-198
20-199
20-200
20-201
20-203
20-204
20-205
20-205
20-206
20-207
20-208
20-209
20-209
20-210
20-210
20-210
20-210
20-210
20-211
20-211
20-211
20-211
20-212
20-214
20-214
20-219
20-219
BT Europe AB
Content
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
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 ...........................................................
BT Europe AB
Service Manual
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Content
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
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 ...........................................................
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BT Europe AB
Content
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
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 .........................................................................
BT Europe AB
Service Manual
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1- 11
Content
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
20.23.7 Shuttle Fork system (including FCU cautions) - code group 6

(t-code 713)
20-313
21- Hydraulic system 6000 ................................................................. 21-1
21.1 General ........................................................................................ 21-1
21.1.1 Symbols ......................................................................... 21-2
21.2 Cabin lifting .................................................................................. 21-4
21.2.1 General .......................................................................... 21-4
21.2.2 Cabin lifting - S44 closed ............................................... 21-4
21.2.3 Cabin lowering - S70 closed .......................................... 21-4
21.2.4 AC hydraulic unit, components ...................................... 21-5
21.2.5 Hydraulic flow diagram, cabin lifting .............................. 21-7
Symbol list, chassis ....................................................... 21-8
21.2.6 B cylinder system .......................................................... 21-9
Hydraulic flow diagram, B cylinder system .................. 21-10
Symbol list, B cylinder system ..................................... 21-10
21.3 Fork units and steering............................................................... 21-11
21.3.1 General ........................................................................ 21-11
21.3.2 Hydraulic flow diagram, DC system (t-code 712) ........ 21-12
21.3.3 Hydraulic diagram (t-code 713) ................................... 21-13
Symbol list, fork unit and steering ................................ 21-14
Turret head fork unit valve (t-code 712) ...................... 21-15
21.3.4 Shuttle fork valve blocks (Tcode 713) ......................... 21-16
21.3.5 Fork rotation (t-code 712) ............................................ 21-17
21.3.6 Traversing movement .................................................. 21-17
21.3.7 Fork lifting .................................................................... 21-18
21.3.8 Fork lowering ............................................................... 21-18
21.3.9 Steering ....................................................................... 21-19
Steering valve .............................................................. 21-20
21.4 Extra hydraulic function (T-code 712) ........................................ 21-21
21.4.1 Valves used for the extra hydraulic functions .............. 21-21
Electrical connection .................................................... 21-21
21.4.2 Hydraulic diagram, extra hydraulic function
(t-code 712) ................................................................. 21-22
1- 12
22- Hydraulic pump 6140 ...................................................................

22.1 General ........................................................................................
22.2 Replacing the hydraulic pump......................................................
22.2.1 Dismantling ....................................................................
22.2.2 Assembling ....................................................................
22-1
22-1
22-2
22-2
22-4
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 ................................................................
23-1
23-1
23-1
23-2
23-5
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 ........................................................................
24-1
24-1
24-1
24-1
24-1
24-1
24-1
24-2
Service Manual
BT Europe AB
Content
Order number
227761-040
Date
2005-11-28

919699-
24.4
24.5
T-code
712, 713
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 ......................................................................
Cleaning.......................................................................................
Lubrication ...................................................................................
24-2
24-2
24-3
24-4
24-4
24-5
24-5
24-5
24-5
24-6
25- Initial mast/Turret head fork unit 7200 (t-code 712) ................... 25-1
25.1 General ........................................................................................ 25-1
25.2 Assembly/disassembly of the initial mast ..................................... 25-2
25.2.1 Mast assembly ............................................................... 25-2
25.2.2 Installation of belts on a new truck ................................ 25-6
25.2.3 Installing the hydraulic hose and electric cabling .......... 25-8
25.2.4 Mast disassembly .......................................................... 25-9
25.3 Inspection and replacement of belts used for fork traversing ..... 25-10
25.3.1 Inspection .................................................................... 25-10
Inspecting the belt condition ........................................ 25-10
25.3.2 Replacing the belt ........................................................ 25-11
Disassembly of the belt ............................................... 25-11
Installing the belt .......................................................... 25-12
25.3.3 Checking belt tensioning ............................................. 25-14
Belt tension meter 213973 ........................................... 25-14
Span measurement of the traversing arm ................. 25-14
Tension measurement of the traversing belt ............... 25-15
Tension measurement of the drive belt ....................... 25-15
25.4 Friction plate adjustment ............................................................ 25-17
26- Shuttle fork unit 7800 (t-code 713) ............................................. 26-1
26.1 Assembling shuttle forks .............................................................. 26-1
26.2 Maintenance ................................................................................ 26-3
26.2.1 Maintenance schedule ................................................... 26-4
26.2.2 Lubrication ..................................................................... 26-6
Oil and grease specification .......................................... 26-6
26.2.3 Adjustment of chains ..................................................... 26-7
Adjustment of fork chains .............................................. 26-7
26.3 Replacement of shuttle fork unit................................................. 26-10
BT Europe AB
27- Wire guidance equipment 8200 ...................................................

27.1 General ........................................................................................
27.2 Generator.....................................................................................
27.2.1 Technical data ...............................................................
27-1
27-1
27-2
27-2
28- Control/computer equipment 8700 .............................................

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 ..................................................
28-1
28-1
28-1
28-1
28-2
28-2
28-5
28-6
Service Manual
1- 13
Content
T-code
712, 713

919699-
28.5
28.6
28.7
28.8
Date
2005-11-28
Order number
227761-040
28.4.2 Menu window tree ......................................................... 28-7

28.4.3 Disconnection ................................................................ 28-7
Menus .......................................................................................... 28-8
28.5.1 File menu ....................................................................... 28-8
Open package ............................................................. 28-9
Save truck report ....................................................... 28-10
Save output window to file ........................................ 28-11
Save parameter setup to file ..................................... 28-12
Update parameter setup in truck ............................... 28-13
Save height pre-selection setup to file ...................... 28-14
Update height pre-selection from file ........................ 28-14
28.5.2 View menu ................................................................... 28-15
Read configuration .................................................... 28-15
Update ....................................................................... 28-15
Run ............................................................................ 28-16
Abort communication ................................................ 28-16
28.5.3 Tools menu .................................................................. 28-17
Log In ........................................................................ 28-17
Log In Production mode ............................................ 28-17
Log Out ..................................................................... 28-17
Read error log ........................................................... 28-18
Erase error log .......................................................... 28-20
Set hour meters ......................................................... 28-21
Set all parameters to default ..................................... 28-22
Download package .................................................... 28-22
28.5.4 Option menu ................................................................ 28-23
Program settings ....................................................... 28-23
Download package, Function for firmware downloading ......... 28-24
28.6.1 Normal firmware download .......................................... 28-25
Errors encountered during downloading ...................... 28-27
28.6.2 Emergency download ................................................ 28-28
Using the menu tree to verify/change parameters and perform diagnostics........................................................................................ 28-30
28.7.1 Software .................................................................... 28-30
28.7.2 Parameters ................................................................ 28-31
28.7.3 Diagnostics/troubleshooting ........................................ 28-33
Digital IO ................................................................... 28-33
Analog IO .................................................................. 28-34
Example: Diagnostics procedure for the Initial lift
function ........................................................................ 28-34
Installation.................................................................................. 28-41
28.8.1 Installation of TruckCom SE on a PC .......................... 28-42
Downloading TruckCom SE via the Internet ................ 28-42
Installing/updating TruckCom SE on the PC ............... 28-44
28.8.2 Necessary changes in Windows XP and Windows 2000
for TruckCom SE
28-46
Changes in Windows Control Panel ......................... 28-50
28.8.3 In case of communication errors with the CAN ........... 28-52
28.8.4 To uninstall .................................................................. 28-52
29- Height pre-selection 9390 ............................................................

29.1 General ........................................................................................
29.2 Parameters ..................................................................................
29.2.1 MCU parameters ...........................................................
Parameter 159 ...............................................................
1- 14
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29-1
29-1
29-1
29-2
BT Europe AB
Content
Order number
227761-040
Date
2005-11-28

919699-
29.3
BT Europe AB
T-code
712, 713
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/Automatic operations ....................................
General ..........................................................................
Collecting a load ............................................................
Depositing a load ...........................................................
Order picking .................................................................
Service Manual
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29-3
29-3
29-4
29-4
29-4
29-5
29-5
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Content
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
This page is intentionally left blank
1- 16
Service Manual
BT Europe AB
Presentation of the truck M2 (t-code 712)

Ergonomics
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713

(t-code 712)
2.1 Ergonomics
VCE150A/VCE150AC has been designed to meet the highest requirements on efficient VNA equipment in terms of high performance, excellent ergonomics, and continuous availability.
The truck has been designed to make both pallet handling and order
picking highly ergonomic. The mast, cab front and fork carriage are
designed to promote good visibility both to the front and rear, thus
allowing safe and efficient handling of goods. The operator's position
can be easily adapted to allow a comfortable working position with all
controls and information panels within easy reach. Emphasis has been
placed on an ideal work environment for the operators with low noise
and whenever possible a low stress level to enable them to perform at
their best while at the same time feeling well.
2.2 Performance
The truck uses articulated steering allowing smooth manoeuvering
both in and outside narrow aisles. It can be ordered both for rail guided
and wire guided narrow aisle systems. It has four wheel and two drive
motors which together with the rigid mast afford safe and efficient load
handling even for high lifts. Thanks to its high stability, the maximum
travel speed of 10 km/h can be used even for high cabin heights, adding to the high performance and low operational cost of the truck.
It is equipped with a newly developed fork unit that includes design
solutions, which are new for this type of truck. Traversing is controlled
by a hydraulic motor and synchronous drive belts allowing close to
silent traversing and a design that requires almost no maintenance at
all.
To increase the lift speed of the main lift and conserve energy, the truck
uses a hydraulic-pneumatic lifting system. A balance cylinder is the
main component in this system. The balance cylinder is at the rear of
the mast and consists of a pressure chamber filled with gas. Using this
design, it is possible to properly balance the weight of the mast and
cabin. In actual use, the hydraulic pressure that builds up when the
operator cabin is lowered is accumulated in the balance cylinder and
used for the next lifting operation.
Together with regnerative feedback of power to the battery during lowering operations, this makes the VCE150A/VCE150AC a truck with
impressive lifting performance.
BT Europe AB
Service Manual
2- 1

Electrical system
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
2.3 Electrical system

The truck uses a 48 V electric system and is operated with ergonomic
controls and pushbuttons. In the centre of the control panel, a colour
Integrated Control Panel (ICP) presents all necessary information of
the trucks status to the operator. The electric system of the truck incorporates the latest advances in CAN technologies, thus increasing the
number of operating modes while reducing the cabling requirements.
The truck's movements are supervised by a microcomputer and controlled by acceleration/retardation sensors. By adjusting the truck
parameters in the main computer, it is possible to tailor truck movements and behaviour to an extended range of applications. The drive
and lifting movements are smooth and uniform, further enhancing the
high level of operator comfort.
2.3.1 Intended application of the truck

The truck is designed and manufactured to carry out order picking and
pallet handling inside a warehouse. The truck should be fitted with the
appropriate accessories relevant to the application.
2.3.2 Forbidden application of the truck

The truck has been designed for order picking and pallet handling
indoors. It is not permitted to use the truck for other purposes including
the following:
- In areas that contain dust or gases which can cause fires or explosions
- As a tow-truck for trailers
- To tow other trucks
- To transport/lift passengers
- For work on sloping floors
2- 2
Service Manual
BT Europe AB

Truck data
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
2.4 Truck data

The table provides information regarding some technical data, which is
of value with daily use of the truck.
Note: To maintain safe handling, the travel speed will be limited by the
electronic system with regard to various parameters, such as the lifting
height, the steering system type for narrow aisle operation and steering
angle of the articulated centre.
Model designation
Fork skew,
rail guidance
Fork skew, wire

guidance
Rated capacity, kg
1500
1500
Load centre distance, mm
600
600
Travel speed without load, m/s
3,33
2,5
Travel speed with rated load, m/s
2,78
2,5
Lift speed, operator cage, without load, m/s
> 0,42
> 0,42
Lift speed, operator cage, with rated load, m/s
> 0,40
> 0,40
Lift speed with 800 kg load, m/s
0,41
0,41
Lowering speed without load, m/s
0,40
0,40
Lowering speed with rated load, m/s
0,40
0,40
Lift speed, initial lift, without load, m/s
0,20
0,20
Lift speed, initial lift, with rated load, m/s
0,15
0,15
Lowering speed, initial lift, without load, m/s
0,30
0,30
Lowering speed, initial lift, with rated load, m/s
0,30
0,30
Weight without battery, kg
6680
(fork height = 10,25 m)
6680
Battery (5h discharge), V (Ah)
48 (1200)
48 (1200)
Weight of battery, kg
1680 -1780
1680 -1780
Drive motors, kW
intermittence %
2 x 5,5
60
2 x 5,5
60
Lifting motor, kW
intermittence %
14
15
14
15
Motor, initial lift, kW

intermittence %
7,4
20
7,4
20
Control system
Electrohydraulic servo
Driving brake
Electromechanical +
reversing
Electromechanical +
reversing
Parking brake
Electromechanical
Electromechanical
BT Europe AB
Service Manual
2- 3

Truck data
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Model designation
Fork skew,
rail guidance
Fork skew, wire

guidance
Continuous noise level, dB (A)
72
72
Vibration level, m/s2
0,7
0,7
B cylinder/hydraulic-pneumatic power,kW
Intermittency, %
2-7
100
2-7
100
2- 4
Service Manual
BT Europe AB

Truck data
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
BT Europe AB
Service Manual
2- 5

Truck dimensions
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
2.5 Truck dimensions

The illustration shows the dimensions for the truck in its standard
design.
2- 6
Service Manual
BT Europe AB

Truck dimensions
Order number
227761-040
BT Europe AB
Date
2005-11-28

919699-
T-code
712, 713
Dimensions
Triplex mast (mm)
h1 Height of truck (with lowered forks)
4450
h3 Lift height
8180
h4 Height of truck, max.
10961
h7 Instep height, with lowered cabin
420
h12 Picking heights
10200
h9 Initial lift height
1990
h15 Total height
2781
hges Total lift height
10250
Ast Narrow aisle width
1450-1820
b1 Chassis width
1270/1420/1520/1620
b5 Fork widening
Min.380. Max.793/1193/
1493
b14 Cabin width
1220-1820
e Fork tip width
120
l Fork length (standard)
1200
l2 Length, incl. fork back rest
3616 (A=500)
m1 Ground clearance
60
s Fork thickness
40
Wa Turning radius
1698
l1 Truck length
3846 (A=500)
Service Manual
2- 7

Identification plate
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
2.6 Identification plate

The illustration shows the identification plate used on the truck.
Table 1:
Item
Text
Unit
MODEL
SERIAL NO
RATED CAPACITY
kg
WEIGHT WITHOUT BATTERY
kg
BATTERY WEIGHT
BATTERY VOLTAGE
MAX
MIN
kg
kg
V
2.7 Capacity plate
The illustration shows the capacity plate used on the truck.
Table 2:
2- 8
Item
Text
SERIAL NO
LIFT HEIGHT
mm
ACTUAL CAPACITY
kg
LOAD CENTRE DISTANCE
mm
Service Manual
Unit
BT Europe AB

Additional plates (VNA)
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
2.8 Additional plates (VNA)
S
T
CTXSKY4.WMF
Item
Text
SERIAL NO
MAXIMUM LIFT HEIGHT LIMITED TO xxx MM OUT

OF AISLE
* Only applies to lifting heights over 7000 mm.
2.9 Modification plate

The illustration shows the modification plate which is found on the truck
if it is supplied as non-standard or if it has been modified after leaving
the manufacturer. The plate includes information according to the table
below.
Item
Text
Modification plate
Type
Serial number
Place of manufacture
Modification number
Date
2.10 Identification plate, mast

The illustration shows the mast identification plate which can be found
on the side of the mast. The plate shows information according to the
table below.
BT Europe AB
Item
Text
Type
Serial number
Date
Service Manual
2- 9

Main components
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
2.11 Main components
2- 10
Service Manual
BT Europe AB

Main components
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
1. Rotation och traverseringsaggregat

2. Initialmast
3. Identification plate:
With model designation, serial number, year of manufacture,
weight without battery, battery weight, rated capacity, battery voltage and manufacturer
4. Cabin
5. Load carrier
6. Huvudmast
7. Warning light
8. Bakchassi med batterirum
9. Skerhetsgrindar (2 pcs)
10. Drive wheel (2 pcs)
11. Support arm wheel (4 pcs)
12. With support arm brakes installed on the inner wheel pairs.
BT Europe AB
Service Manual
2- 11

Warning and information plates and symbols
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
2.12 Warning and information plates

and symbols
The figure shows the position and significance of the plates and symbols located on the truck.
12
11a
11b
10
9
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Attachment point for spring-loaded hooks

Passengers prohibited
Reglagefunktioner vnster
Reglagefunktioner hger
Trycksatt system, se servicemanualen C-code 6000
Emergency lower
Hydraulic oil filling
Risk of crushing
A) Do not walk under an elevated load
B) Do not stand on the forks
11. Lifting points
2- 12
Service Manual
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713

(t-code 713)
VCE125ASF has been designed to meet the highest requirements on
efficient VNA equipment in terms of high performance, excellent ergonomics, and continuous availability.
VCE125ASF has been designed to make both pallet handling and
order picking highly ergonomic. The mast, cab front and fork carriage
are designed to promote good visibility both to the front and rear, thus
allowing safe and efficient handling of goods. The operator's position
can be easily adapted to allow a comfortable working position with all
controls and information panels within easy reach. Emphasis has been
placed on an ideal work environment for the operators with low noise
and whenever possible a low stress level to enable them to perform at
their best while at the same time feeling well.
VCE125ASF uses articulated steering allowing smooth manoeuvering
both in and outside narrow aisles. The truck can be ordered both for rail
guided and wire guided narrow aisle systems. It has four wheel and two
drive motors which together with the rigid mast afford safe and efficient
load handling even for high lifts. Thanks to its high stability, the maximum travel speed of 10 km/h can be used even for high cabin heights,
adding to the high performance and low operational cost of the truck.
VCE125ASF is equipped with a newly developed fork unit that includes
design solutions, which are new for this type of truck. Traversing is controlled by a hydraulic motor and chaines allowing close to silent traversing and a design easy for maintenance.
To increase the lift speed of the main lift and conserve energy, the truck
uses a hydraulic-pneumatic lifting system. A balance cylinder is the
main component in this system. The balance cylinder is at the rear of
the mast and consists of a pressure chamber filled with gas. Using this
design, it is possible to properly balance the weight of the mast and
cabin. In actual use, the hydraulic pressure that builds up when the
operator cabin is lowered is accumulated in the balance cylinder and
used for the next lifting operation.
Together with regnerative feedback of power to the battery during lowering operations, this makes the VCE125ASF a truck with impressive
lifting performance.
The truck uses a 48 V electric system and is operated with ergonomic
controls and pushbuttons. In the centre of the control panel, a colour
Integrated Control Panel (ICP) presents all necessary information of
the trucks status to the operator. The electric system of the truck incorporates the latest advances in CAN technologies, thus increasing the
number of operating modes while reducing the cabling requirements.
The truck's movements are supervised by a microcomputer and controlled by acceleration/retardation sensors. By adjusting the truck
parameters in the main computer, it is possible to tailor truck movements and behaviour to an extended range of applications. The drive
BT Europe AB
Service Manual
3- 1

Intended application of the truck
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
and lifting movements are smooth and uniform, further enhancing the
high level of operator comfort.
3.1 Intended application of the truck

The truck is designed and manufactured to carry out order picking and
pallet handling inside a warehouse. The truck should be fitted with the
appropriate accessories relevant to the application.
3.2 Prohibited application of the truck

The truck has been designed for order picking and pallet handling
indoors. It is not permitted to use the truck for other purposes including
the following:
- In areas that contain dust or gases which can cause fires or explosions
- As a tow-truck for trailers
- To tow other trucks
- To transport/lift passengers
- For work on sloping floors
3- 2
Service Manual
BT Europe AB

Truck data
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
3.3 Truck data

The table provides information regarding some technical data, which is
of value with daily use of the truck.
Note: To maintain safe handling, the travel speed will be limited by the
electronic system with regard to various parameters, such as the lifting
height, the steering system type for narrow aisle operation and steering
angle of the articulated centre.
Model designation
VCE125ASF
(rail guidance)
VCE125ASF
(wire guidance)
Rated capacity, kg
1250
1250
Travel speed without load, with

supportarmbrake, m/s
3,33
2,78
Travel speed without load, without

supportarmbrake, m/s
2,78
2,78
Travel speed with rated load, m/s
2,78
2,5
Lift speed, operator cage, without load, m/s
> 0,25
> 0,25
Lift speed, operator cage, with rated load, m/s
> 0,20
> 0,20
Lowering speed without load, m/s
0,20
0,20
Lowering speed with rated load, m/s
0,20
0,20
Lift speed, initial lift, without load, m/s
0,25
0,25
Lift speed, initial lift, with rated load, m/s
0,20
0,20
Lowering speed, initial lift, without load, m/s
0,30
0,30
Lowering speed, initial lift, with rated load, m/s
0,30
0,30
Traverse speed without load, m/s
0,45
0,45
Traverse speed with load, m/s
0,25
0,25
Weight without battery, kg
6600
6600
(fork height = 10,25
m)
Battery (5h discharge), V (Ah)
48 (1200)
48 (1200)
Weight of battery, kg
1680 -1850
1680 -1850
Drive motors, kW
intermittence %
2 x 5,5
60
2 x 5,5
60
Lifting motor, kW
intermittence %
14
25
14
25
Motor, initial lift, kW

intermittence %
7,4
20
7,4
20
BT Europe AB
Service Manual
3- 3

Truck dimensions
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Model designation
VCE125ASF
(rail guidance)
VCE125ASF
(wire guidance)
Control system
Electrohydraulic
servo
Driving brake
Reversing (without
supportarmbrake)
Electromechanical +
Reversing (with supportarmbrake)
Electromechanical +
Reversing
Parking brake
Electromechanical
Electromechanical
Continuous noise level, dB (A)
72
72
Vibration level, m/s2
0,7
0,7
B cylinder/hydraulic-pneumatic power,kW
Intermittency, %
2-7
100
2-7
100
3.4 Truck dimensions

The illustration shows the dimensions for the truck in its standard
design.
3- 4
Service Manual
BT Europe AB

Truck dimensions
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
VCE125ASF
BT Europe AB
Service Manual
3- 5

Truck dimensions
T-code
712, 713

919699-
Dimensions
Date
2005-11-28
Order number
227761-040
VCE125ASF (mm)
Lift height
h3
369
0
429
0
492
0
564
0
699
0
8190
9390
1059
0
1119
0
1224
0
Height of truck,
min.
h1
279
0
296
0
316
0
346
0
396
0
4460
4960
5460
5660
6040
Height of truck,
max.
h4
623
0
683
0
743
0
818
0
953
0
1073
0
1193
0
1313
0
1373
0
1478
0
Max.Lift height
750mm
initial lift
h23
478
0
538
0
598
0
673
0
808
0
9280
1048
0
1168
0
1228
0
1333
0
Max.Lift height
1100mm
initial lift
h23
513
0
573
0
633
0
708
0
843
0
9630
1083
0
1203
0
1263
0
1368
0
Initial lift height
h9
750/1100
Height of
initial mast
h15
1335/1685
Picking
heights
h20
570
0
630
0
690
0
765
0
900
0
1020
0
1140
0
1260
0
1320
0
1425
0
Platform
heights
h12
410
0
470
0
530
0
605
0
740
0
8600
9800
1100
0
1160
0
1265
0
Step in height
h7
420
Ground clearance
M1/M2
60/40
Fork thickness
40
Height of lowered forks
h13
350
3- 6
Service Manual
BT Europe AB

Truck dimensions
Order number
227761-040
BT Europe AB
Date
2005-11-28

919699-
T-code
712, 713
Dimensions
VCE125ASF (mm)
b1 Chassis width
1270/1420/1520/1620
b5 Fork widening
Min.380. Max.793/1193/1493
b14 Cabin width
1220-1820
e Fork tip width
120
l Fork length (standard)
1200
Wa Turning radius
1698
l1 Truck length
3846 (A=500)
Service Manual
3- 7

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
3.5 Identification plate

The illustration shows the identification plate used on the truck.
Item
Text
Unit
MODEL
NO
RATED CAPACITY
kg
WEIGHT WITHOUT BATTERY
kg
BATTERY WEIGHT
kg
kg
BATTERY VOLTAGE
MAX
MIN
3.6 Capacity plate

The illustration shows the capacity plate used on the truck.
Item
Text
Unit
NO
LIFT HEIGHT
mm
ACTUAL CAPACITY
kg
LOAD CENTRE
mm
3.7 Additional plates (VNA)

K
Item
Text
SERIAL NO
MAXIMUM LIFT HEIGHT LIMITED TO xxx MM

OUT OF AISLE
* Only applies to lifting heights over 7000 mm.
S
T
CTXSKY4.WMF
3- 8
Service Manual
BT Europe AB

Modification plate
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
3.8 Modification plate

The illustration shows the modification plate which is found on the truck
if it is supplied as non-standard or if it has been modified after leaving
the manufacturer. The plate includes information according to the table
below.
Item
Text
Modification plate
Type
Serial number
Modification number
Date
3.9 Identification plate, mast

The illustration shows the mast identification plate which can be found
on the side of the mast. The plate shows information according to the
table below.
BT Europe AB
Item
Text
Type
Serial number
Date
Service Manual
3- 9

Identification plate, mast
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
3- 10
Service Manual
BT Europe AB
Introduction, maintenance P1 (t-code 712)

Safety precautions for maintenance work
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
4- Introduction, maintenance P1
(t-code 712)
To achieve maximum safety and minimum downtime, all items in the
service programme must be covered. The service intervals are merely
a guideline and need not be strictly followed. The truck operators
should adapt these to local requirements, however, it is important that
the intervals coincide with the minimum BT requirements.
The service intervals are based on operating hours and can be adapted
to most standard 8-hour shifts. When calculating the intervals, the following operating hours have been used:
Day time: 08.00-17.00 (20 hours/week)
2 shifts: 06.00-14.00, 14.00-22.00 (40 hours/week)
3 shifts: 06.00-14.00, 14.00-22.00, 22.00-06.00 (60 hours/week)
Make sure the truck is subjected to regular maintenance at intervals of
250 operating hours. Truck safety, truck efficiency and the truck's
expected service life depend on the service and maintenance the truck
receives.
Only use spare parts approved by BT when servicing and repairing the
truck.
4.1 Safety precautions for maintenance

work
Only personnel specially trained for service and repairs of this truck
type are authorised to perform service and repair work of the truck.
Do not carry out any maintenance work on the truck unless you have
completed the appropriate training and possess the required knowledge to perform such work.
Always keep the maintenance work site clean. Spilled oil and water
will make the floor slippery.
Never wear loose items or jewellery when working on the truck.
WARNING!
Shortcircuiting/Burn injury.
When working on the electrical system on the truck, there is a risk of
shortcircuiting/burn injury if metal objects come into contact with live
electric parts.
Remove wristwatches, rings and other metal objects beforehand
Unless otherwise stated in the instructions herein or the Service

Manual, always disconnect the battery connector prior to performing
any maintenance work on the truck.
Always switch off the truck's power supply before opening any covers to drive units or the electrical system.
BT Europe AB
Service Manual
4- 1

Safety precautions for maintenance work
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Always depressurise the system prior to performing any work on the

hydraulic system of the truck.
Use paper or cardboard to search for possible oil leaks. Do not use
your hand!
Keep in mind that the transmission oil and the hydraulic system oil
may be hot.
WARNING!
Risk of burn injury.
Hot transmission and hydraulic oil.
Allow the truck to cool down before replacing the oil.
Only fill up the hydraulic system with new, clean oil.

Fill up oil through the oil filter.
WARNING!
Risk of damaging the hydraulic system.
If the oil is contaminated, the hydraulic components will suffer damage.
Always use new, clean oil in the hydraulic system.
Store and discard of replaced oil according to local regulations.

Solvents and other harmful substances that have been used in the
course of cleaning must not be flushed down into drains that are not
specially designed for this. Always follow applicable local regulations for discarding solvents and harmful substances.
Disconnect the battery prior to performing any welding work on the
truck.
NOTE!
The battery could become damaged.
When welding using an electric welding unit, welding current may
reach the battery.
Because of this, be sure to disconnect the battery.
Before welding or grinding painted surfaces on the truck, scrape off

the paint within an area of at least 100 mm around the welding/grinding area by blasting or through use of paint remover.
WARNING!
Harmful gasses.
Paint that has been heated gives off harmful gasses.
Remove all paint within 100 mm of the welding/grinding site.
When work under the truck is required, secure the truck with trestles
prior to performing such work.
WARNING!
Risk of crushing.
A truck that has not been secured could fall down.
Never work under a truck that has not been secured with trestles or
secured by a sufficiently strong lifting device.
4- 2
Service Manual
BT Europe AB

Maintenance work to be performed by the operator
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
4.1.1 Gas-charged accumulators

The balance cylinder, which is mounted on the rear side of the mast,
and the steering accumulator are pressure vessels under high gas and
oil pressure. Also the conduits and connected devices constitute elements of risk. Any work on these components should only be performed
by trained service technicians.
Bear in mind the following:
Do not open the pressure vessel until the gas and oil sides have
been depressurised.
Only charge the pressure vessel with nitrogen gas.
NOTE!
Nitrogen gas can cause suffocation!
Do not perform any mechanical work on the pressure vessel (e.g.

welding, drilling or forced opening).
4.2 Maintenance work to be performed

by the operator
Daily inspection and operational inspection according to the check list
in the Operator's Manual.
Maintenance items listed under Daily, Weekly and Monthly maintenance in the maintenance schedule may be performed by the operator.
Other maintenance items may only be performed by service technicians who have completed training for this type of truck.
4.2.1 Maintenance work that may be

performed by trained service technicians
All maintenance items in the maintenance schedule.
All service and repair work in addition to the maintenance schedule
must be performed by service technicians who have completed specialist training for this type of truck.
BT Europe AB
Service Manual
4- 3

Cleaning and washing
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
4.3 Cleaning and washing

Cleaning and washing of the truck will maintain a high level of reliability.
Perform general cleaning and washing once a week.
NOTE!
Risk of shortcircuiting.
The electric system could become damaged.
Prior to washing the truck, disconnect the battery by disconnecting
the battery connector.
4.3.1 Exterior cleaning

Remove dirt and rubbish from the wheels daily.
Use a well-known degreasing agent, diluted to the proper concentration.
Rinse off loose dirt with tepid water.
NOTE!
Seizure, corrosion.
Mechanical parts could become damaged.
After cleaning the truck, lubricate it according to the lubrication chart
in the Maintenance section.
4.3.2 Cleaning the motor compartment

Cover electric motors, connectors and valves prior to washing.
NOTE!
The electric system could become damaged.
Do not wash electric components with a high-pressure jet.
Wash the motor compartment with a well-known degreasing agent,

diluted to the proper concentration.
Rinse off loose dirt with tepid water.
4.3.3 Electric components

Use compressed air to clean electric motors.
Clean electric panels, logic cards, connectors, switches, valves, etc.
with a moist rag and a cleaning agent.
NOTE!
The electric components could become damaged.
Do not break off any warranty seals on the logic cards.
4- 4
Service Manual
BT Europe AB

Secure lifting
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
4.4 Secure lifting

All lifts should be performed on a level, nonslip and sturdy surface.
Avoid newly laid asphalt or an asphalt surface in warm weather.
To prevent the truck from moving during the lift, always apply the
parking brake. If the brake wheel needs to be lifted, chock the other
wheels to keep in the truck immobilised.
Select the lifting points to make the lift as light as possible (one corner at a time). If the lifting points on the truck are indicated at the lower part of the chassis, only use these points to achieve balanced lifting.
Make sure the surface, where the jack is placed, is clean and free of
any spilled oil or grease.
Make sure your hands and the jack lever are free of grease and oil.
Only use the lever supplied with the jack. Too short a lever requires
increased and unnecessary exertion. Too long a lever could overload the jack.
Place trestles under the lifted truck:
- as close as possible to the lifted part of the chassis to limit the falling height in case the jack collapses.
- to prevent the truck from moving.
Never block up the jack to achieve higher lifts.
Never work under a lifted truck unless it has been secured with proper and sufficiently strong trestles beforehand.
WARNING!
Risk of crushing.
A truck that has not been secured could fall down.
Never work under a truck that has not been secured with trestles or
secured by a sufficiently strong lifting device.
BT Europe AB
Service Manual
4- 5

Lifting points
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
4.5 Lifting points

4.5.1 Lifting the truck
The truck may only be lifted by the indicated lifting points and with
lifting equipment approved by BT.
Please contact BT service for more information.
WARNING!
Risk of overturning.
The truck can overturn if it is lifted from the wrong lifting points.
Always lift the truck from the marked lifting points.
WARNING!
The truck can overturn if it is lifted incorrectly.
Always lift the truck secured to, and with the centre of gravity between, the lifting trucks forks.
4- 6
Service Manual
BT Europe AB
Maintenance P1 (t-code 713)

Safety regulations with maintenance work
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
5- Maintenance P1 (t-code 713)

Ensure the truck is given a regular maintenance service after 500 operating hours. The trucks safety, efficiency and service life is dependent
on the service and maintenance it is given.
Only use BT approved spare parts when service and repair work are
carried out.
BT recommends that you contact your closest BT representative to sign
a service and maintenance agreement to ensure the trucks operating
economy and safety.
5.1 Safety regulations with

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 trucks electrical system, short-circuiting/
burns can occur if a metal object comes into contact with live electrical connections.
Remove watches, rings or other types of metal jewellery.
Always disconnect the battery by pulling out the emergency disconnector when carrying out maintenance work on the truck unless otherwise stated in this publication or the Service Manual.
Always switch off the trucks power supply before opening the covers on the drive unit or electrical system.
Relieve the system pressure slowly before starting work on the
trucks hydraulic system.
Use paper or a rigid sheet of cardboard when checking for oil leakage. 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 replacing the oil.
BT Europe AB
Service Manual
5- 1

Safety regulations with maintenance work
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Only fill the hydraulic system with new and clean oil.
Fill with oil through the oil filter.
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 release solvents and the like, which are used for cleaning/
washing, into drains that are not intended for this purpose. Follow
the local directives that apply for disposal.
Disconnect the battery when welding on the truck.
WARNING!
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.
Remove at least 100 mm (4) of paint around the welding/grinding

area through sand-blasting or the use of a paint stripper when welding or grinding on painted surfaces.
WARNING!
Harmful gases.
Paint that is heated gives off harmful gases.
Remove 100 mm (4) of paint from the work area.
When working underneath the truck, support the truck on trestleblocks.

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.
Gas-charged accumulators
The balance cylinder, located on the rear of the mast, and the steering
accumulator are both pressure vessels with very high gas and oil pressure. The connections and associated equipment should also be
regarded as high-risk components. Service and maintenance is only
allowed by trained service technicians.
Pay attention to the following:
Do not open the pressure vessel until the gas and oil lines have been
depressurised.
Only charge the pressure vessel with nitrogen.
NOTE!
Nitrogen can cause suffocation!
Do not perform any mechanical measures on the pressure vessel

(e.g. welding, drilling or forcing it open).
5- 2
Service Manual
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
5.1.1 Maintenance work that is to be carried

out by the operator
Daily service and function checks as set out in the checklist in chapter
Daily service and function checks.
Maintenance points with intervals 1 day, 1 week and 1 month as set out
in the maintenance chart may be carried out by the operator.
Other maintenance points as set out in the maintenance chart may only
be carried out by personnel who have completed maintenance training
for this type of truck.
5.1.2 Maintenance work that may be carried

out by trained maintenance personnel
All maintenance points as set out in the maintenance chart.
With uncertainty regarding working procedures, consult the Service
Manual for the truck.
In addition to the maintenance points in the maintenance chart, all service and repair work should be carried out by personnel with special
training for this type of truck.
5.2 Cleaning and washing

Cleaning and washing of the truck is important to ensure the trucks reliability.
Carry out general cleaning and washing weekly.
WARNING!
Risk of short-circuiting.
The electrical system can be damaged
Disconnect the battery before washing by pulling out the emergency
disconnector.
5.2.1 External cleaning

Remove rubbish, etc. from the wheels daily.
Use a well-known degreasing agent, diluted to a suitable concentration.
Rinse off loose grime using tepid water.
WARNING!
Jamming, corrosion.
Mechanical components can be damaged.
After washing, the truck should be lubricated as set out in the lubrication chart in chapter Maintenance.
BT Europe AB
Service Manual
5- 3

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
5.2.2 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.
5.2.3 Electrical components

Blow electric motors down using compressed air.
Clean the electrical panels, electronic boards, contactors, connections, solenoid valves, etc. using a damp cloth and a cleaning agent.
NOTE!
Electrical components can be damaged.
Do not break the guarantee seal on the electronic board.
5- 4
Service Manual
BT Europe AB

Transporting and storing the truck
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
5.3 Transporting and storing the truck

5.3.1 Lifting the truck
The truck may only be lifted by the indicated lifting points and with
lifting equipment approved by BT.
Please contact BT service for more information.
WARNING!
The truck can overturn if it is lifted from the wrong lifting points.
Always lift the truck from the marked lifting points.
WARNING!
The truck can overturn if it is lifted incorrectly.
Always lift the truck secured to, and with the centre of gravity between, the lifting trucks forks.
5.3.2 Towing and transporting a defective

truck
Tow or transport a defective truck to a repair station as follows:
1. With the parking brake released:
On the right side of the truck, under the battery cover, there are
switches to manually release the parking brake.
To release the brake, depress all three switches to position I.
Then tow the truck, using a towing truck and draw bar, at low
speed.
WARNING!
Risk of injury.
The truck can start to roll when the parking brake has been released.
Never leave the truck unattended when the parking brake has been released unless the wheels have been blocked in a satisfactory manner.
BT Europe AB
Service Manual
5- 5

Transporting and storing the truck
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
2. Transport using a counter-weight truck:

When transporting the VCE125ASF with a counter-weight truck, be
sure to use a truck with a lifting capacity of minimum 4 tonnes.
Insert the forks of the counter-weight truck about 30-40 cm under
the rear chassis of the truck.
Anchor the truck to the counter-weight truck using a suitable chain
or strap.
Lift the chassis until the rear wheels just clear the floor.
Then transport the truck at very low speed.
WARNING!
Risk of injury.
The truck can slide off the forks of the counter-weight truck.
Never transport the truck unless it has been properly secured to the
counter-weight truck.
5.3.3 Storing the truck

Take the following action if the truck is not used for a long period of time:
Battery
Recharge the batteries fully and carry out usual battery maintenance.
Maintenance charge the battery every third month and check the
fluid level.
Hydraulic system
Change the oil in the hydraulic system when the truck is stored for
periods longer than one year, see the oil specification in the Maintenance chart and Oil and grease specification in chapter Maintenance.
Drain the hydraulic-pneumatic accumulators of all oil when putting
away the truck for storage for more than 3 months.
Drive unit
Block up the trucks drive section to take the load off the drive wheel,
when stored for periods longer than three months.
5- 6
Service Manual
BT Europe AB

Starting after a period of disuse
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
5.4 Starting after a period of disuse

Before the truck is put into operation after a period of disuse it should
undergo a function and safety check as set out in the chapter Daily
service and function checks.
Carry out preventive maintenance as set out in the instructions, 250
hours interval.
Inspect the gas pressure in the accumulators and replace the oil.
BT Europe AB
Service Manual
5- 7

Starting after a period of disuse
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
5- 8
Service Manual
BT Europe AB
Preventive maintenance P2 (t-code 712)

Maintenance schedule
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
6- Preventive maintenance P2 (tcode 712)

6.1 Maintenance schedule
I: Inspect, adjust and replace if necessary. T: Tighten. C: Clean. L: Lubricate.
M: Measure and adjust if necessary.
Pos.
no.
Work to be performed
Interval in hours - can vary depending on
application
Initial500
ly 250 h
1000
2000
3000
Interval in days/weeks/months - can vary

depending on application
3m
6m
12 m
24 m
36 m
0000
Chassis
0000.1
Inspect the battery locking device
0000.2
Inspect for cracking and other damage
0000.3
Inspect the overhead guard mounting
0800
Protective equipment
0800.1
Inspect the life line
0640
Operator controls
0640.1
Inspect the mounting
0640.2
Inspect the strength of the gas struts and the

locking performance
1700
Electric motors
1700.1
Inspect all cable connections
1700.2
Tighten all mounting bolts
1700.3
Inspect all cooling fan functions
1800
Hydraulic motors
1800.1
Inspect mounting, and retighten the mounting

bolts
I/T
1800.2
Check for leakage
BT Europe AB
Service Manual
6- 1

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040

Pos.
no.
application
Initial500
ly 250 h
1000
2000
3000

3m
12 m
24 m
36 m
6m
2550
Drive unit
2550.1
Inspect for leakage/inspect the oil level
2550.2
Replace the drive gear oil
2550.3
Inspect any noise
3180
Electrically controlled service brake
3180.1
Clean
3180.2
Inspect wear on the brake disc/ohm measure the

brake coil
3180.3
Inspect play in the neutral position
3370
Electric parking brake
3370.1
Clean
3370.2
Inspect the braking torque
3370.3
3500
Wheels
3500.1
Remove strings and other dirt
3500.2
Inspect the drive wheel for wear and the tightening torque of the bolts
I/T
6- 2
I
I
IC1
I
Service Manual
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713

Pos.
no.
application
Initial500
ly 250 h
1000
2000
3000

3m
12 m
24 m
36 m
6m
5000
Electric functions
5000.1
Tighten all cable connectors
5000.2
Inspect the contactor tips and their function
5000.3
Inspect the emergency stop switch function (ICP,

chassis)
5000.4
Inspect the operation of the safety gates
5000.5
Inspect the warning light (blinker) function
5000.6
Inspect the slack chain guards
5000.7
Inspect the error code log & operating hours
5110
Battery
5110.1
Inspect the electrolyte level: 10-15 mm above the

cell plates
5110.2
Inspect all battery, truck and charger connections
5110.3
Verify that the cell and pole protectors are not

damaged
5110.4
Inspect the fluid density and temperature
5110.5
Suck up excess fluid from the battery pan
6100
Hydraulic unit
6100.1
Inspect leakage of hoses, connections, filters

and cylinder gaskets
6100.2
Inspect the oil level/leakage
6100.3
Inspect the gas pressure in the accumulators
6100.4
Replace the hydraulic oil
6100.5
Replace the oil and air filter
6100.6
Inspect carbon brush wear in the

initial pump motor and clean
BT Europe AB
Service Manual
T
I
I
IB
I
M
6- 3

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040

Pos.
no.
application
Initial500
ly 250 h
1000
2000
3000

3m
12 m
24 m
36 m
6m
7100
Main mast
7100.1
Inspect emergency lowering
7100.2
Inspect the lifting cylinder mounting
7100.3
Inspect wear on the lifting chains and the chain

wheel
7100.4
Lubricate the lifting chains
LA
7100.5
Lubricate the mast rails at the guide rollers and

lateral guide rollers
7100.6
Inspect the adjustment of the lifting chains.

Inspect the chain bolts and the chain mounting.
Retighten locking nuts to the correct torque and
inspect the safety cotter pin.
7200
Initial mast
7200.1
LA
7200.2

Retighten locking nuts to the correct torque and
inspect the safety cotter pin.
7200.3
Lubricate the turning chain
LA
7200.4
Inspect the belt tension.
7200.5
Lubricate the guide roller contact surface at the U

member. NOTE
7200.6
Lubricate the mast rails at the guide rollers
7200.7
Lubricate the interrupt roller bearings (interrupt

roller x4 for the belts)
7200.8
Lubricate the mast rails at the sliding block
7200.9
Lubricate the support roller (x4) contact surfaces

(steel rims x2 in anticorrosive material).
7200.10
Lubricate the initial mast rotation bearing (x2)
7200.11
Inspect hoses, couplings and cylinders for leakage
7200.12
Inspect line components, cylinders and the

hydraulic motor for leakage
6- 4
Service Manual
LF
LF
I
I
LD
LF
LE
LG
LG
LF
LE
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713

Pos.
no.
application
Initial500
ly 250 h
1000
2000
3000

3m
12 m
24 m
36 m
6m
7200.13
Inspect the rotation cylinders for internal leakage.

(Remove the bleeder valve)
7200.14
Inspect hoses for wear
I
NOTE: 500 h is based on average loads of 700-800 kg. For higher average loads, the interval should be changed to 250 h.
1 = Replace the oil the first time after 250 hours/3 months and then every 3000 hours/36 months.
Unless otherwise indicated, whenever performing service according to
longer service intervals, all service items at shorter intervals should
also be carried out.
The letters A-G indicate the lubricant type to be used. See the separate
table in P3.
BT Europe AB
Service Manual
6- 5

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
7100.3
7100.4
7100.6
7100.2
7200.4 7200.11
7200.10 7200.12
7200.3
7200.13
7200.16
7200.7
5110
0000
7200.1
7200.2
1700
3370
5000
0640
0800
7200.6
7200.8
7200.5
6- 6
Service Manual
3500
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
7100.5
6100
2550
BT Europe AB
Service Manual
6- 7

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
6- 8
Service Manual
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
7- Preventive maintenance P2
(t-code 713)
Pos.
no.
Interval in hours - can vary depending
on application
Initially
250 h
500
1000
2000
3000
Interval in months - can vary

3m
6m
12 m
24 m
36 m
0000
Chassis
0000.1
Inspect the battery locking device
0000.2
Inspect for cracking and other damage
0000.3
Inspect the overhead guard mounting
0800
Protective equipment
0800.1
Inspect the life line
0640
Operator controls
0640.1
Inspect the mounting
0640.2
Inspect the strength of the gas struts and the

locking performance
1700
Electric motors
1700.1
Inspect all cable connections
1700.2
Tighten all mounting bolts
1700.3
Inspect all cooling fan functions
1800
Hydraulic motors
1800.1
Inspect mounting, and retighten the mounting bolts
I/T
1800.2
Check for leakage
2550
Drive unit
2550.1
Inspect for leakage/inspect the oil level
2550.2
Replace the drive gear oil
2550.3
Inspect any noise
BT Europe AB
Service Manual
I
I
IC1
I
I
7- 1

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040

Pos.
no.
7- 2
on application
Initially
250 h
500
1000
2000
3000

3m
6m
12 m
24 m
36 m
3180
Electrically controlled service brake
3180.1
Clean
3180.2
Inspect wear on the brake disc/ohm measure

the brake coil
3180.3
3370
Electric parking brake
3370.1
Clean
3370.2
Inspect the braking torque
3370.3
3500
Wheels
3500.1
Remove strings and other dirt
3500.2
Inspect the drive wheel for wear and the

tightening torque of the bolts
I/T
5000
Electric functions
5000.1
Tighten all cable connectors
5000.2
Inspect the contactor tips and their function
5000.3
Inspect the emergency stop switch function

(ICP, chassis)
5000.4
Inspect the operation of the safety gates
5000.5
Inspect the warning light (blinker) function
5000.6
Inspect the slack chain guards
5000.7
Inspect the error code log & operating hours
5000.8
Check the horn
Service Manual
T
I
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713

Pos.
no.
on application
Initially
250 h
500
1000
2000
3000

3m
6m
12 m
24 m
36 m
5110
Battery
5110.1
Inspect the electrolyte level: 10-15 mm

above the cell plates
5110.2
Inspect all battery, truck and charger connections
5110.3
Verify that the cell and pole protectors are

not damaged
5110.4
Inspect the fluid density and temperature
5110.5
Suck up excess fluid from the battery pan
6100
Hydraulic unit
6100.1
Inspect leakage of hoses, connections, filters

and cylinder gaskets
6100.2
Inspect the oil level/leakage
6100.3
Inspect the gas pressure in the accumulators
6100.4
Replace the hydraulic oil
6100.5
Replace the oil and air filter
6100.6
Inspect carbon brush wear in the

initial pump motor and clean
7100
Main mast
7100.1
Inspect emergency lowering
7100.2
Inspect the lifting cylinder mounting
7100.3
Inspect wear on the lifting chains and the

chain wheel
7100.4
LA
7100.5

and lateral guide rollers
7100.6

Retighten locking nuts to the correct torque
and inspect the safety cotter pin.
BT Europe AB
Service Manual
I
IB
I
M
LF
LF
I
7- 3

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040

Pos.
no.
on application
Initially
250 h
500
1000
2000
3000

3m
6m
12 m
24 m
36 m
7200
Initial mast
7200.1
LA
7200.2

Retighten locking nuts to the correct torque
and inspect the safety cotter pin.
7200.3
Lubricate the guide roller contact surface at

the U member (NOTE)
LD
7200.4
LF
7200.5
Inspect hoses, couplings and cylinders for

leakage.
7200.6
Inspect hoses for wear
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
7800.6
Check the adjustment of the shuttle fork

chain
7800.7
Check the reach carriage play +/- 2mm
7800.8
Check the mounting and wear on the chain

wheel
7800.9
Inspect line components and the hydraulic

motor for leakage
a) After 250 h, after which further replacement is not necessary.
b) Oil replacement every 2000 hours or every 2nd year.
The letters A-G indicate the lubricant type to be used. See the separate
table.
7- 4
Service Manual
BT Europe AB
Oil and grease specifications P3 (T-code 712)

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
8- Oil and grease specifications P3

(T-code 712)
Pos.
Lubricant
Ambient
temperature
Viscosity
class
Use
Recommended
products*
Chain Lubrication
> - 40C
< - 30C
VG 150
Chains
Klberoil 4UH 1-15,

Klber Lubrication
> - 30C
< + 5C
VG 68
Chains
Klberoil 4UH 1-68N,

Klber Lubrication
Anticorit LBO 160 TT,
Fuchs DEA
> + 5C
< +45C
VG 150
Chains
Klberoil 4UH 1-150N,

Klber Lubrication
Anticorit LBO 160,
Fuchs DEA
Rexoil, Rexnord Kette
>+ 45C
<+ 80C
VG 220
Chains

Klber Lubrication
> - 40C
< - 15C
ISO-VG 15
Hydraulic system
> -15C
< +45C
ISO-VG 32
Hydraulic system
> - 40C
< - 15C
Hypoid oil
SAE 75W
Gears
> -15C
< +45C
Hypoid oil
SAE 80W/90
Gears
> - 40C
< - 15C
---------
Support roller
contact surfaces
Klberpasta 46 MR
401 (Klber)
> -15C
< +45C
---------
Support roller
contact surfaces
Grafloscon
C-SG 2000 Ultra
(Klber)
> - 40C
< - 15C
---------
Rotation bearings and interruption rollers
Polylube GLY 801

(Klber)
> -15C
< +45C
---------
Microlube GL 261
(Klber)
Hydraulic oil
Transmission
oil
Grease
Grease
BT Europe AB
Service Manual
8- 1
Oil and grease specifications P3 (T-code 712)

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Pos.
Lubricant
Ambient
temperature
Viscosity
class
Use
Recommended
products*
Grease
> - 40C
< - 15C
EP2
Mast girders
Gleitmo 805
Q8 Rubens LT
> -15C
< +45C
EP2
Mast girders
Gleitmo 805
Q8 Rembrandt EP2
8- 2
Service Manual
BT Europe AB
Oil and grease specification P3 (t-code 713)

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
9- Oil and grease specification P3

(t-code 713)
Pos.
Lubricant
Ambient
temperature
Viscosity
class
Use
Recommended
products*
Chain Lubrication
> - 40C
< - 30C
VG 150
Chains
Klberoil 4UH 1-15,

Klber Lubrication
> - 30C
< + 5C
VG 68
Chains
> + 5C
< +45C
VG 150
Chains
>+ 45C
<+ 80C
VG 220
Chains
Klberoil 4UH 1-68N,

Klber Lubrication
Fuchs DEA
Klber Lubrication
Anticorit LBO 160,
Fuchs DEA
Klber Lubrication
> - 40C
< - 15C
ISO-VG 15
Hydraulic system
> -15C
< +45C
ISO-VG 32
Hydraulic system
> - 40C
< - 15C
Hypoidoil
SAE 75W
Gears
> -15C
< +45C
Hypoidoil
SAE 80W/90
Gears
> - 40C
< - 15C
---------
Support roller
contact surfaces
Aeroshell Grease 17
(Shell)
> -15C
< +45C
---------
Support roller
contact surfaces
> - 40C
< - 15C
---------
> -15C
< +45C
---------
> - 40C
< - 15C
EP2

Mast girders
Grafloscon
C-SG 2000 Ultra
(Klber)
Polylube GLY 801
(Klber)
> -15C
< +45C
EP2
Mast girders
Hydraulic oil
Transmission
oil
Grease
Grease
Grease
BT Europe AB
Service Manual
Microlube GL 261
(Klber)
Q8 Rubens LT
Q8 Rembrandt EP2
9- 1
Oil and grease specification P3 (t-code 713)

T-code
712, 713

919699-
Pos.
Lubricant
Grease
9- 2
Ambient
temperature
Viscosity
class
---------
Service Manual
Date
2005-11-28
Use
Order number
227761-040
Recommended
products*
Gleitmo 805
BT Europe AB
Tools P4
Super Seal contact
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
10- Tools P4
10.1 Super Seal contact
1
3
3
2
Tools
BT Europe AB
Service Manual
Number
Use
159232
Tools for fitting pins/sleeves
159229
Tools for loosening locks (1)
159230
Tools for fitting secondary locks

2 pole (2)
159231
Tools for fitting secondary locks

4 pole (2)
159228
Tools for removing pins/sleeves

(3)
10- 1
Tools P4
Super Seal contact
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
10.1.1 AMP connector

PT = Power Timer (4,8. 5,8. 6,3 mm)
JPT = Junior Power Timer (2,8 mm)
MPT = Micro Power Timer (1,5 mm)
Tools
Number
Use
151080 (PT)
213296 (JPT)
213298 (MPT)
1=163787 (JPT)
2=163788 (JPT)
Tools for fitting sleeves
1=213336 (MPT)
2=213337 (MPT)
1=213336 (JPT)
2=213549 (JPT)
10- 2
Tools for fitting sleeves

for 0,52,5 mm2
Service Manual
BT Europe AB
Tools P4
Super Seal contact
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
10.1.2 Diverse tools

Tools
BT Europe AB
Service Manual
Number
Use
156263
Service instrument (CAN)
1=163793
2=163792
Service instrument for program

changes
213017-xxx
TruckCom program
08-15444
Drive motor/Pump motor
10-15639
Socket for transmission nuts
10- 3
Tools P4
Super Seal contact
T-code
712, 713

919699-
Tools
10- 4
Service Manual
Date
2005-11-28
Order number
227761-040
Number
Use
08-13022
Puller, transmission
08-13585
Pressing tool for the support

arm wheels
08-13585-2
Tools for wheel axle
08-13585-1/5.1
08-13585-1/5.2

A=30
A=40
08-13585-1/4
BT Europe AB
Tools P4
Super Seal contact
Order number
227761-040
Date
2005-11-28

919699-
Tools
T-code
712, 713
Number
Use
808-410
Socket for support arm wheel
V08-14044

arm wheels
V08-14044/1

arm wheel bearings
V08-14044/2
Socket for support arm wheel
Kpl=V1015191
1=V10-15191-1
2=V10-15191-2
3=V10-15191-3
4=V10-15191-4
Oil cleaning
1=Filter for cleaning
2=Filter for removing water
3=Pipe
4=Pipe
219730
Hydraulic pressure gauge
808-4XX
-1
-2
-3
-4
BT Europe AB
Service Manual
10- 5
Tools P4
Super Seal contact
T-code
712, 713

919699-
Tools
10- 6
Service Manual
Date
2005-11-28
Order number
227761-040
Number
Use
214303
Cabin lift remote control
V11-1053/4
Lifting yoke fitted with support

plates, which are attached using
bolts screwed into the threaded
holes in the mast frame. Capacity 8000 kg.
BT Europe AB
Tools P4
Super Seal contact
Order number
227761-040
Date
2005-11-28

919699-
Tools
BT Europe AB
Service Manual
T-code
712, 713
Number
Use
V10-16169
Tool set for work on the mast:

A) Guide stopper - used to lock
the intermediate guide at a level
with the upper part of the front
chassis.
B) Cabin stopper - locks the
cabin to the inner guide.
C) Distribution block attachment
D) Cylinder pipe attachment used when replacing the top nut
on the B cylinder.
E) Spacer used when replacing
the top nut.
10- 7
Tools P4
Super Seal contact
T-code
712, 713
10- 8

919699-
Service Manual
Date
2005-11-28
Order number
227761-040
BT Europe AB
Chassis 0000 Truck installation

General
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
11- Chassis 0000

Truck installation
11.1 General
These instructions explain how to unload, erect and assemble the
truck. The instructions also show how to install the truck and how to
perform an operational inspection.
11.2 Tool list

2 counterweight trucks with a capacity of min. 5,000 kg each to unload the truck.
To unload a standing truck:
Without battery = 8,000 kg counterweight truck
With battery = 10,000 kg counterweight truck
Overhead crane or hoisting crane with a capacity of min. 5,000 kg
and 1 counterweight truck to erect the truck.
Alternatively, 2 counterweight trucks each with a capacity of min.
5,000 kg.
Lifting bridle V11-1053/4
Pins V11-1053/14
Lifting bridle V11-1310
Lifting loops each with a capacity of min. 5,000 kg (min. 2 pcs.)
1/2 locking handle
1/2 torque wrench 0 - 270 Nm
14 mm socket for 1/2 locking handle
Socket wrench set, 2-10 mm
Spanner wrench set, 8-24 mm
27 mm spanner wrench
Long socket, 4-KM5, for locking nut
Belt tensioning meter, order no. 213973
Rags
Absorption agent
Bundling ribbon
BT Europe AB
Service Manual
11- 1

Unloading the truck
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
11.3 Unloading the truck

Trucks with low lifting height, i.e. under 4,700 mm, is supplied fully
assembled standing on its wheels.
Trucks with lifting heights exceeding 4,700 mm are supplied lying on
the side on pallets. See picture. In some cases, the initial mast/turret
head fork unit may have been disassembled on trucks supplied lying on
their sides.
The recommended unloading procedure uses two fork lifts with the indicated capacity.
Prior to transport, the truck's articulated centre, which connects the
front and rear chassis, has been locked mechanically with a locking pin.
NOTE!
Prior to first use, do not forget to remove the mechanical locking pin.
11- 2
Service Manual
BT Europe AB

Unloading the truck
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
11.3.1 Unloading a standing truck

Drive the truck off the trailer
If possible, it is best to simply drive the truck off the trailer.
To start the truck, connect a 48 V battery cart to the truck.
If the truck is connected with a battery, connect the battery.
Remove the mechanical locking pin in the articulated centre.
Use a ramp with sufficient capacity for the weight of the truck.
Verify the truck weight on the name plate on the truck.
Carefully drive the truck off the trailer.
Towing the truck off the trailer

If a battery is not available, the truck can be towed off the trailer. Be sure
to tow the truck in reverse.
Use a counterweight truck, or another truck, with sufficient capacity.

The capacity of the towing truck should exceed the indicated truck
weight on the name plate of the truck to be unloaded by at least
50%.
Lift the truck by its rear chassis. Do not lift more than necessary (the
truck's drive wheels should just clear the bed).
Caution!
Risk of damage to components under the truck.
The forks of the lifting truck could cause damage to the components
installed under the rear chassis.
Do not insert the forks too far under the truck.
Do not turn while reversing.
Use a ramp with sufficient capacity for the weight of both trucks.
Verify the total weight of the trucks on the name plates on the trucks.
Carefully reverse off the trailer.
Lower the towed truck as soon as it is standing on firm ground.
Remove the mechanical locking pin in the articulated centre.
BT Europe AB
Service Manual
11- 3

Unloading the truck
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Unloading with a counterweight truck

Use a counterweight truck with the prescribed capacity: 8,000 kg for
a truck without battery and 10,000 kg for a truck with battery.
The forks should be of a length to reach under the full width of the
truck plus a decimetre or two beyond the chassis side.
One fork should be positioned just behind the front chassis wheel.
The other fork should be positioned far back on the rear chassis. Ensure that the forks lift the truck on the solid chassis part and not on
the screwed-on side covers.
Caution!
Risk of damage to components under the truck.
The forks of the lifting truck could cause damage to the components
installed under the rear chassis.
Verify that the forks do not touch any components mounted under the
rear chassis.
Secure the truck on the forks of the counterweight truck.

Lift carefully.
Tilt the forks once the wheels leave the bed of the trailer.
Reverse slowly and once the truck is clear of the trailer, lower it to
the ground.
NOTE!
Prior to first use, do not forget to remove the mechanical locking pin.
11- 4
Service Manual
BT Europe AB

Unloading the truck
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
11.3.2 Unloading a truck lying down

Trucks with lifting heights exceeding 4,700 mm are supplied fully
assembled, except for the battery shelf, battery cover and other loose
parts, which are supplied separately.
The truck has been tipped onto its back, lying down with locked articulated centre on pallets. See the picture.
In certain cases, when required due to a long beam or limited cargo
space, the turret head fork unit has been disassembled.
.
The mast rests on a stack of pallets to allow the truck to lie horizontally.
The main mast, initial mast and cabin have been tied down with straps
prior to transport.
BT Europe AB
Service Manual
11- 5

Unloading the truck
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Unloading the truck from a lorry using a counter

balance truck
When unloading from a lorry, two counterweight trucks with a minimum
recommended capacity of 5 tonnes are required. The trucks must be fitted with forged forks with a length of approx. 1,500 mm. The lifting
points are under the mast and under the operator's cabin. See the picture.
The counterweight trucks must lift the truck together and at the same
time.
Reverse slowly and once the truck is clear of the lorry bed, lower it to
the ground.
WARNING!
The truck may turn over.
If the forks are tilted down while lifting the truck, it may turn over.
Be sure to keep the forks horizontal or slightly tilted up when lifting
the truck.
.
Transport the truck to the place where it will be erected.
11- 6
Service Manual
BT Europe AB

Unloading the truck
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
11.3.3 Unloading the truck using cranes

The pictures show how to unload the truck using cranes.
Warning
Stand at a safe distance when lifting/elevating the truck.
BT Europe AB
Service Manual
11- 7

Unloading the truck
T-code
712, 713
11- 8

919699-
Service Manual
Date
2005-11-28
Order number
227761-040
BT Europe AB

Unloading the truck
Order number
227761-040
BT Europe AB
Date
2005-11-28

919699-
Service Manual
T-code
712, 713
11- 9

Unloading the truck
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
11.3.4 Erecting the truck

Warning
Stand at a safe distance when lifting/elevating the truck.
Fit lifting yoke V11-1053/4.
11- 10
Service Manual
BT Europe AB

Unloading the truck
Order number
227761-040
BT Europe AB
Date
2005-11-28

919699-
Service Manual
T-code
712, 713
11- 11

Unloading the truck
T-code
712, 713
11- 12

919699-
Service Manual
Date
2005-11-28
Order number
227761-040
BT Europe AB

Unloading the truck
Order number
227761-040
BT Europe AB
Date
2005-11-28

919699-
Service Manual
T-code
712, 713
11- 13

Unloading the truck
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
11.3.5 Final assembly

Pull out the aisle transmitter cabling and also the wire guidance cabling (if fitted), from the cavity in the rear chassis.
The battery shelf should be lifted into place with a suitable truck. The
battery shelf has two guide pins that should fit into the corresponding
holes in the rear chassis.
Tighten the supplied 8 screws (A) to a torque of 198 Nm
.
A
Fit the holder for the aisle detection sensors, and if the truck is prepared for wire guidance, also the rear wire guidance antenna.
Lift the battery into place using lifting bridle no. 11-1310
.
C
Fit the battery cover (B) into its brackets
Insert the gas spring (C) into the chassis pivoting sleeve, between
the right drive motor and the hydraulic fluid reservoir, and secure it to
the battery cover.
11.3.6 Assembly of the initial mast

For assembly of the initial mast/turret head fork unit on the cabin,
please refer to the instructions in C code 7200 for VCE150A/
VCE150AC and in C code 7800 for VCE125ASF/VCE125ACSF.
11- 14
Service Manual
BT Europe AB

Preparations for commissioning
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
11.4 Preparations for commissioning

Fill the hydraulic fluid reservoir with oil according to the specifications.
Remove the transport locking device, i.e. the locking pin, from the
articulated centre.
Attach the forks (t-code 712).
Lower the forks and verify the height above the ground according to
C code 7120.
Adjust if necessary.
Verify correct operation by operating the lifting and lowering functions and all fork unit movements.
Inspect to make sure there is no oil leakage from the hydraulic hoses.
Dry off and clean the truck oil from any waste oil.
Calibrate the hydraulic pressure in the lifting accumulator(s) according to the instructions in C code 5000.
If deemed necessary, perform the other calibrations according to the
instructions in C code 5000.
Adjust the truck parameters to the settings desired by the customer
and to suit the installation site. See the instructions in C code 5000.
BT Europe AB
Service Manual
11- 15

Installation in narrow aisle
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
11.5 Installation in narrow aisle

11.5.1 General
Enter the narrow aisle and verify that the truck's aisle transmitters
operate correctly as well as the photocell or the magneto switch.
If the truck is fitted with end-of-aisle braking, verify correct operation.
Handle the maximum load dimension in the narrow aisle. Verify
that there is sufficient clearance between the load on the forks and
the stored items in the racking within the entire lifting area.
11.5.2 Rail-guided truck

Install the side-steering wheels
Test drive the truck in the narrow aisle and verify the play between
the truck and the rail. It should be 5-10 mm.
If necessary, add the same number of shims on both sides of the
side-steering wheels until the play is within the tolerance.
Verify that steering switches to the auto mode when the truck enters
the narrow aisle.
11.5.3 Wire-guided truck

Inspect the frequency and current data of the wire.
Verify the wire-guidance settings of the truck.
See the instructions in C code 5000, parameter 165.
Test drive the truck along the wire with and without any load.
Observe how the truck operates on the wire.
If necessary, perform wire guidance adjustment as explained in
Calibration under C code 5000.
11- 16
Service Manual
BT Europe AB
General tightening torque 0400

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
12- General tightening torque 0400

Millimetre threads.
The following applies under ideal conditions, e.g. steel against steel.
12.0.1 Galvanised, non oiled bolts

Thread
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
12.9
2.0
4.7
9.3
16.3
38.5
75.8
Thread
M12
M14
M16
M20
M24
8.8
77.7
123
189
369.6
638.5
12.9
130.5
208
319.7
623
1075
12.0.2 Untreated, oiled bolts

Thread
M3
M4
M5
M6
M8
M10
8.8
1.2
2.9
5.7
9.8
24.0
47
12.9
2.1
4.9
9.7
17.0
40.0
79.0
Thread
M12
M14
M16
M20
M24
8.8
81
128
197
385
665
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.
BT Europe AB
Service Manual
12- 1
General tightening torque 0400

Tightening torque
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
12.1 Tightening torque

Description
Number
Tightening
torque
C-code
0-270 Nm
0000
on page 1
198 Nm
0000
on page 12
Screw on the bearing

bush
6 Nm
1710
on page 6
Stud screws and nuts
5 Nm
1710
on page 6
Tool 10-15639
60 Nm
1760
on page 4
Motor mounting bolts to

the gearbox
20 Nm
1760
on page 4
Screws for bearing bush

and bearing plate
6 Nm
1760
on page 6
Stud screws
5 Nm
1760
on page 6
Connections
15 Nm
5000
on page 29
16.3 Nm
5000
on page 31
Tool 1/2
Screws
Screws M8
The transistor panels
connections
12- 2
Service Manual
BT Europe AB
Electric pump motor 1710.1

General
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
13- Electric pump motor 1710.1

13.1 General
The pump motor is used for main lifts. It uses a three-phase AC motor.
The motor contains a thermoelectric cell, which measures the motor
temperature, and it also has a ball bearing with an integrated measuring unit to measure the rotation direction and speed.
The pump motor has model designation P112 195.
These service instructions cover explanations for replacing the bearing,
the shaft seal and the temperature sensor.
13.2 Disassembled pump motor
BT Europe AB
Service Manual
13- 1

Disassembly and assembly of the pump motor
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
13.3 Disassembly and assembly of the

pump motor
WARNING!
Pressurised system.
The hydraulic system contains accumulators under pressure at 250
bar.
Never perform any repairs on the hydraulic system unless it has been
fully depressurised beforehand.
2
1. Open the drain valve for the steering accumulator
2. Open the drain valve for the lifting accumulator(s)
13- 2
Service Manual
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
13.3.1 Disassembly
1
2
3
Disconnect the battery connector.

Lower the operator's cabin to its bottom position to relieve the pressure in the hoses and pump.
Pump out the oil in the hydraulic fluid reservoir using the filter pump
V10-15191.
Disconnect the temperature/speed measurement connectors (1, 2)
and the power cables (3) from the motor.
Disconnect the cables from the valve guides (5, 7 and 9)
Remove the return hose (6) and disconnect the two hydraulic output
hoses to the lifting cylinders (8).
Loosen the hose clamp (12) of the oil hose, which originates from
the reservoir behind the pump.
5
6
Attach a lifting loop to the motor axle.
Remove the lifting loop.
Remove the four bolts (10) from the pump motor brackets.
Lift out the pump motor and place it on a clean surface.
Remove the valve plate from the pump using the four hex bolts (4).
Disassemble the pump from the motor.
10
BT Europe AB
Service Manual
13- 3

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
13.3.2 Assembly
If the O-ring on the pump is damaged, it must be replaced.
Attach the carrier between the pump and the pump motor (8).
Attach the pump assembly (13) on the pump motor (8).

Attach the valve plate on the renovated/new pump using the four
hex bolts (4).
Attach both brackets (10) on the pump motor (8).
Screw a lifting loop into the end of the motor axle and connect it to an
overhead travelling crane if required.
13
Lift the hydraulic pump into the truck.
Attach and tighten the four bolts securing the pump motor to the
chassis.
Fit the return hose (6) and the two hydraulic output hoses to the lifting cylinders (8).
Connect the cables from the valve guides (5, 7 and 9)
Connect the temperature speed measurement connectors (1, 2) and
the power cables (3) on the motor.
Fill up the hydraulic fluid reservoir with new hydraulic oil.
Connect the battery connector.
13- 4
Service Manual
BT Europe AB

Replacing the ball bearing
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
13.4 Replacing the ball bearing

16
19
13
6
17
22
2
9
1
4
26
11
10
25
24
36
27
3
8
23
7
5
D
30
28
20
21
13.4.1 Disassembly
Motor without pump.
Loosen the screws (23) and remove the protecting plate (8).
Loosen the stud screws (20) using tool 08-15444.
Remove the shield (3) and the washer (7).
If both ball bearings need replacement, then continue with the next
steps; if only the pulse transducer bearing needs replacement continue
from A.
Remove the screws (22).
Remove the rotor (4) from the armature (1).
Disassemble the shield (2) and radial lip seal (19).
Remove the groove ring (16) and support ring (17).
Pull out the bearing with a puller.
A)
Pull out the bearing (5) with a puller.
BT Europe AB
Service Manual
13- 5

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
13.4.2 Assembly
Make sure all parts are complete and clean before mounting.
Follow the entire instructions if both bearings have been replaced.
Place the bearing bush (9) on the D side of the rotor axle.
Press the bearing (6) onto the rotor axle.
Press the bearing (5) onto the N side of the rotor axle.
Fit the support ring (17) and the groove ring (16) onto the D side of
the axle.
Fit the seal (19) using the mounting tool.
NOTE
Always use a new seal when mounting the rotor axle.
Fir the rotor in the bearing shield (2).

Screw on the bearing bush (9) using the screws (22) to a torque of 6
Nm.
Mount the rotor (4) in the armature (1).
Place the washer (7) on the bearing (5).
Make sure the connection block bracket 11 is correctly positioned.
Fit the bearing shield (3).
Fit the stud screws (20) and nuts (21) and tighten to a torque of 5
Nm.
Fit the ferrite core on the sensor cable.
Fit the protective shield (8) on the N side.
Clamp the cables from the thermo-contact and the pulse transducer
bearing to one of the power cables.
If only the pulse transducer bearing has been replaced:
Press the bearing (5) onto the N side of the rotor axle.
Place the washer (7) on the bearing (5).
Make sure the connection block bracket 11 is correctly positioned.
Fit the bearing shield (3).
Fit the stud screw (20) and nuts (21). Tighten to a torque of 5 Nm.
Fit the ferrite core on the sensor cable.
Fit the protective shield (8) on the N side.
Clamp the cables from the thermo-contact and the pulse transducer
bearing to one of the power cables.
13- 6
Service Manual
BT Europe AB

Assembly instruction for the external temperature sensor
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
13.5 Assembly instruction for the

external temperature sensor
Number 170384
The temperature sensor can be mounted on the left or right side of

the connection block depending on which side provides the best access.
Scrape the surface, where the new temperature sensor will be
mounted, clean.
Place the temperature sensor as shown in the picture.
BT Europe AB
Service Manual
13- 7

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Apply steel plastic on top of the sensor. Make sure the entire sensor
is covered by steel plastic.
13- 8
Service Manual
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
Affix the steel plastic and the sensor with masking tape and allow to
set.
Remove the masking tape. The temperature sensor should now be

firmly positioned and entirely covered by the steel plastic.
Remove the ferrite core from the old sensor and attach it to the cable
of the new sensor.
Remove the motor connector from the old, defective sensor.
Set the new sensor's connector in the old bracket and connect it to
the cable.
Attach the old connector and its cable using bundling ribbon to prevent interference and possible damage.
BT Europe AB
Service Manual
13- 9

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
13- 10
Service Manual
BT Europe AB

General
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
14- Electric pump motor 1710.2

14.1 General
The pump motor is a single phase DC motor with model designation
TTL 180C-P3A.
the shaft seal and carbons.
14.2 Disassembled pump motor
14.2.1 Connection
BT Europe AB
Service Manual
14- 1

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040

pump motor
WARNING!
Pressurised system.
bar.
2
14- 2
Service Manual
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
14.3.1 Disassembly
Lower the forks and the cabin to the bottom position to relieve the
pressure in the hoses and pump.
Pump out the oil in the hydraulic fluid reservoir using the filter pump
V10-15191.
Loosen the fan cover screws (1) and remove the cover.
Disconnect the power cables (2) from the motor (6).
Remove the hydraulic hose (3) and loosen the hose clamp on the return hose (4) and disconnect the hose from the pump.
Remove the bolts securing the pump bracket (5) to the chassis.
Lift out the hydraulic motor and place it on a clean surface.
Remove both brackets (5) from the pump motor (6).
Loosen the screws and disassemble the pump (7).
5
4
Remove the carrier.
BT Europe AB
Service Manual
14- 3

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
14.3.2 Assembly
If the O-ring on the pump is damaged, it must be replaced.
Attach the carrier between the pump and the pump motor (6).
Attach the pump assembly (7) on the pump motor (6).
Attach both brackets (5) on the pump motor (6).
Screw a lifting loop into the end of the motor axle and connect it to an
overhead travelling crane if required.
Lift the hydraulic pump into the truck.
Attach and tighten the four bolts securing the pump motor to the
chassis.
Connect the return hose (4) and the hydraulic hose to the valves (3).
Fit the fan cover (1) and connect the power cables (2).
Fill up the hydraulic fluid reservoir with new hydraulic oil.
Connect the battery connector.
14- 4
Service Manual
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
14.4.1 Disassembly (D side)

Motor without pump.
Loosen the screws (1) and remove the bearing bracing (2).
Disassemble the radial lip seal (3).
Remove the washer (4).
14.4.2 Assembly
NOTE
Always use a new seal when mounting the rotor axle.
Fit the seal (3) using the mounting tool.

Place the washer (4) on the bearing (5) or in the bearing bracing.
Fit the bearing bracing (2) and secure it with screws/washers (1).
14.4.3 Disassembly (N side)

Loosen the screws (6) and remove the fan (7).
Loosen the nuts/washers (8) and the screws (9) and remove the
connection block (10).
Remove the connection cables (11) between the brush-rocker and
armature windings.
Loosen the screws/washers (12) and remove the bearing bush plate
(13).
Loosen the screws/washers (14).
Remove the bearing bracing (15).
Remove the groove ring (16).
BT Europe AB
Service Manual
14- 5

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
14.4.4 Assembly (N side)

Fit the groove ring (16) and the bearing bracing (15).
Attach the screws/washers (14).
Attach the screws/washers (12) and replace the bearing bush plate
(13)
Connect the connection cable (10) between the brush-rocker and armature winding.
Fit the connection block (10) and secure with the screws (9) and the
nuts (8).
Fit the fan (7) and secure with the screws (6).
14.4.5 Carbon brushes and carbon

brush-rocker
New carbon brushes must always be smoothened beforehand
With the TTL 180C P3A motor, new carbons are usually supplied
smoothened (with the same curved shape as the commutator); if not,
then smoothen the brushes as explained below:
Place medium-coarse abrasive paper (not emery cloth) between the
carbons and the commutator, with the paper side facing the commutator.
Apply the usual spring-load on the carbons. Allow the abrasive paper to slip on the commutator surface. When finished, use compressed air to blow clean the carbons and brush-rocker. Final
smoothing should be performed using sandstone.
Commutator
The surface of the commutator should be an even patina, which may
vary depending on the operating conditions. If the surface is rough and
marred with black burn marks, buff it with fine abrasive paper (never
use emery cloth).
14- 6
Service Manual
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
Truing the commutator

When it becomes necessary to turn down a worn or uneven commutator, be sure to do this in the correct manner.
Correctly done, the cutting speed should be minimum 200 r/min
(applies to hard metal) with a feed rate of 0.8-0.1 mm.
When turning with a diamond, which provides the best results, the cutting speed should be considerably higher. In both cases, be sure to limit
the cutting depth to 0.05 mm
With a newly renovated commutator, the maximum wobble should not
exceed 0.02 mm and any surface unevenness should be maximum 4
m. For actual operation, a maximum of wobble of 0.04 mm is acceptable in case of faulty eccentric running. However, in case of lamina offset, this must not exceed 0.02 mm.
The commutator has been designed to allow truing several times. The
minimum diameter is 77 mm. As a guideline, turn off the commutator
with every third replacement of the carbon brush set.
Following truing, clean the mecanite between the laminae to a depth of
0.6 mm. After cleaning, make sure there are no mecanite deposits on
the lamina sides. After clean scraping and cleaning, the result should
be as shown in the picture below.
600
0,6
BT Europe AB
Service Manual
R0,2
14- 7

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
14- 8
Service Manual
BT Europe AB
Electric drive motor 1760

General
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
15- Electric drive motor 1760

15.1 General
The drive motor is a three-phase AC motor. The motor contains a thermoelectric cell, which measures the motor temperature, and it also has
a ball bearing with an integrated measuring unit to measure the rotation
direction and speed.
The drive motor has model designation D112 - 165.
the shaft seal and the temperature sensor.
BT Europe AB
Service Manual
15- 1

Disassembled drive motor
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
15.2 Disassembled drive motor
15- 2
Service Manual
BT Europe AB

Disassembly and assembly of the drive motor
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713

drive motor
14, 63, 15.3.1 Disassembly of the
31
60
drive motor
Loosen the temperature, brake and speed measurement connectors (14, 31, 63) and the power cables (60) from the motor.
Loosen and remove the motor mounting bolts (62).
Lift out the motor using an overhead travelling crane and place the
motor on a clean surface.
29
27
NOTE!
62
51
54
Risk of damaging the gear wheel (51).

The gear wheel on the motor end could become damaged.
Exercise great care when lifting out the motor.
To prevent objects from falling into the gear case, cover the gear
case opening once the motor has been lifted out.
Disassemble the gear wheel

Knock out the nut (54) locking and unscrew the nut using tool 1015639.
Pull off the gear wheel (51) using a puller.
Remove the key (7) holding the gear wheel (51) in position.
Remove the locking ring (27) keeping the bearing cage (29) in place.
55 6 33 37
Pull out the bearing cage (29) using a puller.
Disassemble the brake

Loosen the screws (37) to allow removal of the brake (33).
Remove the outer groove ring (16) from the motor axle.
Remove the brake hub, key (6), plate and the inner groove ring (16).
16
BT Europe AB
Service Manual
15- 3

Disassembly and assembly of the drive motor
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
15.3.2 Assembly of the drive motor

55 6 33 37
Assemble the brake

Fit the inner groove ring (16) and the key (6).
Before attempting to mount the brake, ensure that the friction plate
(55) is centred in relation to the magnet casing. It may be necessary
to power up the magnet coil with 48 V DC to properly set the brake
disc.
Fit the brake assembly onto the motor. Verify that the friction plate
splines do not suffer any damage during the assembly process.
Tighten the brake assembly mounting bolts.
Fit the outer groove ring (16).
Assemble the gear wheel

Fit the bearing cage (29) onto the motor axle.
16
Fit the locking ring (27).

Fit the key (7).
Set the gear wheel (51) in place.
29
27
Fit a new nut (54).

Use tool 10-15639 and tighten to a torque of 60 Nm.
Centre punch the nut to lock it in the key groove.
7 Attach a lifting loop in the motor axle and lift the motor axle into the
62
51
54
gear box using an overhead travelling crane.

NOTE!
Risk of damaging the gear wheel (51).
The gear wheel on the motor end could become damaged.
Exercise great care when lifting out the motor.
Secure the motor (61) mounting bolts to the gearbox with a torque of
20 Nm.
Reconnect the temperature, brake and speed connectors (14, 31,
63) as well as the power cables (60) on the motor.
For brake adjustment, see C code 3100.
14, 63,
31
60
15- 4
Service Manual
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713

14 31
23
54 51 12 11
2 4 10 1 9
24
22
25
33
55
34
38
27 26 50 28 29 30 21 20
17
5 18 16
Disassembly
N side
Loosen the stud screws (20) using tool 08-15444.
Remove the screws (34).
Remove the bearing plate (3).
Disassemble the groove ring (16) and support ring (18).
D side
Remove the groove ring (26) from the bearing housing.
Pull out the bearing housing (29) with a puller.
Pull out the bearing (28) from the bearing housing with a Kukko ball
bearing puller.
Remove the seal (30) if it is untight.
BT Europe AB
Service Manual
15- 5

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
15.4.1 Assembly
N side
Fit the bearing bush (8) onto the motor axle.
Fit the flange ring (17).
Place the washer (18) and fit the lock ring (16).
Using the screws (34), screw the bearing bush (8) and bearing plate
(3) together with a torque of 6 Nm.
Set the insulation tube on the pulse transducer bearing cable.
Place the connection block bracket (10) between the shields.
Set and tighten the stud screws (20) to a torque of 5 Nm.
Clamp the thermo-contact and transducer bearing cables to the
power cable in the centre.
D side
Set the seal (30) in the bearing housing (29).
Push the bearing (28) into the bearing housing.
Fit the locking ring (26).
15- 6
Service Manual
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
15.5 Assembly instruction for the

external temperature sensor
Number 170384
The temperature sensor can be mounted on the left or right side of

the connection block depending on which side provides the best access.
Scrape the surface, where the new temperature sensor will be
mounted, clean.
BT Europe AB
Service Manual
15- 7

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Place the temperature sensor as shown in the picture.
Apply steel plastic on top of the sensor. Make sure the entire sensor
is covered by steel plastic.
15- 8
Service Manual
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
Affix the steel plastic and the sensor with masking tape and allow to
set.
Remove the masking tape. The temperature sensor should now be

firmly positioned and entirely covered by the steel plastic.
Remove the ferrite core from the old sensor and attach it to the cable
of the new sensor.
Remove the motor connector from the old, defective sensor.
Set the new sensor's connector in the old bracket and connect it to
the cable.
Attach the old connector and its cable using bundling ribbon to prevent interference and possible damage.
BT Europe AB
Service Manual
15- 9

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
15- 10
Service Manual
BT Europe AB
Drive unit/gear 2550

General
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
16- Drive unit/gear 2550

16.1 General
This type of truck is equipped with a drive unit attached to the chassis
by means of eight bolts.
The drive shaft, together with motor, brake and sensors for measuring
the speed and drive direction make up a complete drive unit.
The gear in this truck is a 2-step angular gear with conical roller bearings for the drive shaft and pinion. The bearings are pre-tensioned
approx. 5/100th of a millimeter to minimize the risk of play in the bearings.
These service instructions cover descriptions for dismantling the gear
from the truck and re-fitting, filling/exchanging of oil and necessary
measures in case of leakage. A complete overhaul of the drive gear is
such an extensive job that it should only be done in a workshop by specially trained personnel.
16.2 Components/data of the drive unit

and gear
The main components and data of the drive gear are shown in the picture and tables below.
BT Europe AB
Service Manual
16- 1

Components/data of the drive unit and gear
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
16.2.1 Component identification
24
31
30
29
28
27
26
25
24
10
23
22
11
21
12
20
18
19
13
16- 2
Service Manual
15 16 17
BT Europe AB

Order number
227761-040
BT Europe AB
Date
2005-11-28

919699-
T-code
712, 713
Pos. No.
Component
Screw
Washer
3-7
Screw
Gear wheel
Bevel gear
10
Protection
11
Screw
12
Axle
13
Sealing
14
Shim
15
Roller bearing
16
Shim
17
Roller bearing
18
O-ring
19
Washer
20
Nut
21
Cover
22
Roller bearing
33-34
Shim
35
Roller bearing
36
Gear wheel
37
Washer
38
nut
39
Cylinder pin
40
Lock cover
41
Air bleeder
42
Screw
43
Washer
44
Screw
Service Manual
16- 3

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
16.2.2 Technical data

Gear type
2-step angular gear
Gear ratio
17.33:1
Oil volume, liter
3.3
Oil type
Hypoid oil
Viscosity,
normal temperature
SAE 80 W/90
Viscosity, < -15oC
SAE 75 W
16.2.3 Dismantled gear
16- 4
Service Manual
BT Europe AB

Replacing the drive motor/drive gear
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
16.3 Replacing the drive motor/drive

gear
16.3.1 Dismantling of drive unit from truck
Remove the motor cover, upper cover and chassis plate.

Lift up the truck using a jack so that the wheel is lifted off the ground,
then put trestles under the truck in a safe manner.
Drain off the oil from the drive gear.
Remove the motor cables. On the right hand side the speed measurement cables must also be removed.
Loosen and remove six M16x60/drive unit that hold the drive unit
onto the chassis.
Pull out the drive unit far enough for it to be lifted out of the truck with
mechanical aid.
Place the drive unit on a bench or the like.
16.3.2 Fitting the drive unit in truck

Lift the gear into position on the chassis. Lubricated screw (Molykote
1000) are tightened to 339 Nm.
Bolt the drive unit in position by passing the M16 bolts through the
motor plate and tightening them to a torque of 51.5 Nm. The bolts
should be greased before fitting.
Fit the motor cables. Also fit the speed measuring cables on the right
hand side.
Fill the drive gear with oil.
Lower the truck to the floor and fit the chassis plate, upper cover and
motor cover.
BT Europe AB
Service Manual
16- 5

Replacing the drive motor/drive gear
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
16.3.3 Dismantling the drive motor and the

gear
Dismantle the drive wheel (1) from the gear.
Separate the drive motor and the gear by removing the 6 M8x60/
drive unit.
16.3.4 Fitting the drive motor and the gear

Fit a new O-ring (3) on the drive motor's bearing retainer.
Fit together the drive motor and drive gear carefully to avoid damaging the O-ring fitted on the bearing retainer.
Tighten the motor bolts (2) to a torque of 25 Nm. The bolts should be
greased before fitting.
Fit the drive wheel. The wheel nuts (1) should be tightened crosswise at a torque of 130 Nm.
16- 6
Service Manual
BT Europe AB

Oil level check/replacement
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
16.4 Oil level check/replacement

16.4.1 Checking/filling of oil
The oil level in the gear should be checked every 250: working
hours.
Check the oil level in the gear by removing the oil filling plug on the
upper part of the gear housing.
Fill oil up to the hole to get the correct oil level.
Hypoid oil MP in the drive gear.
Use SAE 80 W/90 for operation at normal temperature.
Use SAE 75 W for operation in cold-storage rooms < -15oC.
Oil volume: approx. 3.3 liter.
16.4.2 Oil replacement
The oil in the gear should be replaced the first time after 50-100 working
hours, and after that every 3,000: working hours.
Drain off the old oil by completely removing the lower gear cover.
When replacing the oil, always replace the O-ring sealing as well.
Make sure the new O-ring is not damaged during fitting.
Reattach the cover and tighten the bolts to a torque of 25 Nm. The
bolts should be greased before fitting.
Fill up oil in accordance with filling instructions.
BT Europe AB
Service Manual
16- 7

Repairs
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
16.5 Repairs
24
31
30
29
28
27
26
25
24
10
23
22
11
21
12
20
18
19
13
16- 8
Service Manual
15 16 17
BT Europe AB

Repairs
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
16.5.1 Replacing the drive shaft sealing ring

It is easiest to replace the drive shaft sealing ring when the drive unit
has been dismantled from the truck.
In the case of oil leakage from the drive shaft follow the procedure
below
Dismantling
Dismantle the drive unit from the truck as explained in the chapter
Replacing the drive motor/drive gear.
Remove the lower gear cover and drain the oil.
Loosen the drive shaft nut. Remove the nut and spacer ring.
Knock out the drive shaft using a brass punch and a hammer.
Pull off the bearing from the drive shaft.
NOTE:
A normal clamp puller cannot be used to pull off the bearing.
Use a KUKKO type bearing puller.
Check whether the spacers of the bearing have been damaged. If

the were damaged by the puller, measure the total thickness of the
spacers and replace if necessary prior to assembly.
Remove the sealing ring from the drive shaft.
Assembly
When assembling the gear after replacing the drive shaft seal, follow
the procedure described below.
1. Place the drive shafts outer bearing in the gear housing.
2. Press the new sealing ring in place in the gear housing. Be
careful when pressing it back in place so that the seal is seated correctly in the gear housing.
3. Place the spacers of the shaft unit on the drive shaft, making
sure the thickness is the original thickness during disassembly. Use only spacers free of damage.
4. Press the drive shaft with fitted spacers into the gear housing.
Check that the splines on the drive shaft are aligned with the
splines on the crown wheel
5. Place the spacer ring on the drive shaft end and fit the shaft
bolt.
Always use a new bolt.The drive shaft bolt must be lubricated
prior to being fitted to the shaft.
Tighten the shaft bolt to a torque of 700 Nm and lock it with a
centre punch in the shaft groove.
6. Before fitting the lower cover, replace the O-ring. Make sure
the O-ring is free from damage. Reattach the cover and tighten
the bolts to a torque of 25 Nm. The bolts should be greased be-
BT Europe AB
Service Manual
16- 9

Repairs
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
fore fitting.
16.5.2 Leakage from the top cover

When there is leakage from the gear's top cover follow the procedure
described below:
Dismantle the gear from the truck as explained in the chapter Replacing the drive motor/drive gear.
Loosen all bolts holding the top cover to the gear housing.
Remove the cover from the gear housing and clean the sealing surfaces of the cover and gear housing carefully.
Apply sealant type Curil K2 to the surfaces. Follow the instructions
given on the container.
Fit the cover bolts and tighten to a torque of 46 Nm.
The bolts should be greased prior to assembly.
Fit together the drive gear and the drive motor and fit the drive unit in
the truck as described in the chapter Replacing the drive motor/
drive gear.
16.5.3 Leakage from the lower cover

Drain the remaining oil from the drive gear.
Remover the cover from the drive gear.
Replace the seal on the drain plug and the O-ring on the cover.
Reattach the cover and tighten the bolts to a torque of 25 Nm. Make
sure the O-ring is not damaged. The bolts should be greased before
fitting.
16- 10
Service Manual
BT Europe AB

Repairs
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
16.5.4 Replacing the wheel bolt

The wheel bolts on the gear are pin bolts. Proceed as follows when
replacing the wheel bolts:
Pull out the battery disconnector plug.

Remove the fender next to the drive wheel from the chassis.
Lift the machine using a jack and place trestles under it.
Remove the drive wheel.
Use pin bolt tools to remove wheel bolts with damaged threads.
Broken wheel bolts:
Method 1: Drill a hole in the bolt centre, then unscrew the bolt using
a screw extractor for M14 bolts.
Method 2: If it is not possible to remove the bolt using a screw extractor drill out the bolt:
- Make a centre punch in the bolt being careful to punch in the absolute centre of the bolt.
- Pre-drill a hole through the bolt using a 5 mm drill.
Drill out the bolt using an 11.5 mm drill.
- Remove the remainder of the bolt using a pair of pliers or a similar
tool. If this is not feasible, remove the remainder of the bolt by
cleaning the thread with a pilot tap (M14x 1.5).
Apply LOCTITE 270 to the wheel bolt thread.
Fit the new wheel bolt using the pin bolt tool.
Tightening torque: 80 Nm
BT Europe AB
Service Manual
16- 11

Repairs
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Fit the drive wheel. Tighten the wheel nuts to a torque of 130 Nm.
Remove the trestles and lower the truck to the ground.
Reattach the fender.
Plug in the battery disconnector plug.
16- 12
Service Manual
BT Europe AB
Travel brake system 3100

General
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
17- Travel brake system 3100

17.1 General
The trucks brake system consists of three separate subsystems.
Regenerative motor braking using the drive motor.
Two analogue electromechanical multiple disc brakes fitted in the
support arm wheels.
A single stage electromechanical disc brake fitted on the drive motor.
17.2 Operating description

The travel brake systems primary braking function is the regenerative
motor brake from the drive motor. Braking can be actuated in three different ways:
When the accelerator is released
By switching the travel direction using the travel direction selector,
normal motor braking.
By pushing the brake pushbutton
BT Europe AB
Service Manual
17- 1

Operating description
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
17.2.1 Releasing the accelerator

The regenerative motor brake is automatically engaged when the
accelerator is released.
The braking force can be set via a parameter by the driver.
The motor braking force is regulated progressively in relation to the
speed and the amount the accelerator is released. This functions as follows:
Braking at a high speed, the accelerator is released completely,
gives a high braking force.
Braking at a low speed, the accelerator is released completely, gives
a low braking force.
Braking at a high speed, the accelerator is released halfway, gives
medium braking force.
17.2.2 Travel direction selector

The braking force is regulated by the position of the accelerator, i.e. the
more the brake is pressed down the greater the braking effect.
17.2.3 Pressing down the brake pushbutton

Full regenerative motor braking is obtained when the brake pushbutton
is pressed down. Depending on the running speed, the support arm
brakes are also activated.
17.2.4 Parking brake

The parking brake is activated/is active when:
The parking brake is activated automatically when the truck has
stopped when driving and the truck brakes to a stop with the help of
the brake pushbutton.
The brakes are released when the accelerator is pressed down.
The parking brake is activated automatically when the driver releases right deadman handle.
The parking brake remains active after the ignition switch is
switched on.
17.2.5 Emergency braking

Emergency braking of the truck takes place in the event of a fault with
the control system or a serious fault in the electrical systems.
The electromechanical disc brake on the drive motor is the primary
emergency brake.
The motor brake can act with emergency braking under the condition that the voltage supply works.
17- 2
Service Manual
BT Europe AB

Operating description
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
Brake performance with support arm brakes
Brake Force
Support arm brake
Regenerative motor brake
0%
25%
50%
75%
100%
Required brake performance
BT Europe AB
Service Manual
17- 3

Electromechanical disc brake, drive motor
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
17.3 Electromechanical disc brake,

drive motor
The brake is a single stage electromechanical spring force brake that
releases when the magnetic coil is energised.
The brake acts as a parking brake and emergency brake.
The resistance in the coil is approx. 32 ohm at 20 degree Celcius.
17.3.1 Assembling
Fit the brake on the motor shaft.

Ensure that the friction disc (4) is centred in relation to the magnet
housing before you try to install the brakes.
It may be necessary to energise the magnet coil with 48 V DC to position the brake disc.
Fit the brake assembly onto the motor. Check that the splines on the
friction disc were not damaged during installation.
Fit and tighten the brake units three securing bolts.
Check the play between the magnet housing and the pressure plate
with the brake applied, should be 0,20-0,40 mm.
The play may need to be adjusted, see section adjustment.
Connect the brake cable (11) to the trucks electrical system.
Switch on the ignition switch and release the parking brake.
Check that the friction disc rotates freely.
Cut the voltage and check that the pressure plate locks the friction
disc and that the play (0,2 mm) is correct.
17- 4
Service Manual
BT Europe AB

Maintenance
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
17.3.2 Dismantling
Dismantle the brake in the reverse order.
Place the brake on a clean and dry workbench with the magnet
housing (1) facing upward.
Unscrew the 3 adjuster screws (8) gradually to reduce the spring
tension equally.
The brake unit can now be dismantled fully for inspection of the component parts.
17.3.3 Inspection
Investigate the parts regarding damage and/or wear.
Check the brake disc (4) and the wear surfaces on the pressure
plates (2) and (5) extra carefully.
Check the springs (7) and the spacers (6) with regard to damage.
NOTE!
Bear in mind the spacer nut is made of brass.
Check for signs of damage to the splines on the hub (3) and friction
disc (4).
Check for signs of swelling or damage to the magnet (1) and pressure plate (2).
17.3.4 Assembling
Clean the parts carefully.
Assemble the brake in the reverse order to dismantling.
Bear in mind the following:
- That the hole in the pressure plate (2) aligns with the corresponding hole in the magnet housing.
- That the right number of springs have been fitted.
- That the play 0,20-0,40 mm is set correctly, some adjustment
may be necessary.
17.4 Maintenance
The brake is included as a checkpoint in the trucks maintenance chart,
for intervals see the maintenance chart section P2.
Maintenance comprises inspection and adjustment of the play between
the pressure plate and magnet housing, wear, braking force and cleaning.
NOTE!
The friction surfaces must not come into to contact with oil or grease
as this will seriously reduce the brakes braking force.
BT Europe AB
Service Manual
17- 5

Maintenance
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
17.4.1 Adjusting the play
The play must be checked every 1000 operating hours.

Adjust the play by removing shims.
Nominal play with correct adjustment is 0.2 mm.
Maximum permitted play is 0.4 mm before adjustment is necessary.
Tools
Feeler gauges, 14 mm box spanner and 6 mm allen key
Loosen the three bolts (8).
Adjust the play using the three adjuster sleeves (6) to 0,20-0.40 mm.
Measure, using the feeler gauges, by the side of the adjuster sleeve
when adjusting.
Turning anticlockwise reduces and clockwise increases the play.
Tighten the bolts to 20 Nm.
Recheck the play after tightening the bolts.
Repeat the adjustment if necessary until the play is correct.
Check the play all the way around the pressure plate. Maximum permitted deviation from the set play is 0.075 mm.
17.4.2 Wear
Check the friction disc for wear every 3000 operating hours.
Strip the brake as set out in the section Dismantling.
17- 6
Service Manual
BT Europe AB

Multiple disc brake, support arm
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
Measure the thickness of the friction disc. Minimum thickness = 8.0

mm.
17.4.3 Check the braking force

The braking force must be checked at least every 1000 operating
hours.
Lift up the truck so that the drive wheel is free of the ground
Open the motor compartment covers.
Tools
Torque wrench set to 54 Nm and a M12 flange bolt, or a normal bolt
and flat washer
NOTE!
The bolt quality shall be at least 10.9.
Screw in the M12 bolt in the hole (for the lifting hole) in the motor axle.
Turn the motor axle using the torque wrench until the brakes release.
If the brake releases before the torque wrench trips the braking force
is too low.
Adjust the brake play to the right value, see adjusting the play.
Check the braking force again using the torque wrench.
17.5 Multiple disc brake, support arm

The brake is an analogue electromagnetic multiple disc brake, that is
the brake is applied by energising the magnet coil. The current in the
magnet coil is regulated by a potentiometer in the brake and thereby
BT Europe AB
Service Manual
17- 7

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
regulates the braking force. The multiple discs are of steel. The brake
acts as a secondary travel brake and is applied when the driver needs
to brake heavily, >75% of the available braking force.
The brake is assembled inside the support arm wheel on a hub with
splines and a locking heel that takes up the braking force.
The support arm wheel must be dismantled from the truck to check and
maintain the brake, see C-code 3550, except when inspecting the actual magnet coil, which can be done with the wheel fitted. All instructions
given below assume that the wheel has been dismantled.
17.5.1 Assembling
Check that the brakes apply and releases as they should. Connect
the brakes to 48 V D.C. Switch the current on and off.
Check that the play between the end plate (6) and pressure plate (2)
is 1.0-1.25 mm with the current switched on (brakes applied). The
play may need to be adjusted, see section adjustment.
NOTE!
Check the play at the same time in two positions at 180 degree spacing.
Fit the brake in the support arm wheel. Make sure that the inner disc
splines are aligned correctly so that they go on the splines on the
wheel hub without resistance.
Assemble the wheel in the support arm according to instruction Ccode 3550.
Ensure the locking heel (8) is positioned in it cut-out in the support
arm.
Connect the brake cable (14) and check the brake function by pressing down the brake fully.
17- 8
Service Manual
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
17.5.2 Dismantling
Lift the brake out of the support arm wheel.

Place the brake on a clean and dry work bench with the magnet
housing (6) facing upward.
NOTE!
Exercise care so that the components and cables are not damaged
during this and the following work.
Loosen and remove the sex M6x40 socket head screws (12) and
their washers
BT Europe AB
Service Manual
17- 9

Maintenance
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Remove the aluminium end plate (6).

NOTE!
Note the number of shim washers (11) on each spacer (5).
Lift off the pressure plate (2) and the disc assembly that consists of 3
outer discs (3) and 2 inner discs (4).
Remove the brass disc (7).
17.5.3 Inspection
Check the thickness of the discs.
The nominal thickness of a new disc = 2.0 mm
Wear limit = 1.4 mm
When replacing discs. Replace all inner and outer discs at the same
time. Not individually.
Also check that the discs are flat and that the splines or cut-outs are
not damaged.
Check the magnet coils electrical resistance. Nominal 47.7 Ohm at
20o C
NOTE!
The resistance measurement can be performed with the brake/wheel
in the truck.
17.5.4 Assembling
Clean the parts carefully.
NOTE!
Clean only with a wire brush and dry cloth.
Assemble the brake in the reverse order.

Connect the brake to 48 V D.C.
Check the play between the end plate and pressure plate (brake applied). Adjust the play if necessary.
17.6 Maintenance
The brake is included as a checkpoint in the trucks maintenance chart,
for intervals see the maintenance chart section P2.
Maintenance comprises inspection and adjustment of the play between
the pressure plate and end plate, wear and the magnet coils resistance
and cleaning.
Cleaning and inspection/adjusting of the play shall be carried out
every 1000 operating hours.
Check for wear and the magnet coils resistance shall be carried out
every 3000 operating hours.
17- 10
Service Manual
BT Europe AB

Maintenance
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
17.6.1 Adjusting the play

Dismantle the support arm wheel from the truck and remove the
brake.
Connect the brake to 48 V D.C.
Check the play, measurement A, with the brake applied.

NOTE!
Check the play at the same time in two positions at 180 degree spacing.
Maximum permitted play = 2.25 mm

Nominal play of newly adjusted brakes shall be 1.0-1.25 mm.
Before adjusting, dismantle the aluminium end plate.
Remove the shim washers, when adjusting due to wear, or add shim
washers when fitting new discs.
Each shim washer is 0.127 mm thick.
Fit the aluminium end plate, connect to 48 V D.C. and check the
play.
When the play lies within the nominal permitted value, fit the brake in
the wheel and the wheel on the truck.
BT Europe AB
Service Manual
17- 11

Maintenance
T-code
712, 713
17- 12

919699-
Service Manual
Date
2005-11-28
Order number
227761-040
BT Europe AB
Drive wheel 3530

General
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
18- Drive wheel 3530

18.1 General
The drive wheel consists of a cast rim with a vulcanised tread. When
changing the drive wheel you must ensure that you tighten the wheel
nuts to the correct torque.
On the truck the wheel size is 350x130 mm.
18.2 Dismantling the drive wheel

Lift up the truck on blocks so that the drive wheel is off the ground.
Unscrew the four bolts holding the guard plate.
Remove the guard plate.
Unscrew the nuts holding the drive wheel in position.
Lift off the drive wheel.
18.3 Assembling the drive wheel
Lift on the new drive wheel.

Apply MOLYKOTE grease BT number 055-73040 on the wheel
bolts.
Position the spherical washers (1) on the wheel bolts.
Tighten the wheel nuts (2) to 130 Nm.
Fit the guard plate.
Remove the blocks.
BT Europe AB
Service Manual
18- 1
Drive wheel 3530

Assembling the drive wheel
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
18- 2
Service Manual
BT Europe AB
Fork/support arm wheel 3550

Dismantling the wheel
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
19- Fork/support arm wheel 3550

19.1 Dismantling the wheel
Lift up the truck and support using blocks so that the support arm
wheel runs free of the ground.
Unscrew the bolts holding the guard plate above the wheel.
Remove the guard plate.
Loosen the connector/cable to the support arm brake.
Loosen the locking bolt for the brake shoe.
Pull out the wheel axle using tool 08-13585. Use the short punch.
Lift out the wheel.

Take the brake unit out of the wheel.
BT Europe AB
Service Manual
19- 1

Dismantling the wheel
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
The front wheel must be removed inwards. (1)

The rear wheel must be removed outwards. (2)
In order to ensure that the support arm brakes will work, the wheels
must be replaced as a pair.
19- 2
Service Manual
BT Europe AB

Assembling the wheel
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
19.2 Assembling the wheel

300 mm wheel with brake and 350 mm wheel
For wheels with brakes:

Place the brake unit in position in the wheel.
Lift the wheel into position.
NOTE!
On wheels with brakes, guide the brakes locking shoe into its cutout.
To centre the wheel vertically, use a jack to adjust the height.

Check that the wheel axle (3) is not damaged. Minor longitudinal
scratches can be tolerated.
If the axle ends have been damaged, the axle should be ground or
replaced.
Fit a new clamping ring (2) on the wheel axle (3).
WARNING !
Loose wheel.
If the wheel is refitted using the old clamping ring, the wheel can become loose while driving.
Always fit the wheel with a new clamping ring on the wheel axle.
Fit the extension punch on tool 08-13585 and insert it through the
wheel hub.
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.
Lower the truck.
Tighten the locking bolt for the brakes locking shoe and connect the
brake cable. Secure the cable with a tie so that it does not rub
against the wheel.
BT Europe AB
Service Manual
19- 3

Dismantling/assembling the wheel bearings
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
19.3 Dismantling/assembling the wheel

bearings
19.3.1 300 mm wheel with brake and 350 mm
wheel
Dismantling the bearing
Loosen the sleeve nut (1). Tools: Sleeve no. 808-413.
Remove the lock washer (2).
Press out the sleeve (3).
Pull the bearing off the sleeve (4) and remove the seal (5).
Remove the seal (6) and bearing (7).
Use a soft brass punch or similar to tap out the bearing cups (8)
from the hub.
19- 4
Service Manual
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
Assembling bearings
Fit the bearing cups in the hub.
Use an assembly sleeve of the same outside diameter as the bearing cups diameter, 80 mm.
Place the sealing ring (5) on the sleeve.
Press the sleeve into the bearing (4).
Grease the bearing using bearing grease and place the sleeve with
bearing in the wheel. Guide the sealing ring into position on the hub.
Press on the bearing (7) on the other side of the wheel.
Fit the sealing ring (6) on the hub.
Fit the lock washer (2) and sleeve nut (1).
Tighten the nuts to 50 Nm.
Tool 808-413 and a torque wrench.
The threads should be greased prior to assembly.
Lock the nut by folding at least one of the washers tabs down into
the nuts cut-out.
BT Europe AB
Service Manual
19- 5

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
19- 6
Service Manual
BT Europe AB
Electrical system 5000

General
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
20- Electrical system 5000

This document applies to all VCE150A/VCE150AC trucks with
firmware package version 213017-013 and to all VCE125ASF/
VCE125ACSF with firmware package version 224716-001.
Also see the section Firmware.
20.1 General
The electrical system in the AC powered trucks consists of a number of
electronic modules, A1-A32, which communicate with each other via
two separate CANs (Controller Area Network). Communication is
active as long as the truck is switched on.
The following electronic modules are housed in the cab:
ICP, Integrated Control Panel (A16) and FCU, Fork Controller Unit
(A4).
The following electronic modules are housed in the chassis:
MCU, Main Computer Unit (A5), ACTL, left drive motor controller
(A1), ACTR, right drive motor controller (A31), ACH, pump motor
regulator for cab lifting (A2) and DCHI, pump motor regulator for initial lifting and steering (A32).
If the truck is fitted with optional wire guidance, the MCU, Main Computer Unit, has an extra filter card.
NOTE! The functional description in this document, C code 5000, also
contains a description of the wire guidance function.
The input signals for the various truck functions received by the electronic modules are both digital (switches and sensors) and analogue
(potentiometers and sensors).
Likewise, the output signals for the various truck functions received by
the electronic modules are both digital (valves, drive wheel brakes,
etc.) and analogue (proportional valves, support leg brakes, etc.).
The adjoining picture depicts the schematic connections between the
different electronic modules.
BT Europe AB
Service Manual
20- 1

General
T-code
712, 713
20- 2

919699-
Service Manual
Date
2005-11-28
Order number
227761-040
BT Europe AB

General
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
20.1.1 Terminology
Expression
Meaning
Expression
Meaning
MCU
Main Computer
Unit
ACTx
Common abbreviation of both ACTR

and ACTL
ICP
Integrated Control
Panel
ACH
Lifting controller,
M3
FCU
Fork Computer
Unit
DCHI
Motor controller,
M4, initial lifting
and steering
WGU
Wire Guidance Unit
PWM
Pulse Width Modulation
ACTR
Drive controller, M2
ESO
Emergency
Switch-Off
ACTL
Drive controller, M1
20.1.2 Truck firmware applications

The truck programs for the trucks consist of a complete firmware package for all logic cards installed in the truck.
The firmware package file consists of a configuration file, with the .ini
format, which describes the various applications for each logic card.
The firmware package for the VCE150A/VCE150AC has order number:
213017-XXX and the firmware package for the VCE125ASF and
VCE125ACSF has order number 224716-XXX.
The firmware package includes the MCU application 208548-XXX, ICP
application 208551-XXX, FCU application for VCE 150A 208552-XXX
and applications 180854-XXX for the ACTR, ACTL and ACH.
20.1.3 Communication
CAN communication
The MCU is connected both to the CAN1 and CAN2 busses and operates as a CAN communication hub between the truck's different computer units.
CAN1 is used for communication between the truck's Main Computer
Unit, MCU, and the electronic modules, ICP and FCU, housed in the
cab.
CAN 2 is used for communication between the MCU and the electronic
modules, ACTR, ACTL, ACH and DCHI, in the chassis.
BT Europe AB
Service Manual
20- 3

Main Computer Unit, MCU (A5)
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
AUX serial interface

Communication interface, type RS232 and RS485.
The ICP is able to communicate with an onboard PC via the RS232
interface.
The MCU can also communicate with an ID system to identify narrow
aisle operation via the RS485 interface.
20.2 Main Computer Unit, MCU (A5)
20- 4
Service Manual
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
20.2.1 General
The MCU is the trucks main computer unit and is used to control driving, steering and cab lifting/lowering. The MCU communicates with two
drive controllers, two lift controllers, the fork computer unit, the integrated control panel and a personal ID system via a CAN (Controller Area
Network). The settings of the programmable truck parameters for steering (including wire guidance), travel speeds, deceleration and lifting
height limits are stored in the MCU.
The MCU monitors and controls truck steering and driving, braking,
hydraulic operation for lifting/lowering the cab, CAN communication
and various other functions, such as the battery indicator and height
measurements for the main lift.
Any errors that may occur in these functions are recorded and a corresponding error code is displayed on the instrument panel.
The MCU manages the recording and display of error codes, current
codes and reference codes that are generated by the electronic modules in the truck. The data for these codes are sent via the CAN.
The MCU can be reprogrammed via the CAN.
See the block diagram
The MCU also has inputs and outputs for the electrical functions in the
chassis.
BT Europe AB
Service Manual
20- 5

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
The MCU has the following functions:

- Driving: control of ACTL and ACTL via CAN2 based on signals
received from the operator controls and steering potentiometers.
- Lifting/lowering: control of ACH via CAN2 and output signals for
the hydraulic functions based on signals received from the operator controls.
- Steering: control of the signals for the steering functions based on
signals received from the operator controls.
- Wire guidance: control of WGU via CAN2 in the wire guidance
mode.
- Supervision on steering angle and virtual displacement points in
load and tractor direction when truck is locked on wire and actual
drive speed is more than 2,5 km/h.
- Narrow aisle and steering control.
- Optipace.
- Height measurement.
- Control of various input and output signals.
- Management and storing of system errors (including emergency
driving).
- Management of the real-time clock and the hour counter.
- Battery indicator.
- Communication routines.
- Communication network port.
- Aisle ID (RS485).
- Truck log system interface.
- Local parameters.
20.2.2 Voltage feed

The nominal voltage feed is 48 V.
20.2.3 Battery negative

The battery negative is connected directly to the negative pole on the
battery, and as such is isolated from the truck chassis.
20.2.4 Electric connectors

Two 42-pin connectors, installed on the same side of the logic card, and
one sealed 29-pin JPT connector.
20.2.5 Internal status monitoring

A green LED indicates operational status. The LED is situated between
the two JPT connectors and is visible from the outside. The LED indicates both hardware and software status, Power OK and error status.
20- 6
Service Manual
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
20.2.6 External inputs and outputs

X130 connector
I = Input, O = Output
Connection
Cable
Designation (component)
Active
Input/
output
X130:1
16
Voltage feed to the steering angle potentiometer and pressure sensor
+5 V
X130:2
201
Signal 2 in narrow aisle centre zone

(speed reduction at aisle end)
+48 V
X130:3
75
Hydraulic pressure for cab lifting
0-5 V
X130:4
50
Steering angle potentiometer, set point
0-5 V
X130:5
70
Battery guard, current measurement (+)
X130:6
Not connected
Analogue - (minus)
0V
X130:7
Not connected
Analogue - (minus)
0V
X130:8
220
CAN 2L
0-5 V
X130:9
Not connected
RS485 - serial (-), sends/receives data
X130:10
77
Narrow aisle detection, signal 1
+48 V
X130:11
90
Aisle end stop, signal 1
+48 V
X130:12
99
Pulse transducer for main lift height measurement, phase A
+0/15 V
X130:13
153
Inductive sensor, articulated centre unlocked
+48 V
X130:14
Not connected
X130:15
56
Analogue - (minus)
0V
X130:16
202
Aisle end stop, signal 2
+48 V
X130:17
76
System pressure, main lift auxiliary system
0-5 V
X130:18
Not connected
Reserved, analogue
0-5 V
X130:19
71
Battery guard, voltage/current feed (-)
0V
X130:20
118
CAN - serial (-)
0V
X130:21
Not connected
X130:22
219
CAN 2H
0-5 V
X130:23
117
CAN - serial (+)
+15 V
X130:24
78
Narrow aisle detection, signal 2
+48 V
X130:25
Not connected
BT Europe AB
Service Manual
20- 7

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Connection
Cable
Designation (component)
Active
Input/
output
X130:26
100
Pulse transducer for main lift height measurement, phase B
+0/15 V
X130:27
66
Main lift height measurement, reference sensor
+48 V
X130:28
Not connected
X130:29
30
Analogue - (minus)
0V
X130:30
Not connected
Reserved, analogue
0-5 V
X130:31
49
Accumulator pressure, steering
0-5 V
X130:32
72
Battery guard, voltage feed (+)
+48 V
X130:33
197
CAN - serial (-)
0V
X130:34
Not connected
Signal - (minus)
0V
X130:35
Not connected
X130:36
Not connected
RS485 - serial (+), sends/receives data
X130:37
29
Voltage feed sensor
+15 V
X130:38
79
Signal 1 in narrow aisle centre zone

(speed reduction at aisle end)
+48 V
X130:39
Not connected
Hydraulic filter sensor
+48 V
X130:40
154
Inductive sensor, articulated centre locked
+48 V
X130:41
163
Individual aisle ID 1
+48 V
X130:42
Not connected
20- 8
Service Manual
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
X131 connector
Connection
Cable
Designation
Active
Input/
output
X131:1
36
Battery +
+48 V
X131:2
164
+48 V
X131:3
Not connected
PPS signal 1
+48 V
X131:4
205
Speed reduction 1, 0 - inching speed
+48 V
X131:5
26
Battery voltage, (+) 48 V after emergency switch-off
+48 V
X131:6
28
Battery voltage, (+) 48 V chassis relay status
+48 V
X131:7
37
Main connector voltage feed
0V
X131:8
73
Voltage feed of main lift lowering valve
+48 V
X131:9
150
Voltage feed of right-hand routing valve for battery

replacement
+48 V
X131:10
191
PPS signal 1
+48 V
X131:11
155
Travel warning (truck moving)
0V
X131:12
Not connected
Not Specified
+48 V
X131:13
157
Voltage feed to support leg brakes
0-24 V
X131:14
40
Battery - (minus)
0V
X131:15
38
Battery voltage, (+) 48 V after main contactor
+48 V
X131:16
165
+48 V
X131:17
Not connected
PPS signal 2
+48 V
X131:18
206
Speed reduction 2, 2,5-4 km/h
+48 V
X131:19
203
Production mode 1
+48 V
X131:20
61
Parking brake voltage feed, right drive motor
+48 V
X131:21
57
Warning lamp voltage feed
+48 V
X131:22
194
PPS bypass
0V
X131:23
149
Voltage feed of left-hand routing valve for battery

replacement
0V
X131:24
192
PPS signal 2
0V
X131:25
58
Horn voltage feed
0V
X131:26
47
Proportional valve voltage feed, steering left
0-24 V
X131:27
119
CAN 1H
0-5 V
X131:28
Not connected
Battery - (minus)
0V
X131:29
30
Signal - (minus)
0V
BT Europe AB
Service Manual
20- 9

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Connection
Cable
Designation
Active
Input/
output
X131:30
137
Slack chain guard detection, main lift
+48 V
X131:31
190
Speed reduction, max. speed
+48 V
X131:32
207
Speed reduction, 0 km/h stopping
+48 V
X131:33
204
Production mode 2/ Special lift height limiter
+48 V
X131:34
62
Parking brake voltage feed, left motor
+48 V
X131:35
46
Routing valve voltage feed, steering pressure
+48 V
X131:36
151
Routing valve voltage feed, articulated steering

plunger
+48 V
X131:37
152
Main valve voltage feed, steering
+48 V
X131:38
193
PPS signal 3
0V
X131:39
Not connected
Not Specified
0V
X131:40
48
Proportional valve voltage feed, steering right
0-24 V
X131:41
59
Ventilator fan voltage feed
0-24 V
X131:42
120
CAN 1L
0-5 V
20- 10
Service Manual
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
X132 connector
This connector is used for connection of wire guidance antennas.
I = Input, U =Output
Connector
Cable
colour
Description
Signal
type
Input/
output
X132:1
Not connected
X132:2
Not connected
X132:3
Not connected
X132:4
Red
Right coil, front antenna W1
Analogue
signal
X132:5
Violet
Voltage feed (-), front antenna W1
0V
X132:6
Yellow
Digital control signal L1, front antenna W1
X132:7
Grey
Voltage feed (+), rear antenna W2
X132:8
U
+12 V
Shield, rear antenna W2
X132:9
Yellow
Digital control signal T1, rear antenna W2
X132:10
Red
Right coil, rear antenna W2
Analogue
signal
X132:11
Not connected
X132:12
Not connected
X132:13
Not connected
X132:14
Brown
Centre coil, front antenna W1
Analogue
signal
X132:15
Shield, front antenna W1
X132:16
Blue
X132:17
Violet
Voltage feed (-), rear antenna W2
X132:18
Blue
X132:19
Brown
Centre coil, rear antenna W2
X132:20
Not connected
X132:21
Not connected
X132:22
Not connected
BT Europe AB
Service Manual
U
0V
U
U
Analogue
signal
20- 11

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Connector
Cable
colour
Description
Signal
type
Input/
output
X132:23
Black
Right coil, front antenna W1
Analogue
signal
X132:24
Orange
X132:25
Green
X132:26
Grey
Voltage feed (+), front antenna W1
X132:27
Orange
X132:28
Green
X132:29
Black
Right coil, rear antenna W2
+12 V
Analogue
signal
20.2.7 Installing a new card in the truck

The MCU supplied from BT Parts can be ordered with different configurations:
1. Preprogrammed with complete number
= P/N for the card including firmware.
2. Unprogrammed with part number
= only P/N for the card.
When installing a new card in the truck, certain parameters need to be
reprogrammed in order to assure safe operation of the truck.
20.2.8 Programming the MCU

To download new firmware to the MCU, use the Truck Com SE maintenance programme.
Before programming, be sure to read Truck Com SE Manual
20- 12
Service Manual
BT Europe AB

Fork computer unit, FCU (A4)
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
20.3 Fork computer unit, FCU (A4)
20.3.1 General
The FCU monitors the truck's hydraulic functions for the fork unit and
records any operation errors. In this case and to ensure safe operation
of the hydraulics, the FCU will take the necessary measures.
Information about operation errors are sent via CAN1 to the MCU for
registration and storing of the current error code.
The FCU can be reprogrammed via the CAN.
The FCU has inputs and outputs to control fork movement.
The input and output status can be displayed on the ICP display.
The FCU has the following functions:

-
Control of turret head forks or shuttle forks

Control of initial lifting
Height measurement for initial lifting
Management of local errors
Local parameters.
The settings of the programmable truck parameters for the fork unit are
stored in the FCU.
BT Europe AB
Service Manual
20- 13

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
20.3.2 Voltage feed

The FCU receives no power when the start key is in the Off position or
when the emergency switch has been pressed.

20.3.4 Electric connectors

A sealed JPT type 42-pin connector.
20- 14
Service Manual
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713

Connector
Connection
Cable
Designation
Active
Input/
output
001
24
Voltage feed from battery
+48 VDC
002
39
Voltage feed to the turning angle potentiometer and

pressure sensor
+5 V
003
196
Rotation proportional valve (t-code 713)
0-24 V
004
84
Right traversing routing valve
+48 V
005
82
Initial lifting routing valve
+48 V
006
85
Voltage feed to rotation relay (t-code 713)
+48 V
007
65
Potentiometer for turning angle of turret head fork unit

(t-code 713)
0-5 V
008
68
Traversing pulse transducer, phase B
+0/15 V
009
67
Traversing pulse transducer, phase A
+0/15 V
010
103
Traversing reference sensor
+15 V
011
64
Pulse transducer for initial lift height measurement,

phase B
+0/15 V
012
63
Pulse transducer for initial lift height measurement,

phase A
+0/15 V
013
104
Initial lift height measurement, reference sensor
+15 V
014
69
Load pressure sensor
+5 V
015
80
Battery -
0V
016
195
Traversing proportional valve
0-24 V
017
83
Left traversing routing valve
+48 V
018
88
Reserved, valve for extra hydraulic function 1A
+48 V
019
89
Reserved, valve for extra hydraulic function 1B
+48 V
020
Not connected
Reserved
(+48 V)
021
87
Voltage feed detection to proportional valve for clockwise rotation (t-code 713)
0-24 V
022
Not connected
Reserved
(+15 V)
023
Not connected
Reserved
(+15 V)
BT Europe AB
Service Manual
20- 15

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Connection
Cable
Designation
Active
Input/
output
024
Not connected
Reserved
(+15 V)
025
Not connected
Reserved
(+15 V)
026
141
Closed cabin gates detection
+15 V
027
119
CAN 1H
0-5 V
028
15
Voltage feed to sensor
+15 V
029
40
Battery -
0V
030
Not connected
Reserved
031
81
Proportional valve voltage feed, initial lowering
0-24 V
032
Not connected
Reserved, valve for extra hydraulic function 2A
+48 V
033
Not connected
Reserved, valve for extra hydraulic function 2B
+48 V
034
Not connected
Reserved
(+48 V)
035
86
Voltage feed detection to proportional valve for counterclockwise rotation (t-code 713)
0-24 V
036
Not connected
Reserved, analogue
(0-20 V)
037
Not connected
Reserved
038
Not connected
Reserved
039
Not connected
Reserved
040
139
Slack chain guard detection, initial lifting
+48 V
041
15
Relay position (connected to connector 28)
+15 V
042
120
CAN 2L
0-5 V
20- 16
Service Manual
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
20.3.6 Installing a new card in the truck

The FCU supplied from BT Parts can be ordered with different configurations:
= P/N for the card including firmware.
= only P/N for the card.
20.3.7 Programming
To download new firmware to the FCU, use the Truck Com SE maintenance programme.
Before programming, be sure to read Truck Com SE:s user manual
BT Europe AB
Service Manual
20- 17

Integrated Control Panel, ICP (A16)
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
20.4 Integrated Control Panel, ICP (A16)

20.4.1 General
The ICP is the interface between the operator and the truck. The ICP
contains all operator controls (levers, pushbuttons, keyboard, etc.), the
display and a buzzer.
The majority of all truck operations are controlled by the ICP, including
driving, lifting/lowering and fork operation. To facilitate easy operation,
the built-in display shows the truck status, e.g. lifting height, Steering
angle and battery status.
The ICP also has connectors for direct connection of two cameras to
the logic card. The card microprocessor controls use of the selected
camera.
A buzzer is installed on the logic card to sound audible warnings whenever an alarm event (error, aisle operation, etc.) occurs.
Additionally, the ICP is used during servicing and maintenance.
For example, it is used for parameter settings, reading the error code
log, calibration and diagnostic operation.
20- 18
Service Manual
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
The ICP is connected to the truck system via one of the two CAN
busses, in this case CAN1. Information about errors is sent via CAN1 to
the MCU for registration and storing of the appropriate error code.
The ICP can be reprogrammed via the CAN.
The ICP has the following functions:

- Input signals, filtering, monitoring of all signals receiving from the
operator controls. The signals are sent to the MCU via CAN1.
- Control/monitoring of the graphic display. Symbols are used to
show all basic functions. In the case of maintenance work, alphanumeric characters are also used. Commands for the information
to be displayed are mainly generated by the MCU. However, the
ICP may also request information from the MCU and FCU.
- Reading the keypad
- Management of local errors
- Communication routines.
- Electronic key and electronic relay
- Monitoring all outputs
- Management of displayed content and adjustment of parameters
in the various modules.
- Video controller
The logic card can handle signals from two connected cameras.
One or two cameras can be connected to the ICP, using the operator display to display the picture. The keypad is used to selected
the camera. Alternatively, this can be automatically controlled via
the main computer card (MCU) in the truck.
- Optionally, the display and keypad can be replaced by an onboard computer terminal, BTVM.
BT Europe AB
Service Manual
20- 19

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
20.4.2 ICP modules

The ICP consists of three sections. The left control section, the right
control section and the display/pad control section. All sections are
connected to a logic card installed in the ICP. All controls are monitored
by the logic card microprocessor and control values are sent to the
MCU in the form of operator commands. Data to be shown on the display are sent from the MCU.
See the block diagram
20- 20
Service Manual
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
Left section
The left section consists of:
- Dead man's handle
- Steering wheel
- Wire guidance pushbutton
- Horn pushbutton
- Fork lifting/lowering pushbuttons
- Fork operation controls (analogue)
Right section
The right section consists of:
- Dead man's handle
- Fork mode switching button
- Brake pushbutton
- Horn pushbutton
- Cab lifting/lowering pushbuttons
- Drive and brake controls (analogue)
- Emergency switch pushbutton (ESO)
Display/keypad section (Std. version)

The display section consists of:
- 5.5" graphic TFT display
- Keypad
Logic card
The logic card consists of the following main systems:
- Power controllers
- Microprocessor including memories
- Inputs and outputs for sensors and controls
- Display controller
- Video processor
- Buzzer
- Camera interface
- CAN interface
- RS-232 interface
20.4.3 Voltage feed

The FCU receives no power when the start key is switched off or when
the emergency switch is depressed.
BT Europe AB
Service Manual
20- 21

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040


X100 connector
Connection
Cable
Designation
Active
Input/
output
X100:1
158
Counterclockwise rotation
+48 V
X100:2
200
Voltage feed switch
+48 V
X100:3
74
Clockwise rotation
+48 V
X100:4
111
Voltage feed detection, left dead man's handle
+15 V
X100:5
113
Signal - (minus)
0V
X100:6
112
Left dead man's handle detection
+15 V
X100:7
106
Horn switch detection, left-hand side
+48 V
X100:8
105
Horn voltage feed switch, left-hand side
+48 V
X100:9
116
Wire guidance request
+48 V
X100:10
130
Analogue - (minus), left thumb dial
0V
X100:11
129
Left thumb dial potentiometer
0-5 V
X100:12
128
Voltage feed , left thumb dial potentiometer
+5 V
X100:13
91
Voltage feed to steering wheel pulse transducer 1
+15 V
X100:14
92
Pulse transducer 1, phase A
+0/15 V
X100:15
93
Pulse transducer 1, phase B
+0/15 V
X100:16
94
Signal - (minus) to steering wheel pulse transducer

1
0V
X100:17
95
Voltage feed to steering wheel pulse transducer 2
+15 V
X100:18
96
Pulse transducer 2, phase A
+0/15 V
X100:19
97
Pulse transducer 2, phase B
+0/15 V
X100:20
98
Signal - (minus) to steering wheel pulse transducer

2
0V
20- 22
Service Manual
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
X101 connector
Connection
Cable
Designation
Active
Input/
output
X101:1
60
Key relay voltage feed
0V
X101:2
40
Battery -
0V
X101:3
21
Battery + voltage feed
+48 V
X101:4
119
CAN 1H
0-5 V
X101:5
120
CAN 1L
0-5 V
X101:6
23
Key relay detection status
+48 V
X101:7
Not connected
Switch/sensor detection
+48 V
X101:8
Not connected
+48 V
X101:9
Not connected
Signal - (minus)
0V
X101:10
Not connected
Signal - (minus)
0V
X101:11
167
Voltage feed, extra hydraulic function 1A
0V
X101:12
166
Voltage feed, extra hydraulic function 1B
0V
BT Europe AB
Service Manual
20- 23

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
X102 connector
Connection
Cable
Designation
Active
Input/
output
X102:1
Not connected
Analogue detection
0-5 V
X102:2
Not connected
Analogue detection
0-5 V
X102:3
Not connected
+48 V
X102:4
Not connected
+48 V
X102:5
Not connected
Signal - (minus)
0V
X102:6
Not connected
Signal - (minus)
0V
X102:7
Not connected
Switch/sensor voltage feed
+48 V
X102:8
Not connected
Switch/sensor voltage feed
+48 V
X102:9
Not connected
Signal - (minus)
0V
X102:10
Not connected
Voltage feed sensor
+5 V
X102:11
Not connected
Signal - (minus)
0V
X102:12
184
Service key voltage feed
+15 V
X102:13
Not connected
Signal - (minus)
0V
X102:14
Not connected
Signal - (minus)
0V
X102:15
Not connected
Analogue detection
0-5 V
X102:16
Not connected
Analogue detection
0-5 V
20- 24
Service Manual
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
X103 connector
Connection
Cable
Designation
Active
Input/
output
X103:1
134
Cab lowering switch detection
+48 V
X103:2
133
Voltage feed to cab lowering/lifting switch
+48 V
X103:3
135
Cab lifting switch detection
+48 V
X103:4
107
Voltage feed detection, right dead man's handle
+15 V
X103:5
109
Signal - (minus)
0V
X103:6
108
Right dead man's handle detection
+15 V
X103:7
132
Shift switch button detection
+48 V
X103:8
131
Voltage feed to shift switch button
+48 V
X103:9
102
Horn switch detection, right-hand side
+48 V
X103:10
124
Analogue - (minus), right thumb dial
0V
X103:11
123
Right thumb dial potentiometer
0-5 V
X103:12
122
Voltage feed , right thumb dial potentiometer
+5 V
X103:13
125
Brake switch voltage feed
+48 V
X103:14
126
Brake switch detection, normally open
+48 V
X103:15
127
Brake switch detection, normally closed
+48 V
X103:16
Not connected
X103:17
101
Horn voltage feed switch, right-hand side
+48 V
X104 connector
Connector
Cable
Designation
X104:1
256
Display, video signal 2
X104:2
210
Video signal 2
X104:3
156
Display, video signal 1
X104:4
110
Video signal 1
BT Europe AB
Service Manual
Active
Input/
output
I
20- 25

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
X106 connector
Connection
Cable
Designation
Active
Input/
output
X106:1
Not connected
X106:2
Not connected
RS232 , receives data
X106:3
Not connected
RS232 , sends data
X106:4
Not connected
X106:5
Not connected
X106:6
Not connected
X106:7
Not connected
X106:8
Not connected
X106:9
Not connected
RS232 - series (-)
0V
RS232 - series (+)
+12 V
X107 connector
Connection
Cable
Designation
Active
Input/
output
X107:1
Not connected
Ventilator fan voltage feed
0-15 V
X107:2
Not connected
Battery negative (-)
0V
20.4.6 Installing a new ICP in the truck

The ICP, including its logic card, supplied by BT Parts can be ordered
with different configurations:
= P/N for the frequency converter including the firmware.
= only P/N for the ICP or the electronic card.
20.4.7 Programming
To download new firmware to the electronic card, use the Truck Com
SE maintenance programme.
Before programming, be sure to readTruck Com SE manual.
20- 26
Service Manual
BT Europe AB

AC regulators, ACTL (A1), ACTR (A31) and ACH (A2)
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
20.5 AC regulators, ACTL (A1), ACTR

(A31) and ACH (A2)
20.5.1 General
The truck uses three frequency converters to control the drive motors
and the main lift pump motor:
The ACTL (left drive motor), ACTR (right drive motor) and ACH (pump
motor). The three frequency converters are identical and have the
same part number.
The frequency converter has a green LED, which indicates OK status.
The basic firmware to control the drive motors or pump motor is stored
in the frequency converter.
The frequency converter has an internal monitor function for CAN communication, DC voltage level, internal converter temperature as well as
the motor temperature.
The frequency converter also records any errors and sends the corresponding error information via the CAN to the main logic card (MCU)
where the error code is registered and subsequently displayed on the
ICP display.
The frequency converter can be reprogrammed via the CAN.
BT Europe AB
Service Manual
20- 27

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
20.5.2 Connection terminal and terminal

pillars
Connection
Cable
A1/A31/A2
Designation
Active
Input/output
26
Voltage feed after ESO
+48 VDC
Not connected
31/41/51
+ voltage sensor
+12 VDC, 50 mA
32/42/52
- sensor
0V
33/43/53
Pulse transducer, phase 1
+12 V, 1 kohm
34/44/54
Pulse transducer, phase 2
+12 V, 1 kohm
35/45/55
Motor temperature
CAN ID0, ACH
CAN ID0, ACTR
10
219
CAN 2H
0-5 V
I/O
11
220
CAN 2L
0-5 V
I/O
12
Not connected
13
118
CAN -, external
0V
B+
Battery +
+48 VDC
B-
40
Battery -
0V
2/5/9
Motor winding U
0-33 V
3/6/10
Motor winding V
0-33 V
4/7/11
Motor winding W
0-33 V
20- 28
Service Manual
I
1: Open
0: - sensor
I
I
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713

Parameter
Setting
Unit
Description
Operating voltage
48
Max. operating voltage
65
Overvoltage limit
Min. operating voltage
30
Undervoltage limit
Frequency
8/13
kHz
Contactor voltage
48
Ambient operating temperature
-35 - +55
Current limit, downwards

adjustment in case of
cooling body overtemperature
85
oC
0 A at 125o C
Current limit, downwards

adjustment in case of
cooling body undertemperature
-20
oC
50% current limit

at start-up
Current limitation
350
2 minutes
Speed
100
Modulation
20.5.4 Installing a new frequency converter in

the truck
The frequency converter supplied from BT Parts can be ordered with
different configurations:
= P/N for the frequency converter including the firmware.
= only P/N for the frequency converter.
20.5.5 Programming
To download new firmware to the electronic card, use the Truck Com
SE maintenance programme.
Before programming, be sure to read Truck com SE Manual.
BT Europe AB
Service Manual
20- 29

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
20.5.6 Maintenance
There are no user-serviceable components in the transistor regulator.
NOTE!
Do not attempt to open the transistor regulator.
OPENING THE REGULATOR WILL VOID THE WARRANTY!
It is recommended to regularly clean the transistor regulator on the outside. When cleaning the regulator, this is also a good time to check the
diagnostics file in the regulator using the hand-held terminal, if available.
20.5.7 Safety
The regulator is a high-power component. Consequently, when working
on a battery operated vehicle, be sure to observe the necessary safety
procedures. These, among others, stipulate appropriate training, the
use of eye protectors, avoiding wearing loose-fitting clothing, watches
and jewelry. Only use insulated spanners.
WARNING!
Remove any watches and all jewelry and use only insulated tools.
20.5.8 Cleaning
Although the frequency converter when correctly installed does not
require any maintenance, the following minimum upkeep is recommended every 500 operating hours.
Switch off the voltage supply by disconnecting the battery.
Prior to performing any work on the frequency converter, be sure to
discharge the capacitors in the frequency converter by connecting a
load (for example the contactor coil or the horn) across the B+ and
B- connections on the regulator.
Remove all dirt and corrosion from the power connectors. Wipe off
the regulator with a moist rag. Before reconnecting the battery, allow
the regulator to dry completely.
Verify that the power connectors on the regulator are tightened properly.
Tighten the connections to a torque of 15 Nm
NOTE!
To avoid uneven loads on the power connectors, use two well-insulated torque wrenches for this task.
20- 30
Service Manual
BT Europe AB

DC regulator, DCHI (A32)
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
20.6 DC regulator, DCHI (A32)

20.6.1 General description
The regulator has an LED to signal errors. The LED is placed on top of
the regulator and is marked STATUS. On one of the sides of the regulator, there is a connector for connecting the hand-held terminal 1307.
For details, see the section PARAMETERS.
The basic firmware to control the pump motor is stored in the regulator.
The regulator has an internal monitor function for CAN communication
and the DC voltage level.
The regulator also records any errors and sends the corresponding
error information via the CAN to the main logic card (MCU) where the
error code is registered and subsequently displayed on the ICP display.
BT Europe AB
Service Manual
20- 31

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
20.6.2 Connection terminal and terminal

pillars
Connection
Cable
J1-(1-4)
Designation
Active
I/O
CAN 2H
0-5 V
I/O
CAN 2L
0-5 V
I/O
Hand-held terminal
J2-1
219
J2-(3-7)
Not connected
J2-8
220
J2-(915)
Not connected
J2-16
26
Voltage feed after

ESO
+48 VDC
B+
12
Battery +
+48 VDC
B-
40
Battery -
0V
13
Motor connection
The transistor panel has three connectors for the motor and the battery.
The cables are secured using M8 screws which should be tightened to
a torque of max. 16.3 Nm.
20- 32
Service Manual
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713

Parameter
Setting
Unit
Description
Operating voltage
48
Volt
Maximum voltage
61
Volt
Overvoltage limit
Min. operating voltage
30
Volt
Undervoltage limit
Frequency
16
kHz
Ambient operating temperature
-35 - +55
Current limit, downwards adjustment

in case of cooling body overtemperature
85
oC
0 A vid 95o C
Current limit, downwards adjustment

in case of cooling body undertemperature
-25
oC
50% current limit at start-up
Current limitation
250
Amp
2 minutes
Speed
100
Modulation
20.6.4 Installing a new transistor panel

No programming or settings required.
BT Europe AB
Service Manual
20- 33

Parameters
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
20.7 Parameters
The Curtis 1243 has a number of parameters for setting the ID number
and communication options. The table below shows the parameters
that can be changed by a service technician using the hand-held terminal 1307. For viewing and changing parameters, please see the section
Using the hand-held terminal.
No.
Parameter type
01
Unit
Min./Max.
Def. value
Remarks
Module ID
131
Can bus module address
02
TX COB
0-128
CAN bus sending
03
RX COB
0-128
CAN bus receiving
20.7.1 Diagnostics and troubleshooting

Displaying errors codes and error logging
An internal microprocessor continuously monitors the operation of the
regulator. When an error is detected, an error code is sent to the main
logic card, which in turn displays and stores the code. The error code
can also be read using the hand-held terminal 1307 or the blinking pattern of the STATUS LED on top of the regulator. In normal operation,
when no error has occurred, the LED blinks at intervals of approximately once every second.
STATUS
MODEL
VOLTAGE
SERIAL
CURRENT
The regulator keeps a log of all errors in its memory. An error that
occurs repeatedly is only logged once. Using the hand-held terminal,
current errors can be read as well as the history of past errors. The
STATUS LED only shows one error at a time and is unable to signal the
error history.
For reading error codes using the hand-held terminal, please read the
section Using the hand-held terminal.
20- 34
Service Manual
BT Europe AB

Parameters
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
Error codes, troubleshooting

The table below lists all error codes that are shown via the STATUS
LED or on the hand-held terminal. The table also indicates the possible
causes for each error.
STATUS LED
Hand-held terminal display
Explanation
Possible cause
LED Off
No voltage or defective regulator
Blown fuse, poor contact, no

connection, defective regulator
LED On
Defective regulator
Defective regulator
1,2
234
1,3
221
1,4
222
3,1
4,1
4,2
4,3
5,0
5,1
5,2
5,3
5,4
48
46
Resetting errors
Apart from remedying the cause for the error, to reset an error and
remove the error code, the key (S17) must be switched off and then on.
The following errors are exceptions to this:
BT Europe AB
Error
Reset when
4,1
The battery voltage rises above 30 V
4,2
The battery voltage falls below 61 V
4,3
The temperature returns to the allowed range
Service Manual
20- 35

Parameters
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
20.7.2 Maintenance
There are no user-serviceable components in the transistor regulator.
NOTE!
Do not attempt to open the transistor regulator.
OPENING THE REGULATOR WILL VOID THE WARRANTY!
It is recommended to regularly clean the transistor regulator on the outside. When cleaning the regulator, this is also a good time to check the
diagnostics file in the regulator using the hand-held terminal, if available.
20.7.3 Safety
The regulator is a high-power component. Consequently, when working
on a battery operated vehicle, be sure to observe the necessary safety
procedures. These, among others, stipulate appropriate training, the
use of eye protectors, avoiding wearing loose-fitting clothing, watches
and jewelry. Only use insulated spanners.
WARNING!
Remove any watches and all jewelry and use only insulated tools.
20.7.4 Cleaning
Although the transistor regulator when correctly installed does not
require any maintenance, the following minimum upkeep is recommended every 500 operating hours.
Switch off the voltage supply by disconnecting the battery.
Prior to performing any work on the transistor regulator, be sure to
discharge the capacitors in the transistor regulator by connecting a
load (for example the contactor coil or the horn) across the B+ and
B- connections on the regulator.
Remove all dirt and corrosion from the power connectors. Wipe off
the regulator with a moist rag. Before reconnecting the battery, allow
the regulator to dry completely.
Verify that the power connectors on the regulator are tightened properly. To avoid uneven loads on the power connectors, use two well-insulated torque wrenches for this task.
20- 36
Service Manual
BT Europe AB

Parameters
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
20.7.5 Hand-held terminal 1307

The hand-held terminal 1307 is used to programme, test and troubleshoot the transistor regulator 1243. The hand-held terminal is powered
by the transistor regulator via a 4-pin Molex connector on the side of the
regulator.
S1
B-
BT Europe AB
Service Manual
S2
M-
B+
20- 37

Parameters
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Pos.
Function
Remarks
LCD display
4-line LCD display
PROGRAM MODE button
Select this function to display (and change) the regulator

parameters.
TEST MODE button
Select this to display the status of inputs and outputs, etc.
DIAGNOSTICS MODE
Select this to display current errors detected by the regulator.
SCROLL DISPLAY buttons
Scrolls though the displayed text lines (up and down)
MORE INFO button
Depress to display detailed information about the

selected mode.
LEDs in buttons
The LEDs indicate whether the corresponding CHANGE

VALUE button has been selected. If the LED is distinguished, adjustment is not possible.
CHANGE VALUE buttons
The buttons are used to increase and decrease the value

of the selected item.
Operating mode LEDs
These LEDs indicate the selected operation mode.
20- 38
Service Manual
BT Europe AB

Parameters
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
20.7.6 Using the hand-held terminal
S1
B-
S2
M-
B+
Connect the hand-held terminal to the programming connector on

the regulator.
Ensure power to the truck has been switched on.
Once this is done, the terminal will display its serial number, the manufacturing date and the firmware version. The terminal then displays a
prompt for user input.
The terminal has three main modes: PROGRAM, TEST and DIAGNOSTICS.
The PROGRAM mode is used to display the terminal parameters
Certain parameters can also be replaced in this mode.
The TEST mode shows the input and output signal status in real
time as well as the internal regulator temperature. In the TEST
mode, the current item need not necessarily be the first in the order
among the four displayed items. The TEST mode is useful to verify
the operation of the regulator during installation and to troubleshoot
malfunctions.
The DIAGNOSTICS mode displays current errors detected by the
regulator.
The user also has access to two other modes: the SPECIAL PROGRAM MODE and the SPECIAL DIAGNOSTIC MODE.
The SPECIAL PROGRAM MODE is used for miscellaneous tasks,
e.g. to select the display language, adjust the LCD contrast,
and clear the DIAGNOSTIC HISTORY FILE.
The SPECIAL DIAGNOSTIC MODE is used to call up errors from
the history log. The regulator logs all errors that occurs and stores
them in the DIAGNOSTIC HISTORY FILE. Errors are kept until this
file is cleared.
BT Europe AB
Service Manual
20- 39

Parameters
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
20.7.7 Viewing and adjusting parameters

Depress the PROGRAM mode button. The Program mode LED
lights.
The terminal now displays the first four parameters.
See the picture below.
PROGRAM
Parameters are displayed four at a time. Each line represents one

parameter. (A) indicates the parameter name. The arrow (B) indicates
the selected parameter. (C) indicates the parameter value.
Depress one of the SCROLL DISPLAY buttons to display more parameters.
To adjust a parameter, scroll up or down the display until the arrow (B)
points to the desired parameter.
Increase the value by depressing the CHANGE VALUE up button
or decrease it by depressing the CHANGE VALUE down button.
NOTE!
As soon as a parameter value in the display is changed, the new value
is immediately transmitted to the regulator.
Using the MORE INFO PROGRAM MODE

When the MORE INFO button is depressed in the PROGRAM MODE,
details of the selected parameter are displayed. The parameter is
shown using a horizontal bar graph together with the parameter's minimum and maximum values.
MODE 1 ACCELERATION
RATE; SECS
MIN 0.2
20- 40
Service Manual
1.3
MAX 3.0
BT Europe AB

Parameters
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
20.7.8 SPECIAL PROGRAM MODE
MORE INFO
The SPECIAL PROGRAM MODE is used for a number of different

functions, all of which are self-explanatory. In the SPECIAL PROGRAM
MODE, it is possible to select the display language, save settings,
return to previous settings, download settings to a regulator, adjust the
LCD contrast and clear the DIAGNOSTIC HISTORY FILE.
PROGRAM
To access the SPECIAL PROGRAM MODE, depress the MORE INFO

button while holding the PROGRAM button depressed. The LED in the
PROGRAM button should light, just as in the PROGRAM. Once in the
SPECIAL PROGRAM MODE, use the MORE INFO button to select an
item.
Example: To adjust the LCD contrast, select Contrast Adjustment by
using the SCROLL buttons until Contrast Adjustment is shown at the
top of the display. Then depress MORE INFO to set the item.
20.7.9 Using the TEST mode

Depress the TEST mode button. The TEST mode LED lights.
The terminal will display the input and output signal value status in real
time. See the picture below.
TEST
Values are displayed four lines at a time. Each line represents a signal
or value of an input/output. (A) indicates the name and (B) the current
value.
Depress one of the SCROLL DISPLAY buttons to display more values.
BT Europe AB
Service Manual
20- 41

Parameters
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
20.7.10 Using the DIAGNOSTICS MODE

Depress the DIAGNOSTICS mode button. The DIAGNOSTICS
mode LED lights.
The terminal will display a list of all current errors detected by the regulator. The picture below shows the display when no errors have been
detected.
DIAGNOSTICS
20.7.11 SPECIAL DIAGNOSTICS MODE
MORE INFO
In the SPECIAL DIAGNOSTICS MODE, the DIAGNOSTIC HISTORY

FILE of the regulator is displayed. This file contains all errors detected
by the regulator since the file was last cleared. Each error is only
recorded once no matter how many times it has occurred.
DIAGNOSTICS
To access the SPECIAL DIAGNOSTICS MODE, depress the MORE

INFO button while holding the DIAGNOSTICS button depressed. The
LED in the DIAGNOSTICS button will light.
To clear the DIAGNOSTICS HISTORY FILE, switch to the SPECIAL
PROGRAM MODE and select Clear Diag History, then depress the
MORE INFO button for further instructions.
20- 42
Service Manual
BT Europe AB

Electrical system, overview
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
20.8 Electrical system, overview

CHASSIS
24
OVER MAST
CABLE
24
X1
G1 48V
+
SHUNT WIRE
X1
F63
20
40
40
40
MCU, MAIN CONTROL UNIT (A5)

X16
40
MEASURING WIRES
142
OUT. STEER PRESSURE VALVE X131:35
F66
OUT. STEER PROP. VALVE LEFT X131:26
72
X130:32 INP.BATT. IND. CURRENT -(+)

OUT. STEER PROP. VALVE RIGHT X131:40
71
X130:19 INP.BATT. IND. - / CURRENT OUT. STEER LOCK VALVE X131:37
70
X130:15 INP.BATTERY INDICATION +
S22
K10
S23 26
25
Y31
H2
57
X131:5 INP. ESO IN

OUT. (PWM) FAN X131:41
37
F62
Y3
48
152
28
Y4
47
OUT. (NPN) WARNING LAMP X131:21
26
24
Y7
46
M12
59
M10
X131:7 OUT. (NPN) MAIN CONTACTOR/CHASSIS RELAY

M16
38
X131:15 INP. MAIN CONTACTOR/CAP. CHARGE
H1
8
F61
K18
26
F60
OUT. (NPN) HORN X131:25
36
X131:1 INP. +48VDC POWER MCU

INP. SLACK CHAIN GUARD BOTTOM X131:30
40
Y1
31
U11
OUT. (NPN) PARKING BRAKE M2 X131:34

X131:6 INP. CHASSIS POWER RELAY STATUS
FREQUENCY INVERTER, DRIVE MOTOR LEFT

A1
CAN 2L 11
8
F1 125A
B+
32
33
34
26
INP. STEER ACCUMULATOR PRESSURE X130:31
220
X130:8 CAN 2L
219
CAN 2H 10
B-
X130:22 CAN 2H
118
GND. CAN 13
X130:20 GND
GND ANALOGUE X130:29

PIVOT POT. +5VDC SUPPLY X130:1
INP. PIVOT ANGLE X130:4
PIVOT GND X130:15
4 GND. SENSOR
U
3 +12VDC
5
+15VDC SUPPLY X130:37
M1
INP. CABIN HEIGHT PULSE A X130:12

INP. CABIN HEIGHT PULSE B X130:26
INP. CABIN < REFERENCE HEIGHT X130:27

R100
1 +48VDC ESO
OUT. CABIN LOWER VALVE 1 & 2 X131:8
B2
45
41
43
44
26
INP. PUMP PRESSURE REFERENCE VALVE X130:3
CAN 2H 10
INP. LIFT SUPPORT SYSTEM PRESSURE X130:17
GND. CAN 13
INP. IN AISLE SIGNAL 1 X130:10
B-
40
4 GND. SENSOR
U
V
3 +12VDC
5
16
50
R7
56
29
55
51
53
54
26
16
U10
99
28
30
40
100
66
S71
Y21
73
B5
75
76
B6
S5
77
M2
INP. IN AISLE SIGNAL 2 X130:24
S7
78
S8
S178
79
S9
INP. AISLE END BRAKE 1 X130:38

S4
1 +48VDC ESO
220
219
118
INP. AISLE END BRAKE 2 X130:2
CAN 1H X131:27
CAN 2H 10
CAN 1L X131:42
B-
GND X130:33
15VDC CAN SUPPLY X130:23
7
4 GND. SENSOR
3 +12VDC
5
U
V
W
M3
TRANSISTOR REGULATOR, FORK LIFT A32

26
J2:16 +48VDC ESO
12
B+ 48VDC PWR. SUPPLY
40
B- GND POWER
219
CAN 2H J2:8
10
11
S123
201
S124
8 INVERTER ID
52
F4
R91
1 +48VDC ESO
M4
M4
BT Europe AB
30
S156
GND. CAN 13
U12
49
F75
S133
B4
S6
FREQUENCY INVERTER, MAIN PUMP MOTOR

A2
CAN 2L 11
F2 125A
8
B+
B3
S132
Y2
62
9 INVERTER ID
42
U14
61
Y29
CAN 2
FREQUENCY INVERTER, DRIVE MOTOR RIGHT

A31
CAN 2L 11
F2 125A
8
B+
40
S81
136
S131
28
35
S82
27
28
B1
IN
-
X131:14 INP. GND POWER MCU
OUT. (NPN) PARKING BRAKE M1 X131:20
40
58
137
Service Manual
13
CAN 2L J2:1
M OUT. INITIAL FORK MOTOR
220
119
119
120
120
197
OVER MAST
CABLE
CAN 1
117
SERVICE KEY INTERFACE,

CHASSIS X41
117
1
2
197
119
120
R99
20- 43

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
T-code 712
CABIN
ICP, INTEGRATED CONTROL PANEL (A16)
F67
20
21
40
40
F68
60
K17
OVER MAST
CABLE
X101:3 +48VDC POWER

X101:2 GND. POWER
INP. HORN, RIGHT HAND SECTION X103:9
X101:1 OUT. (NPN) SET KEY RELAY
AUX. EQUIP. CABIN
INP. HORN, LEFT HAND SECTION X100:7
102
S18
105
102
S62
40
24
101
143
F71
23
+15VDC X103:4
X101:6 INP. +48V KEY IN
S21
GND X103:5
91
U1
92
93
E1
94
E2
95
U2
96
97
98
128
129
R2
130
131
S72
132
133
134
S70
S44
135
INP. RIGHT DEADM. HANDLE X103:6

X100:13 +15VDC SUPPLY
+15VDC X100:4
X100:14 INP. STEER SENSOR 1 PULSE A
GND X100:5
X100:15 INP. STEER SENSOR 1 PULSE B
INP. LEFT DEADM. HANDLE X100:6

X100:16 GND. STEER SENSOR 1
DRIVE POT SUPPLY +5VDC X103:12

INP. SPEED REF. VALUE X103:11

DRIVE POT GND X103:10
+48VDC X103:13
INP. BRAKE N.O. X103:14

INP. BRAKE N.C. X103:15
X100:11 INP. BUTTERFLY L. (FORK LIFT/TRAV./AUTOROT.)

X100:10 GND. BUTTERFLY LEFT
ROTATION COUNTER CLOCKWISE X100:1

+48V X100:2

X103:7 INP. FUNCTION SHIFT
ROTATION CLOCKWISE X100:3
CAN 1L X101:5
X103:3 INP. CABIN UP
X108
109
108
S100
111
113
112
122
123
R1
124
125
126
158
S48
127
S80
200
74
S74
120
119
X103:1 INP. CABIN DOWN
X105
S101
107
184
40-P CONNECTOR
X109

CABIN X45
184
1
X110
119
CAN 1
120
40
119
120
OVER MAST
CABLE
R109
Y10
Y11
U9
Y9
S93
Y8
U13
Y25
R9
S50
S83
138
K19
Y27
S84
Y28
S87
140
S88
Y16
Y17
B7
R8
20- 44
Service Manual
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
OPTIONS CONNECTED TO CHASSIS

MCU, MAIN CONTROL UNIT (A5)
28
40
37
X131:7 OUT. (NPN) MAIN CONTACTOR/CHASSIS RELAY
38
OUT. (NPN) DRIVE DIR INDICATOR LEFT X131:12

X131:15 INP. MAIN CONTACTOR/CAP. CHARGE
36
40
LOAD ANTENNA
W1
OUT. (NPN) DRIVE DIR INDICATOR RIGHT X131:39
150
H25
H15
H26
H16
F64
X131:1 INP. +48VDC POWER MCU
H3
X131:14 INP. GND POWER MCU

OUT. (NPN) TRAVEL ALARM X131:11
28
X131:6 INP. CHASSIS POWER RELAY STATUS

OUT. (PWM) SUPPORT ARM BRAKE X131:13
BLACK
J1:1
149
155
Y5
157
X132:23 INP. RIGHT COIL
17
Y6
BROWN
J1:2
X132:14 INP. NEAR WIRE COIL
29
RED
X132:4 INP. LEFT COIL
J1:3
INP. INDIVIDUAL AISLE ID 1 X130:41
ORANGE
X132:24 OUT. LO
J1:5
GREEN
S173
164
X132:6 OUT. L1
J1:7
PPS, ELECTRONIC CARD (A26)
YELLOW
J1:6
S172
163
X9:1 INP +48VDC POWER

165
S174
X9:2 INP GND
X132:25 OUT. L2
BLUE
X132:16 OUT. L3
J1:8
INP. AISLE END STOP 1 X130:11
VIOLET
J1:14
X132:5 GND
GREY
J1:15
INP. AISLE END STOP 2 X130:16
X1:3 OUT EMERG. RELAY AL1
S110
X1:4 INP EMERG. RELAY AL2
X132:26 OUT. + 12VDC
X132:15 SHIELD
J1:13
202
X1:1 INP EMERG. RELAY AL1
S54
90
INP. PERSONAL PROTECTION 1 X131:3
188
X1:5 OUT EMERG. RELAY AL2
189
X1:6 INP WARNING RELAY
TRACTOR ANTENNA
W2
INP. SPEED REDUCTION X131:31

BLACK
J1:1
X132:29 INP. RIGHT COIL
OUT DRIVE FORWARD X131:10
190
X1:7 OUT WARNING RELAY
191
X2:4 INP DRIVE FORWARD

R20
BROWN
J1:2
X2:3 INP +48VDC
X132:19 INP. NEAR WIRE COIL

RED
J1:3
192
X132:10 INP. LEFT COIL
OUT DRIVE BACKWARD X131:24
X2:6 INP DRIVE BACKWARDS

R21
ORANGE
X2:5 INP +48VDC
X132:27 OUT. TO
J1:5
193
YELLOW
J1:6
X132:9 OUT. T1
GREEN
J1:7
X2:12 INP IN AISLE

R22
X2:10 INP +48VDC
X132:28 OUT. T2
194
BLUE
X132:18 OUT. T3
J1:8
OUT IN AISLE X131:38
OUT. OVERRIDE PPS X131:22
X1:15 INP PPS OVERIDE SIGNAL

R23
VIOLET
J1:14
J1:15
X1:14 INP +48VDC
X132:17 GND
GREY
J1:13
X132:7 OUT. + 12VDC

21
X132:8 SHIELD
40
OVER MAST
CABLE
60
23
CAN 1L X131:42
CAN 1H X131:27
BT Europe AB
Service Manual

X101:2 GND. POWER
INP. WIRE GUIDANCE REQUEST X100:9
105
116
S120
119
120
119
X101:3 +48VDC POWER
CAN 1
120
X101:5 CAN 1L
20- 45

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
OPTIONS CONNECTED IN THE CABIN

20
F67
21
OVER MAST
CABLE
40
40
F68
60
K17
X101:3 +48VDC POWER
M15
FAN POWER (PWM) X107:1
X101:2 GND. POWER

FAN GND X107:2
THIN CLIENT (A17)
RS 232
9-P DSUB CONNECTOR X106

23
F69
X111 9-P DSUB CONNECTOR
F71
XPS (A25)
USB MASTER
AUX. EQUIP. CABIN

18
40
F70
S99
E3
8-P MODULAR PLUG X147

X141:1 +48V IN
X112 8-P MODULAR PLUG

214
214
215
215
X113:1 +13,2VDC POWER SUPPLY
+13,2VDC OUT X140:1

X141:3 GND IN
GND OUT X140:3
E4
X113:3 GND
SCREEN X140
X113 SCREEN
E5
E6
E7
STEREO/CD (A14)
E8
DC/DC CONVERTER, CABIN (A11)

A:4 +12V KEY
312
F72
OUT. +12V +
160
+ +48V IN
40
A:7 +12V IN
340
OUT. GND (GALV. SEPARATED) -
A:8 IN -
- INP. GND
H4
B:5 OUT LEFT (+)
B:6 OUT LEFT (-)
H5
B:3 OUT RIGHT (+)
W5
B:4 OUT RIGHT (-)

F73
198
+ +48V IN
40
OUT. +12V +
- INP. GND

F74
198
+ +48V IN
40
OUT. +24V +
- INP. GND
20- 46
Service Manual
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
T-code 713
CABIN
F67
20
21
40
40
F68
60
K17
OVER MAST
CABLE
X101:3 +48VDC POWER

X101:2 GND. POWER
INP. HORN, RIGHT HAND SECTION X103:9
AUX. EQUIP. CABIN

INP. HORN, LEFT HAND SECTION X100:7
24
102
S18
105
102
S62
40
101
143
F71
23
+15VDC X103:4
S21
GND X103:5
91
U1
92
E1
93
E2
94
95
U2
96
97
98
128
129
R2
130
131
S72
132
133
134
S70
S44
135
INP. RIGHT DEADM. HANDLE X103:6

+15VDC X100:4
GND X100:5
INP. LEFT DEADM. HANDLE X100:6

DRIVE POT SUPPLY +5VDC X103:12
INP. SPEED REF. VALUE X103:11
DRIVE POT GND X103:10
+48VDC X103:13
INP. BRAKE N.O. X103:14

X100:11 INP. BUTTERFLY L. (FORK LIFT/TRAV./AUTOROT.)
X100:10 GND. BUTTERFLY LEFT
INP. BRAKE N.C. X103:15
ROTATION COUNTER CLOCKWISE X100:1
+48V X100:2
X103:7 INP. FUNCTION SHIFT
ROTATION CLOCKWISE X100:3
CAN 1L X101:5
X103:3 INP. CABIN UP
X108
109
108
S100
111
113
112
122
123
R1
124
125
126
158
S48
127
S80
200
74
S74
120
119
X103:1 INP. CABIN DOWN
X105
S101
107
184
40-P CONNECTOR
X109

CABIN X45
184
1
X110
119
CAN 1
120
40
119
120
OVER MAST
CABLE
R109
Y10
Y11
U9
Y9
Y8
S93
U13
Y25
S50
S83
138
S87
S84
140
S88
Y16
Y17
B7
BT Europe AB
Service Manual
20- 47

List of symbols and electric circuit diagrams
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
20.9 List of symbols and electric circuit

diagrams
20.9.1 List of symbols
Symbol
Description
Symbol
Description
Battery
Contact
Brake coil,
normally released
Brake coil,
normally applied
Push-button switch,
normally open
Non-locking switch,
normally closed
Push-button switch,
two contacts,
one closed, one open
Push-button switch,
two contacts,
normally open
Magnet-sensing switch,
normally closed
Emergency stop switch
Pressure sensor, analogue
Photocell
Inductive sensor, normally

open
Capacitive switch,
normally open
Pulse transducer
Temperature sensor
Motor,
general
20- 48
Series motor,
Direct Current (DC)
Service Manual
BT Europe AB

Order number
227761-040
Symbol
Date
2005-11-28

919699-
Description
Symbol
T-code
712, 713
Description
Three-phase motor,
Alternating Current (AC)
Shunt winding
AC/DC converter
DC/DC converter
Variable resistor
(potentiometer)
Fixed resistor
Relay/contactor,
single contact
Relay/contactor,
two contacts
Lamp
Fluorescent tube
Horn
Buzzer
Valve
BT Europe AB
Loudspeaker
Radio antenna
Fuse
Measurement cable
Service Manual
20- 49
X1
G1
-
SHUNT WIRE
X1
40
Sh. 2
48V
ELECTRONIC CARD, MAIN CONTROL UNIT

A5
MEASURING WIRES
X19
X19
Sh. 7
24
X42 X29 X10
S22
25
S23
X10
26
70
26
MAIN CONTACTOR
K10
A1
A2
37
BATT. INDI. CURRENT -(+)
X130:19 INP.
BATT. INDI - / CURRENT -
X130:5
INP. BATTERY INDICATION +
X131:5
INP. ESO IN
X131:7
OUT. (NPN) MAIN CONTACTOR/CHASSIS RELAY
CHASSIS FUSE PANEL

F62
38
X131:15 INP.
MAIN CONTACTOR/CAP. CHARGE
5A
Sh. 2
8
CHASSIS FUSE PANEL
F61
36
X131:1
INP. +48VDC POWER MCU
5A
Sh. 2
X20
CHASSIS POWER RELAY

K18
2
10
26
40
X131:14INP.
GND POWER MCU
CHASSIS FUSE PANEL

F60
27
10A
3
28
28
X131:6
INP. CHASSIS POWER RELAY STATUS
BT Europe AB
1/30 181726
Prod K
F
1
F
8
Order number
227761-040
Sh. 2
Date
2005-11-28

919699-
EMERG. SWITCH OFFEMERG. SWITCH OFF

CHASSIS, LEFT
CHASSIS, RIGHT
71
X130:32 INP.
20.9.2 Electrical wiring diagrams (T-code 712)
Service Manual
X19
72
Sh. 8
T-code
712, 713
20- 50
1

A1
A
Sh. 1 3
Sh. 1 3
F1
125A
+
U
40
DRIVE MOTOR LEFT

M1
U
B-
1
2
35
B1
W
32
V
W
3~A
220
GND, SENSOR
33
34
118
GND, CAN
13
CAN 2H
10
118
219
26
+48VDC ESO
CAN 2L
220
11
X130:22CAN
2H
120~E
X130:8
CAN 2L
28
28
203
204
203
204
LIFT HEIGHT LIMIT SPECIAL
X131:19 INP.
PRODUCTION MODE 1
PRODUCTION MODE 2 /
X131:33 INP.
S32
2/30 181726
Prod K
20- 51
F
8
PRODUCTION MODE INTERFACE

X27
Sh. 1 6
X130:20GND
T-code
712, 713
Sh. 3
R100
Sh. 1 3
Sh. 3

A5
|R
+12VDC

919699-
Service Manual
219
31
3
SPEED MEASURING IN M1
U11
B
Sh. 3
Date
2005-11-28
THERMO ELECTRICAL SENSOR IN M1
Order number
227761-040
BT Europe AB
8
A
A
Sh. 2 4
Sh. 2 4
F2
125A
+
U
40
DRIVE MOTOR RIGHT

M2
U
B-

1
2
45
V
W
INVERTER ID
3~A
B
42
41
U14
Sh. 2 4
43
44
|R
26
GND SENSOR
+12VDC
GND, CAN
13
CAN 2 H
10
CAN 2 L
11
118
Sh. 2 4
+48VDC ESO
219
220
Sh. 2 4
Sh. 2 4
Date
2005-11-28
BT Europe AB
3/30 181726
Prod K
Order number
227761-040
2
B

919699-
Service Manual
B2

A31
T-code
712, 713
20- 52
A
A2
Sh. 3 5
F3
325A
+
U
40
PUMP MOTOR
M3
B-
1
2
3~A
11
B3
52
GND, SENSOR
+12VDC
C
51
53
54
|R
5
13
CAN 2H
10
CAN 2L
11
D
Sh. 3 5
26
118
Sh. 3
+48VDC ESO
219
220
Sh. 3 5
Sh. 3 5
4/30 181726
Prod K
20- 53
GND, CAN
6
T-code
712, 713
U12

919699-
Service Manual

55
V
W
10
INVERTER ID
Date
2005-11-28
Sh. 3 5
Order number
227761-040
BT Europe AB
A
TRANSITOR REGULATOR, FORK LIFT
A32
Sh. 4
F4
12
B+
48VDC PWR. SUPPLY
125A
Sh. 4 7
R91
40
40
B-
CAN 2H.
J2:1
219
219
220
220
Sh. 4
120~E
GND POWER
CAN 2L
J2:8
Sh. 4
B
C1
0,1~NF
C2
0,1~NF
13
OUT. INITIAL FORK MOTOR
SHUNT FIELD IN M4
E1
INP. +48VDC ESO
J2:16
26
26
Sh. 4
C
A5
117
117
197
197
119
119
120
120
X130:23 +15VDC
CAN SUPPLY
X130:33 GND
X131:27 CAN
1H
X131:42 CAN
1L
Date
2005-11-28
R99
Sh. 8
Sh. 8
X42
119
X29
X21
X14
120~E
X42
120
X29
X22
X13
BT Europe AB
5/30 181726
Prod K
F
1
Order number
227761-040
SERVICE KEY INTERFACE CHASSIS

X41

919699-
Service Manual
INITIAL FORK MOTOR

A2/E2
D1
M4
T-code
712, 713
20- 54

A5
Y7
Sh. 2 7
28
46
X131:35OUT.
(NPN) STEER PRESSURE VALVE
X131:26OUT.
(PWM) STEER PROP. VALVE LEFT
X131:40OUT.
(PWM) STEER PROP. VALVE RIGHT
X131:37OUT.
(NPN) STEER LOCK VALVE
Y4
1
47
Order number
227761-040
BT Europe AB
Y3
48
152
49
B4
P
X130:31INP.
STEER ACCUMULATOR PRESSURE
Sh. 13
30
30
16
16
ELECTRONIC CARD, INTEGRATED CONTROL PANEL

A16
X130:29GND, ANALOGUE
C
Sh. 13
X130:1
91
PIVOT POT. +5VDC SUPPLY
X16
X15
50
X130:4
INP. PIVOT ANGLE
X14
56
X130:15PIVOT
GND
92
93
|R
94
STEER SENSOR 1 PULSE A
X100:15 INP.
STEER SENSOR 1 PULSE B
X100:16 GND,
X100:17+15V
STEER SENSOR 1
DC SUPPLY
U2
1
96
97
|R
98
X100:18 INP.
X100:19 INP.
X100:20 GND,
STEER SENSOR 2
20- 55
6/30 181726
Prod K
95
X100:14 INP.
VDC SUPPLY
T-code
712, 713
R7
X100:13+15
U1

919699-
Service Manual
Y31
1
2
Date
2005-11-28
A
Sh. 6 9
X10
28
H2
X10
57
X131:21 OUT.
(NPN) WARNING LAMP
X131:25 OUT.
(NPN) HORN
X131:41 OUT.
(PWM) FAN
H1
Sh. 5
+
-
X20
40
58
IN
FAN, ELECTRIC PANEL
M12
2
1
M
59
FAN, PUMPMOTOR M3
M10
2
1
M
X15
X23
LEFT
S81
X10
RIGHT
S82
3
136
X23
X13
137
X131:30 INP.
SLACK CHAIN GUARD BOTTOM

A16
S18
102
X103:17+48V
DC SUPPLY
X103:9
INP. HORN, RIGHT HAND SECTION
X100:8
+48VDC SUPPLY
X100:7
INP. HORN, LEFT HAND SECTION
D
Sh. 16
105
105
Sh. 8
S62
106
184
184
X102:12+15VDC
Date
2005-11-28
SUPPLY
CABIN LIGHT, LEFT
E
Sh. 1 8
24
X56
X43
X46
E1
X68
X46
X29
X21
X15
CABIN LIGHT, RIGHT

E2
X20
E
40
Sh. 8
BT Europe AB
7/30 181726
Prod K
F
1
F
8
Order number
227761-040
101

919699-
Service Manual
FAN, CAP
M16
2
1
M
X10

A5
T-code
712, 713
20- 56
Sh. 18
Sh. 7 9
40
F63

A16
CABIN FUSE PANEL
CHASSIS FUSE PANEL

Sh. 1 9
20
X16 X21 X29
20
F67
X43
X56
21
X101:3
+48VDC POWER
X101:2
GND POWER
X101:1
OUT. (NPN) SET KEY RELAY
Order number
227761-040
BT Europe AB
5A
20A
X20 X15 X21 X29 X68
X43
CABIN FUSE PANEL
22
X43
X56
40
60
7,5A
B
9
Date
2005-11-28
F68
KEY RELAY CABIN

K17
2
10
X56
X43
Sh. 7 11
119
120
184
X56
X44
X56
X43
X56
X44
X101:4
CAN 1H
X101:5
CAN 1L
SERVICE KEY INTERFACE CABIN

X45
184
40
119
120
AUXILIARY EQUIPMENT CABIN

CABIN FUSE PANEL
F71
8/30 181726
Prod K
20- 57
Sh. 7
INP. +48V KEY IN
X56
120
X101:6
X56
X56
119
23
Sh. 5 11
24
X56
T-code
712, 713
Sh. 5 11
EMERGENCY SWITCH OFF

CABIN
X65
S21
X65
2
1

919699-
Service Manual

A16
X66
S101
X66
Bk
Bu
Bn
107
108
X66
109
X64
B
S100
X64
Bu
Bk
112
X64
113
122
X103:6
INP. RIGHT DEAD MAN'S HANDLE
X103:5
GND
X100:4
+15VDC
X100:6
INP. LEFT DEAD MAN'S HANDLE
X100:5
GND
X103:12 DRIVE
POT SUPPLY +5VDC
+15VDC
123
X103:11 INP.
SPEED REFERENCE VALUE
124
Sh. 7 10
PARKING BRAKE, M1
Y1
1
2
28
125
X103:13+48VDC
40
X20
S131
126
127
S132
61
EMERG. BRAKE RELEASE 3
159
S133
X103:15 INP.
BRAKE N.C.
PARKING BRAKE, M2
Y2
1
2
62
5A
X131:20OUT.
(NPN) PARKING BRAKE M1
X131:34OUT.
BT Europe AB
9/30 181726
Prod K
F
1
F
8
Order number
227761-040
F75
BRAKE N.O.

A5
X103:14 INP.
Sh. 8 10
POT GND
S48
Sh. 8 10
X103:10 DRIVE
Date
2005-11-28
R1

919699-
Service Manual
Bn
111
X103:4
T-code
712, 713
20- 58

A5
A
Sh. 21
29
29
X15
X23
U10
3
Sh. 9 11
Sh. 9 13
40
X20
X15
X15
28
X23
X23
X14
99
|R
X23
X14
100
X130:37+15VDC
SUPPLY
X130:12INP.
CABIN HEIGHT PULSE A
X130:26INP.
CABIN HEIGHT PULSE B
X23
S71
X23
X14
66
X130:27INP.
CABIN < REFERENCE HEIGHT
C
Sh. 11
X48
X59
U9
X47
80
X59
X59
X48
C
63
X48
64
X58
S93
X58
X47
104
INP. HEIGHT COUNTER INITIAL LIFT PULSE A
011
INP. HEIGHT COUNTER INITIAL LIFT PULSE B
013
INP. FORKS < REFERENCE HEIGHT
Sh. 9 23
CHASSIS FUSE PANEL

F66
40
142
10A
10/30 181726
Prod K
20- 59
AUXILIARY EQUIPMENT CHASSIS

X18
|R
X59
2
B
012
T-code
712, 713
Sh. 11
15

919699-
Service Manual
ELECTRONIC CARD, FORK CONTROL UNIT

A4
Date
2005-11-28
Order number
227761-040
BT Europe AB

A4
A
Sh. 8 27
Sh. 10 12
Sh. 10 12
24
X56
X43
24
X20
40
X15
X21
X29
X68
40
80
80
B
Sh. 8
Sh. 10
X44
120
X56
X56
INP. +48VDC ESO CABIN
029
GND
015
GND
027
CAN 1H
042
CAN 1L
028
OUT. + 15VDC SUPPLY
X43
119
R109
X43
120
15
15
120~E
C
X60
U13
1
X53
LEFT
S83
X51
X60
X48
X61
X47
X61
|R
LEFT
S87
67
X60
X48
68
S50
Br
Bk
RIGHT
S84
3
138
X48
X61
X47
103
009
INP. TRAVERSE COUNTER PULSE A
008
INP. TRAVERSE COUNTER PULSE B
010
INP. TURRET UNIT IN END POSITION
040
INP. SLACK CHAIN GUARD CABIN
026
INP. GATES CLOSED
Bu
X47
X60
3
A
X53
2
X51
140
X52
RIGHT
S88
1
4
X52
139
141
Date
2005-11-28
BT Europe AB
11/30 181726
Prod K
F
1
Order number
227761-040
X48

919699-
Service Manual
Sh. 8
X43
119
001
T-code
712, 713
20- 60

A4
Sh. 11 14
40
X20 X15 X21 X29 X68
Y10
1
2
X50
X49
Y11
1
2
X50
X49
X49
Y8
X50
X49
X50
83
84
195
005
OUT. (PNP) FORK LIFT
017
OUT. (PNP) TRAVERSE LEFT
004
OUT. (PNP) TRAVERSE RIGHT
016
OUT. (PWM) PROP. VALVE, TRAVERSE
006
OUT. (PNP) SET RELAY
035
INP. CCW VALVE CHECK
003
OUT. (PWM) PROP. VALVE, ROTATE
021
INP. CW VALVE CHECK
014
INP. LIFT PRESSURE
002
OUT. + 5VDC SUPPLY
007
INP. FORK ROTATION ANGLE
85
11
12
1 K~E / 5W
K19
A2
A1
14
12/5D
R9
X49
X49
X49
B7
B
X49
87
69
39
X62
X48
X62
Sh. 11
80
65
X62
X48
1
R8
X47
X49
196
11
12/30 181726
Prod K
20- 61
X49
14
12
86
CLOCKWISE
Y28
1
2
86
COUNTER CLOCKWISE
Y27
X50
1
2
T-code
712, 713
OUT. (PWM) PROP. VALVE FORK LOWER

919699-
Service Manual
Y25
1
2
X49
82
031
Date
2005-11-28
Y9
X50
81
Order number
227761-040
BT Europe AB

A16
A
X100:12+5VDC
SUPPLY
128
129
X100:11INP.
BUTTERFLY L. (FORK LIFT/TRAV./AUTOROT.)
R2
130
131
+48VDC SUPPLY
X100:2
ROTATION COUNTER CLOCKWISE
X100:1
ROTATION CLOCKWISE
Sh. 10 14
X64
158
X64
74
132
Pk
Pk
Wh
S80
S70
Gy
S74
Gy
S44
X66
X66
133
134
135
+48VDC SUPPLY
X103:7
INP. FUNCTION SHIFT
X103:2
+48VDC SUPPLY
X103:1
INP. CABIN DOWN
X103:3
INP. CABIN UP

A5
CABIN LOWER VALVE 1

Y21
1
2
28
Wh
X66
X103:8
73
X131:8
OUT. (NPN) CABIN LOWER VALVE 1 & 2
X130:3
INP. PUMP PRESSURE REFERENCE VALUE
CABIN LOWER VALVE 2

Y29
1
2
Date
2005-11-28
B5
B
16
75
Sh. 6
30
X16
B6
B
X14
E
76
X130:17INP.
LIFT SYSTEM PRESSURE
Sh. 6
X15
BT Europe AB
13/30 181726
Prod K
F
1
F
8
Order number
227761-040
X100:3
X64
200
S72
BUTTERFLY LEFT

919699-
Service Manual

A16
X100:10GND,
T-code
712, 713
20- 62
8
A

A5
FORWARD DIRECTION 1
X15
28
X24
S5
X24
X14
77
BACKWARD DIRECTION 1
X11
X28
S6
X28
X130:10INP.
IN AISLE SIGNAL 1
X11
BACKWARD DIR., RIGHT

S156
3
1
X20
X11
X15
40
FORWARD DIRECTION 2
X24
S7
X24
X14
78
X11
X28
S8
X28
X130:24INP.
IN AISLE SIGNAL 2
X11
FORWARD DIR., LEFT

S178
3
1
2
X24
FORWARD DIRECTION 1
S9
X24
X14
79
X11
X28
S4
X28
X130:38INP. AISLE
END BRAKE 1
X11
FORWARD DIRECTION 2
X24
S123
X24
X14
201
X11
X28
S124
X28
X130:2
INP. AISLE END BRAKE 2
X11
14/30 181726
Prod K
20- 63
X15
T-code
712, 713
X15

919699-
Service Manual
Sh. 12 18
Date
2005-11-28
Sh. 13 18
Order number
227761-040
BT Europe AB
Date
2005-11-28
Order number
227761-040
BT Europe AB

919699-
Service Manual
15/30 181726
Prod K
STANDARD DISPLAY
T-code
712, 713
20- 64
X108
7
6
5
4
3
2
1
X105
40-P CONNECTOR
40
30
30-P CONNECTOR
40-P CONNECTOR
X109
X110
30-P CONNECTOR
B
A16
KEYPAD
A22
DISPLAY
A6
8
7
6
5
4
3
2
1
OPTION
WIRE GUIDANCE
LOAD ANTENNA
W1

A5
BLACK
J1L:1
X132:14
INP. NEAR WIRE COIL
X132:4
INP. LEFT COIL
X132:24
OUT. L0
X132:6
OUT. L1
X132:25
OUT. L2
X132:16
OUT. L3
B
RED
J1L:3
Service Manual
ORANGE
J1L:5
YELLOW
J1L:6
GREEN
J1L:7
BLUE
GREY
J1L:15
X132:5
GND
X132:26OUT.
+ 12VDC

A16
Sh. 7
105
S120
116
X100:9
INP. WIRE GUIDANCE REQUEST
16/30 181726
Prod K
20- 65
X132:15SHIELD
J1L:13
VIOLET
J1L:14
T-code
712, 713
J1L:8

919699-
INP. RIGHT COIL
Date
2005-11-28
BROWN
J1L:2
X132:23
Order number
227761-040
BT Europe AB
OPTION
WIRE GUIDANCE
TRACTOR ANTENNA
W2

A5
BLACK
J1T:1
BROWN
J1T:2
X132:29INP.
RIGHT COIL
X132:19INP.
NEAR WIRE COIL
X132:10INP.
LEFT COIL
B
RED
J1T:3
YELLOW
J1T:6
X132:9
GREEN
J1T:7
VIOLET
J1T:14
OUT. T1
X132:28OUT.
T2
X132:18OUT.
T3
X132:17GND
GREY
J1T:15
T0
J1T:13
X132:7
OUT. + 12VDC
X132:8
SHIELD
Date
2005-11-28
BT Europe AB
17/30 181726
Prod K
F
1
F
8
Order number
227761-040
BLUE
J1T:8
X132:27OUT.

919699-
Service Manual
ORANGE
J1T:5
T-code
712, 713
20- 66
OPTIONS
28
X15

A5
LEFT ARM
Y5
1
2
X24
X24
X13
157
RIGHT ARM
Y6
1
2
X21
X29
F70
ROOF, LEFT
S99
144
8
10A
145
E3
ROOF, RIGHT
146
E4
9
7
CABIN SIDE, LEFT UPPER

1
E5
2
CABIN SIDE, LEFT LOWER
E6
CABIN SIDE, RIGHT UPPER
E7
WORKING LIGHT
D
Sh. 14 19
40
X20
X15
X21
X29
E8
X68
18/30 181726
Prod K
F
20- 67
CABIN SIDE, RIGHT LOWER
T-code
712, 713
147
3
(PWM) SUPPORT ARM BRAKE

919699-
Service Manual
20
X16
X131:13OUT.
SUPPORT ARM BRAKE
CABIN FUSE PANEL

Sh. 8 19
Date
2005-11-28
Sh. 14 21
Order number
227761-040
BT Europe AB
OPTION
THIN CLIENT TOUCH SCREEN DISPLAY
THIN CLIENT
A17

A16
RS232
9-P DSUB CONNECTOR
9
X111
9-P DSUB CONNECTOR
X107:1
OUT. (PWM) FAN POWER
X107:2
FAN GND
M15
XPS
A25
USB MASTER
C
8-P MODULAR PLUG
X112
GND X113:3
SCREEN
214
214
215
215
X113
X147
8-P MODULAR PLUG
X140:1
+13,2VDC OUT
X140:3
GND OUT
X140
SCREEN
X141:1
+48V IN
X141:3
+GND IN
Date
2005-11-28
CABIN FUSE PANEL

Sh. 18 20
Sh. 18 20
20
X16
X21
X29
F69
X43
X56
18
5A
40
X20
X15
X21
X29
X68
X43
X56
40
BT Europe AB
19/30 181726
Prod K
F
1
F
8
Order number
227761-040
+13,2 VDC POWER SUPPLY X113:1

919699-
Service Manual
X106
T-code
712, 713
20- 68
OPTION
Sh. 19 22
X29
F72
160
40
X20
X15
X21
X29
X68
40
+48V IN
INP. GND
340
OUT. GND (GALV. SEPARATED)
312
OUT. +12V
STEREO/CD
A14
312
+12V KEY
A:8
IN -
B:5
OUT. LEFT (+)
B:6
OUT. LEFT (-)
B:3
OUT. RIGHT (+)
B:4
OUT. RIGHT (-)
H4
LEFT +
D
LEFT -
H5
RIGHT +
RIGHT -
E
W5
20/30 181726
Prod K
20- 69
F
8
A:4
+12V IN
T-code
712, 713
340
A:7

919699-
Service Manual
7,5A
Date
2005-11-28
Sh. 19 21
20
X21
DC/DC CONVERTER, CABIN

A11
STEREO/CD
CABIN FUSE PANEL

X16
Order number
227761-040
BT Europe AB
Sh. 18 25
X15
28
X15
Sh. 20 22
40
X15
X25
X20
X15
X23
FRONT
H26
2
1
162
X23
S172
X25
X25
X13
X13
X13
149
X131:23OUT.
(NPN) DRIVE DIR. INDICATOR LEFT
DRIVE DIRECTION INDICATORS

150
163
X131:9
OUT. (NPN) DRIVE DIR. INDICATOR RIGHT
X130:41INP.
INDIVIDUAL AISLE ID. 1
29
161
REAR
H16
1
2
X23

A5
FRONT
H25
2
1
S173
1
X12
164
X131:2
INP. INDIVIDUAL AISLE ID. 2
INDIVIDUAL AISLE ID. INPUTS,

SEE PARAMETER SETTINGS
X25
S174
1
X25
X12
165
S54
1
X14
90
X130:11INP. AISLE
END STOP 1
X25
AISLE END STOP
S110
X25
202
X130:16INP. AISLE
END STOP 2
X12
Date
2005-11-28
H3
X17
X17
155
X131:11OUT.
(NPN) TRAVEL ALARM
TRAVEL ALARM
BT Europe AB
21/30 181726
Prod K
F
F
1
Order number
227761-040
X131:16INP.

919699-
Service Manual
Sh. 10 25
X23
REAR
H15
2
1
OPTIONS
T-code
712, 713
20- 70
OPTION
12V AND/OR 24V (150W) POWER IN CABIN

A12
CABIN FUSE PANEL

Sh. 20 28
X21
X29
F73
198
40
X20
X15
X21
X29
X68
40
INP. +48VDC
INP. GND
OUT. +12VDC
OUT. +12VDC
199
INP. +48VDC
40
INP. GND
OUT. +24VDC
E
4
OUT. +24VDC
22/30 181726
Prod K
20- 71
F
8
7,5A
F74
T-code
712, 713

A13
CABIN FUSE PANEL

919699-
Service Manual
7,5A
Date
2005-11-28
Sh. 21 23
20
X16
Order number
227761-040
BT Europe AB
CHASSIS FUSE PANEL
OPTION
F64
PPS, PERSONAL PROTECTION SYSTEM
17
X9:2
INP. GND
X1:1
INP. EMERGENCY RELAY AL1
X1:3
OUT. EMERGENCY RELAY AL1
X1:4
X1:5
X1:6
INP. WARNING RELAY
X1:7
OUT. WARNING RELAY
X2:4
INP. DRIVE FORWARD (FORK DIRECTION)
X2:3
INP. +48VDC
X2:6
INP. DRIVE BACKWARDS
X2:5
INP. +48VDC
X2:12
INP. IN AISLE
X2:10
INP. +48VDC
X20
188
189
C
INP. SPEED REDUCTION PPS X131:31
OUT. (NPN) DRIVE FORWARD (FORK DIRECTION) X131:10
190
191
R20
820~E/5W
D
OUT. (NPN) DRIVE, BACKWARDS X131:24
192
R21
OUT. (NPN) IN AISLE X131:38
820~E/5W
193
R22
Date
2005-11-28
820~E/5W
17
BT Europe AB
23/30 181726
Prod K
F
1
Sh. 24
Order number
227761-040
INP. +48VDC POWER

919699-
Service Manual
X9:1
7,5A
40
PPS ELECTRONIC CARD

A26

A5
Sh. 22 25
A
Sh. 10 26
T-code
712, 713
20- 72
OPTION
OUT. (NPN) OVERRIDE PPSX131:22
194
R23
INP. PPS OVERRIDE SIGNAL
X1:14
INP. +48VDC
17
20- 73
T-code
712, 713

919699-
Service Manual
Sh. 23
X1:15
820~E/5W
Date
2005-11-28
PPS ELECTRONIC CARD

A26

A5
Order number
227761-040
BT Europe AB
OPTION

A5
Sh. 21 30
S12
28
205
S13
S14
X15
X26
207
Y55
X26
X13
C
Sh. 21
X15
29
S69
X26
X26
X13
151
154
INP. SPEED REDUCTION 1
X131:18INP.
SPEED REDUCTION 2
X131:32INP.
SPEED REDUCTION 3
X131:36OUT.
X130:40INP.
(NPN) PIVOT LOCK, LOCKING VALVE
PIVOT LOCK, LOCKED POSITION
S68
Sh. 23 26
40
X20
X15
X26
X13
153
X130:13INP.
PIVOT LOCK, RELEASED POSITION
X26
Date
2005-11-28
BT Europe AB
25/30 181726
Prod K
F
1
F
8
Order number
227761-040
PIVOT LOCKING DEVICE (IN AISLE)

919699-
Service Manual
206
X131:4
T-code
712, 713
20- 74
8
A
CAMERA(S) WITH STD DISPLAY
110
115
114
INP. GND
40
115
INP. +48VDC
19
156
VIDEO SIGNAL 1
INP. +12VDC SUPPLY
INP. GND
SHIELD VIDEOSIGNAL 1
Sh. 23
Sh. 25 27
CAMERA, FRONT
A52
F65
5A
210
X20
40
114
115
X30
X31
X31
X31
X31
X54
X54
X54
X54
X57
X57
X57
X57
INP. GND

A16
110
156
210
INP. +12VDC SUPPLY
256
X104:4
VIDEO SIGNAL 1
X104:3
SHIELD, VIDEOSIGNAL 1
X104:2
VIDEOSIGNAL 2
X104:1
20- 75
26/30 181726
Prod K
X30
X30
VIDEO SIGNAL 2
T-code
712, 713
256
X30

919699-
Service Manual
CHASSIS FUSE PANEL
Date
2005-11-28
114
OUT. GND (GALVANICALLY ISOLATED)
7
CAMERA, REAR
A51
OUT. +12VDC
OPTION
VOLTAGE CONVERTER
A10
Order number
227761-040
BT Europe AB
Sh. 26 28
40
X20
X15
X21
X29
X68
Y16
1
2
X50
X50
Y17
1
2
X50
X50
8
A

A4
88
018
OUT. (PNP) SPARE 1A
019
OUT. (PNP) SPARE 1B
1 ADDITIONAL HYDR. FUNCTION

89
B
ELECTRONIC CARD, INTEGRATED CONTROL UNIT
A16
24
X56
X43
X48
X70
Y19
1
2
X70
Y18
1
2
X70
X47
X47
X44
X44
X55
X55
166
167
X101:12OUT.
(NPN) AUX. VALVE 1B
X101:11OUT.
(NPN) AUX VALVE 1A
Date
2005-11-28
BT Europe AB
27/30 181726
Prod K
F
1
F
8
Order number
227761-040

919699-
Service Manual
Sh. 11 29
2 ADDITIONAL HYDR. FUNCTIONS
OPTION
T-code
712, 713
20- 76
OPTION
SEAT HEATING (IN COLDSTORE)

A15
AUX EQUIPMENT CABIN PANEL
Sh. 27 29
20
X16
X21
X29
F71
221
40
X20
X15
X21
X29
X68
40
225
INP. +48VDC
INP. GND
222
OUT +24VDC
BACK REST
X63
223
E10
E11
224
4
2
X63
28/30 181726
Prod K
20- 77
S126
8
T-code
712, 713
SEAT
SEAT HEAT SWITCH

919699-
Service Manual
10A
Date
2005-11-28
Sh. 22
Order number
227761-040
BT Europe AB
Date
2005-11-28
C
C
Order number
227761-040

919699-
Service Manual
COMFORT FANS IN CABIN
T-code
712, 713
20- 78
F
29/30 181726
Prod K
BT Europe AB
B
227
7
6
5
4
3
2
1
X69
X46
X68
X29
X21
X15
X20
40
Sh. 28
4
3
M
9
226
24
Sh. 27
RIGHT
M14
FAN POWER SWITCH
LEFT
M13
S96
X69
X46
X43
X56
OPTION
A
8
7
6
5
4
3
2
1
OPTION
COMPETITOR AISLE LAYOUT

A5
FORWARD DIRECTION 1
28
X15
X24
S5
X24
X14
77
FORWARD DIRECTION 3
1
S139
X130:10INP.
IN AISLE SIGNAL 1
Date
2005-11-28
Sh. 25
Order number
227761-040
BT Europe AB
S7
X24
X14
78
FORWARD DIRECTION 4
1
S140
X130:24INP.
IN AISLE SIGNAL 2
S9
X24
X14
79
FORWARD DIRECTION RIGHT 3

1
S137
X130:38INP. AISLE
END BRAKE 1

S123
X24
X14
201

1
S138
X130:2
30/30 181726
Prod K
20- 79
T-code
712, 713

919699-
Service Manual
FORWARD DIRECTION 2
4
X1
G1
-
SHUNT WIRE
X1
40
Sh. 2
48V

A5
MEASURING WIRES
X19
X19
Sh. 7
24
X42 X29 X10
S22
25
S23
X10
26
70
26
MAIN CONTACTOR
K10
A1
A2
37
BATT. INDI. CURRENT -(+)
X130:19INP.
BATT. INDI - / CURRENT -
X130:5
INP. BATTERY INDICATION +
X131:5
INP. ESO IN
X131:7
OUT. (NPN) MAIN CONTACTOR/CHASSIS RELAY
CHASSIS FUSE PANEL

F62
38
X131:15INP.
MAIN CONTACTOR/CAP. CHARGE
5A
Sh. 2
8
CHASSIS FUSE PANEL
F61
36
X131:1
INP. +48VDC POWER MCU
5A
Sh. 2
X20
CHASSIS POWER RELAY

K18
2
10
26
40
X131:14INP.
GND POWER MCU
CHASSIS FUSE PANEL

F60
27
10A
3
E
28
28
X131:6
INP. CHASSIS POWER RELAY STATUS
BT Europe AB
1/29 221874
Prod A
Order number
227761-040
Sh. 2
Date
2005-11-28

919699-
EMERG. SWITCH OFFEMERG. SWITCH OFF

CHASSIS, LEFT
CHASSIS, RIGHT
71
X130:32INP.
20.9.3 Electrical wiring diagrams (T-code 713)
Service Manual
X19
72
Sh. 8
T-code
712, 713
20- 80
1

A1
A
Sh. 1 3
Sh. 1 3
F1
125A
+
U
40
DRIVE MOTOR LEFT

M1
U
B-
1
2
35
B1
W
32
V
W
3~A
220
GND, SENSOR
33
34
118
GND, CAN
13
CAN 2H
10
118
219
26
+48VDC ESO
CAN 2L
220
11
X130:22CAN
2H
120~E
X130:8
CAN 2L
28
28
203
204
203
204
X131:19INP.
PRODUCTION MODE 1
X131:33INP.
PRODUCTION MODE 2 /
S32
2/29 221874
Prod A
20- 81
PRODUCTION MODE INTERFACE

X27
Sh. 1 6
X130:20GND
T-code
712, 713
Sh. 3
R100
Sh. 1 3
Sh. 3

A5
|R
+12VDC

919699-
Service Manual
219
31
3
U11
B
Sh. 3
Date
2005-11-28
Order number
227761-040
BT Europe AB
A
Sh. 2 4
Sh. 2 4
F2
125A
+
U
40
DRIVE MOTOR RIGHT

M2
U
B-

1
2
45
V
W
INVERTER ID
3~A
B
42
41
U14
Sh. 2 4
43
44
|R
26
GND SENSOR
+12VDC
GND, CAN
13
CAN 2 H
10
CAN 2 L
11
118
Sh. 2 4
+48VDC ESO
219
220
Sh. 2 4
Sh. 2 4
Date
2005-11-28
BT Europe AB
3/29 221874
Prod A
F
1
F
8
Order number
227761-040
2
B

919699-
Service Manual
B2

A31
T-code
712, 713
20- 82
A
A2
Sh. 3 5
F3
325A
+
U
40
PUMP MOTOR
M3
B-
1
2
V
W
3~A
11
B3
52
GND, SENSOR
+12VDC
C
51
U12
53
54
|R
5
13
CAN 2H
10
CAN 2L
11
D
Sh. 3 5
26
118
Sh. 3
+48VDC ESO
219
220
Sh. 3 5
Sh. 3 5
4/29 221874
Prod A
20- 83
F
8
GND, CAN
6
T-code
712, 713

919699-
Service Manual

55
10
INVERTER ID
Date
2005-11-28
Sh. 3 5
Order number
227761-040
BT Europe AB
A
TRANSITOR REGULATOR, FORK LIFT
A32
Sh. 4
F4
12
B+
48VDC PWR. SUPPLY
125A
Sh. 4 7
R91
40
40
B-
CAN 2H.
J2:1
219
219
220
220
Sh. 4
120~E
GND POWER
CAN 2L
J2:8
Sh. 4
B
C1
0,1~NF
C2
0,1~NF
13
OUT. INITIAL FORK MOTOR
SHUNT FIELD IN M4
E1
INP. +48VDC ESO
J2:16
26
26
Sh. 4
C
A5
SERVICE KEY INTERFACE CHASSIS

X41
117
117
197
197
119
119
120
120
X130:23+15VDC
CAN SUPPLY
X130:33GND
X131:27CAN
1H
X131:42CAN
1L
Date
2005-11-28
R99
Sh. 8
Sh. 8
X42
119
X29
X21
X14
120~E
X42
120
X29
X22
X13
BT Europe AB
5/29 221874
Prod A
F
1
F
8
Order number
227761-040

919699-
Service Manual
INITIAL FORK MOTOR

A2/E2
D1
M4
T-code
712, 713
20- 84

A5
Y7
Sh. 2 7
28
46
X131:35OUT.
(NPN) STEER PRESSURE VALVE
X131:26OUT.
(PWM) STEER PROP. VALVE LEFT
X131:40OUT.
(PWM) STEER PROP. VALVE RIGHT
X131:37OUT.
(NPN) STEER LOCK VALVE
Order number
227761-040
BT Europe AB
Y4
1
47
Y3
48
152
49
B4
P
X130:31INP.
STEER ACCUMULATOR PRESSURE
Sh. 13
30
30
16
16

A16
X130:29GND, ANALOGUE
C
Sh. 13
X130:1
91
PIVOT POT. +5VDC SUPPLY
X16
X100:14INP.
X100:15INP.
U1
X15
50
X14
56
X130:4
INP. PIVOT ANGLE
X130:15PIVOT
GND
92
93
|R
94
STEER SENSOR 1
X100:17+15VDC
SUPPLY
U2
1
96
97
|R
98
X100:18INP.
X100:19INP.
X100:20GND,
STEER SENSOR 2
6/29 221874
Prod A
20- 85
F
8
95
X100:16GND,
VDC SUPPLY
T-code
712, 713
X100:13+15

919699-
Service Manual
Y31
1
2
Date
2005-11-28
7
A5
A
Sh. 6 9
X10
28
H2
X10
57
X131:21OUT.
(NPN) WARNING LAMP
X131:25OUT.
(NPN) HORN
X131:41OUT.
(PWM) FAN
H1
Sh. 5
+
-
X20
40
IN
58
FAN, ELECTRIC PANEL
M12
1
2
M
59
FAN, PUMPMOTOR M3
M10
1
2
M
X15
X23
LEFT
S81
X10
RIGHT
S82
3
136
X23
X13
137
X131:30INP.
SLACK CHAIN GUARD BOTTOM

A16
S18
102
X103:17+48VDC
SUPPLY
X103:9
INP. HORN, RIGHT HAND SECTION
X100:8
+48VDC SUPPLY
X100:7
INP. HORN, LEFT HAND SECTION
D
Sh. 16
105
105
Sh. 8
S62
106
184
184
X102:12+15VDC
Date
2005-11-28
SUPPLY
CABIN LIGHT, LEFT
E
Sh. 1 8
24
X56
X43
X46
E1
X68
X46
X29
X21
X15
CABIN LIGHT, RIGHT

E2
X20
E
40
Sh. 8
BT Europe AB
7/29 221874
Prod A
F
1
F
8
Order number
227761-040
101

919699-
Service Manual
FAN, CAP
M16
1
2
M
X10
T-code
712, 713
20- 86
Sh. 18
CHASSIS FUSE PANEL

Sh. 1 9
Sh. 7 9
20
40
F63

A16
CABIN FUSE PANEL

X16 X21 X29
20
F67
X43
X56
21
X101:3
+48VDC POWER
X101:2
GND POWER
X101:1
OUT. (NPN) SET KEY RELAY
Order number
227761-040
BT Europe AB
5A
20A
X20 X15 X21 X29 X68
X43
CABIN FUSE PANEL
22
X43
X56
40
60
7,5A
B
9
Date
2005-11-28
F68
KEY RELAY CABIN

K17
2
10
X56
X43
Sh. 7 11
Sh. 7
119
120
184
X44
X56
X43
X56
X44
X101:4
CAN 1H
X101:5
CAN 1L
SERVICE KEY INTERFACE CABIN

X45
184
40
119
120
AUXILIARY EQUIPMENT CABIN

CABIN FUSE PANEL
F71
8/29 221874
Prod A
20- 87
X56
INP. +48V KEY IN
X56
120
X101:6
X56
X56
119
23
Sh. 5 11
24
X56
T-code
712, 713
Sh. 5 11
EMERGENCY SWITCH OFF

CABIN
X65
S21
X65
2
1

919699-
Service Manual

A16
X66
S101
X66
Bk
Bu
Bn
107
108
X66
109
X64
B
S100
X64
Bu
Bk
112
X64
113
122
X103:6
INP. RIGHT DEAD MAN'S HANDLE
X103:5
GND
X100:4
+15VDC
X100:6
INP. LEFT DEAD MAN'S HANDLE
X100:5
GND
X103:12DRIVE
POT SUPPLY +5VDC
+15VDC
123
SPEED REFERENCE VALUE
X103:11INP.
124
Sh. 7 10
PARKING BRAKE, M1
Y1
1
2
28
125
X103:13+48VDC
40
X20
S131
126
127
S132
61
159
S133
X103:15INP.
BRAKE N.C.
PARKING BRAKE, M2
Y2
1
2
62
5A
X131:20OUT.
X131:34OUT.
BT Europe AB
9/29 221874
Prod A
F
1
F
8
Order number
227761-040
F75
BRAKE N.O.

A5
X103:14INP.
Sh. 8 10
POT GND
S48
Sh. 8 10
X103:10DRIVE
Date
2005-11-28
R1

919699-
Service Manual
Bn
111
X103:4
T-code
712, 713
20- 88

A5
A
Sh. 21
29
29
X15
X23
U10
1
Sh. 9 11
Sh. 9 13
40
X20
X15
X15
28
X23
X23
X14
99
|R
X23
X14
100
X130:37+15VDC
SUPPLY
X130:12INP.
CABIN HEIGHT PULSE A
X130:26INP.
CABIN HEIGHT PULSE B
X23
S71
X23
X14
66
X130:27INP.
CABIN < REFERENCE HEIGHT
C
Sh. 11
80
X48
U9
X76
X47
X76
X76
X48
C
63
X48
64
S93
X76
X47
104
INP. HEIGHT COUNTER INITIAL LIFT PULSE A
011
INP. HEIGHT COUNTER INITIAL LIFT PULSE B
013
INP. FORKS < REFERENCE HEIGHT
Sh. 9 23
CHASSIS FUSE PANEL

F66
40
142
10A
10/29 221874
Prod A
20- 89
F
8
AUXILIARY EQUIPMENT CHASSIS

X18
|R
X76
2
B
012
T-code
712, 713
Sh. 11
15

919699-
Service Manual

A4
Date
2005-11-28
Order number
227761-040
BT Europe AB

A4
A
Sh. 8 28
Sh. 10 12
Sh. 10 12
24
X56
X43
24
X20
40
X15
X21
X29
X68
40
80
80
B
Sh. 8
Sh. 10
X44
120
X56
X56
INP. +48VDC ESO CABIN
029
GND
015
GND
027
CAN 1H
042
CAN 1L
028
OUT. + 15VDC SUPPLY
X43
119
R109
X43
120
15
15
120~E
C
U13
X48 X77 X78
X48 X77 X78
X78
X77
X48
67
|R
X78
S50
Br
X48
68
X78
Bk
X77
X47
103
INP. TRAVERSE COUNTER PULSE A
008
INP. TRAVERSE COUNTER PULSE B
010
INP. FORKS IN HOME POSITION
040
INP. SLACK CHAIN GUARD CABIN
026
INP. GATES CLOSED
Bu
X77
009
X53
LEFT
S83
X51
RIGHT
S84
3
138
LEFT
S87
X53
2
X51
140
X52
RIGHT
S88
1
4
X52
139
141
Date
2005-11-28
BT Europe AB
11/29 221874
Prod A
F
1
F
8
Order number
227761-040

919699-
Service Manual
Sh. 8
X43
119
001
T-code
712, 713
20- 90
8
A

A4
Sh. 11 14
40
X20 X15 X21 X29 X68
Y10
1
2
X50
X49
Y11
1
2
X50
X49
X50
X49
Y8
X50
X49
X50
83
84
195
OUT. (PWM) PROP. VALVE FORK LOWER
005
OUT. (PNP) FORK LIFT
017
OUT. (PNP) TRAVERSE LEFT
004
OUT. (PNP) TRAVERSE RIGHT
016
OUT. (PWM) PROP. VALVE, TRAVERSE
69
014
INP. LIFT PRESSURE
80
OUT. + 5VDC SUPPLY
20- 91
Sh. 11
X49
X49
002
X49
B7
T-code
712, 713
39

919699-
Service Manual
Y25
1
2
X49
82
031
Date
2005-11-28
Y9
81
Order number
227761-040
BT Europe AB

A16
A
X100:12+5VDC
SUPPLY
128
129
X100:11INP.
BUTTERFLY L. (TRAV.)
R2
130
131
+48VDC SUPPLY
X100:2
FORK LIFT DOWN
X100:1
FORK LIFT UP
Sh. 10 14
X64
200
X64
158
X64
74
S72
132
Pk
Pk
Wh
S80
S70
Gy
S74
Gy
S44
X66
X66
133
134
135
+48VDC SUPPLY
X103:7
INP. FUNCTION SHIFT
X103:2
+48VDC SUPPLY
X103:1
INP. CABIN DOWN
X103:3
INP. CABIN UP

A5
CABIN LOWER VALVE 1

Y21
1
2
28
Wh
X66
X103:8
73
X131:8
OUT. (NPN) CABIN LOWER VALVE 1 & 2
X130:3
INP. PUMP PRESSURE REFERENCE VALUE
CABIN LOWER VALVE 2

Y29
1
2
Date
2005-11-28
B5
16
75
Sh. 6
30
X16
B6
B
X14
E
76
X130:17INP.
LIFT SUPPORT SYSTEM PRESSURE
Sh. 6
X15
BT Europe AB
13/29 221874
Prod A
F
1
F
8
Order number
227761-040
X100:3
BUTTERFLY LEFT

919699-
Service Manual

A16
X100:10GND,
T-code
712, 713
20- 92
Order number
227761-040
BT Europe AB
Sh. 13 18
X15
28
X24
S5
X24
X14
77
X11
X28
S6
X28
IN AISLE SIGNAL 1
X11
BACKWARD DIR., RIGHT

S156
1
3
Sh. 12 18
X20
X11
X15
40
FORWARD DIRECTION 2
X24
S7
X24
X14
78
X11
X28
S8
X28
X130:24INP.
IN AISLE SIGNAL 2
X11
X24
FORWARD DIRECTION 1
1
S9
X24
X14
79
X28
X15
X24
S4
X28
END BRAKE 1
X11
FORWARD DIRECTION 2
1
S123
X24
X14
201
X11
X28
S124
X28
X130:2
X11
14/29 221874
Prod A
20- 93
X11
X130:38INP. AISLE
X15
T-code
712, 713
FORWARD DIR., LEFT

S178
1
3

919699-
Service Manual
X130:10INP.
Date
2005-11-28

A5
FORWARD DIRECTION 1
Date
2005-11-28
Order number
227761-040

919699-
Service Manual
F
15/29 221874
Prod A
BT Europe AB
STANDARD DISPLAY
A
A
T-code
712, 713
20- 94
X108
7
6
5
4
3
2
1
X105
40-P CONNECTOR
40
30
30-P CONNECTOR
40-P CONNECTOR
X109
X110
30-P CONNECTOR
B
A16
KEYPAD
A22
DISPLAY
A6
8
7
6
5
4
3
2
1
OPTION
WIRE GUIDANCE
LOAD ANTENNA
W1

A5
BLACK
J1L:1
X132:14
INP. NEAR WIRE COIL
X132:4
INP. LEFT COIL
X132:24
OUT. L0
X132:6
OUT. L1
X132:25
OUT. L2
X132:16
OUT. L3
B
RED
J1L:3
Service Manual
ORANGE
J1L:5
YELLOW
J1L:6
GREEN
J1L:7
GREY
J1L:15
X132:5
GND
X132:26OUT.
+ 12VDC

A16
Sh. 7
105
S120
116
X100:9
INP. WIRE GUIDANCE REQUEST
16/29 221874
Prod A
20- 95
F
8
X132:15SHIELD
J1L:13
VIOLET
J1L:14
T-code
712, 713
BLUE
J1L:8

919699-
INP. RIGHT COIL
Date
2005-11-28
BROWN
J1L:2
X132:23
Order number
227761-040
BT Europe AB
OPTION
WIRE GUIDANCE
TRACTOR ANTENNA
W2

A5
BLACK
J1T:1
BROWN
J1T:2
X132:29INP.
RIGHT COIL
X132:19INP.
NEAR WIRE COIL
X132:10INP.
LEFT COIL
B
RED
J1T:3
YELLOW
J1T:6
X132:9
GREEN
J1T:7
VIOLET
J1T:14
OUT. T1
X132:28OUT.
T2
X132:18OUT.
T3
X132:17GND
GREY
J1T:15
T0
J1T:13
X132:7
OUT. + 12VDC
X132:8
SHIELD
Date
2005-11-28
BT Europe AB
17/29 221874
Prod A
Order number
227761-040
BLUE
J1T:8
X132:27OUT.

919699-
Service Manual
ORANGE
J1T:5
T-code
712, 713
20- 96
OPTIONS
28
X15

A5
LEFT ARM
Y5
1
2
X24
X24
X13
157
RIGHT ARM
Y6
1
2
X16
X21
X29
F70
ROOF, LEFT
S99
144
8
10A
145
E3
ROOF, RIGHT
146
E4
9
7
CABIN SIDE, LEFT UPPER

E5
E6
CABIN SIDE, RIGHT UPPER
E7
WORKING LIGHT
D
Sh. 14 19
40
X20
X15
X21
X29
E8
X68
18/29 221874
Prod A
20- 97
F
8
CABIN SIDE, RIGHT LOWER
CABIN SIDE, LEFT LOWER
T-code
712, 713
147
3
(PWM) SUPPORT ARM BRAKE

919699-
Service Manual
20
X131:13OUT.
SUPPORT ARM BRAKE
CABIN FUSE PANEL

Sh. 8 19
Date
2005-11-28
Sh. 14 21
Order number
227761-040
BT Europe AB
OPTION
THIN CLIENT TOUCH SCREEN DISPLAY
THIN CLIENT
A17

A16
RS232
9-P DSUB CONNECTOR
9
X111
9-P DSUB CONNECTOR
X107:1
OUT. (PWM) FAN POWER
X107:2
FAN GND
XPS
A25
USB MASTER
C
8-P MODULAR PLUG
GND X113:3
SCREEN
214
214
215
215
X113
X147
8-P MODULAR PLUG
X140:1
+13,2VDC OUT
X140:3
GND OUT
X140
SCREEN
X141:1
+48V IN
X141:3
+GND IN
Date
2005-11-28
CABIN FUSE PANEL

Sh. 18 20
Sh. 18 20
20
X16
X21
X29
F69
X43
X56
18
5A
40
X20
X15
X21
X29
X68
X43
X56
40
BT Europe AB
19/29 221874
Prod A
F
1
F
8
Order number
227761-040
+13,2 VDC POWER SUPPLY X113:1
8
X112

919699-
Service Manual
X106
M15
T-code
712, 713
20- 98
OPTION
Sh. 19 22
X29
F72
160
40
X20
X15
X21
X29
X68
40
340
312
+48V IN
INP. GND
OUT. +12V
STEREO/CD
A14
312
+12V KEY
A:8
IN -
B:5
OUT. LEFT (+)
B:6
OUT. LEFT (-)
B:3
OUT. RIGHT (+)
B:4
OUT. RIGHT (-)
H4
LEFT +
D
LEFT -
H5
RIGHT +
RIGHT -
E
W5
20/29 221874
Prod A
20- 99
A:4
+12V IN
T-code
712, 713
340
A:7

919699-
Service Manual
7,5A
Date
2005-11-28
Sh. 19 21
20
X21

A11
STEREO/CD
CABIN FUSE PANEL

X16
Order number
227761-040
BT Europe AB
Sh. 18 25
X15
28
X15
Sh. 20 22
40
X15
X25
X20
X15
X23
FRONT
H26
2
1
162
X23
S172
X25
X25
X13
X13
X13
149
X131:23OUT.
(NPN) DRIVE DIR. INDICATOR LEFT
DRIVE DIRECTION INDICATORS

150
163
X131:9
OUT. (NPN) DRIVE DIR. INDICATOR RIGHT
X130:41INP.
29
161
REAR
H16
2
1
X23

A5
FRONT
H25
2
1
S173
X12
164
X131:2
INP. INDIVIDUAL AISLE ID. 2
INDIVIDUAL AISLE ID. INPUTS,

SEE PARAMETER SETTINGS
X25
S174
X25
X12
165
S54
X14
90
X130:11INP. AISLE
END STOP 1
X25
X25
X12
202
X130:16INP. AISLE
END STOP 2
AISLE END STOP
S110
Date
2005-11-28
H3
X17
X17
155
X131:11OUT.
(NPN) TRAVEL ALARM
TRAVEL ALARM
BT Europe AB
21/29 221874
Prod A
1
Order number
227761-040
X131:16INP.

919699-
Service Manual
Sh. 10 25
X23
REAR
H15
2
1
OPTIONS
T-code
712, 713
20- 100
OPTION
12V AND/OR 24V (150W) POWER IN CABIN

A12
CABIN FUSE PANEL

Sh. 20 27
X16
X21
X29
F73
198
40
X20
X15
X21
X29
X68
40
INP. +48VDC
INP. GND
OUT. +12VDC
OUT. +12VDC
199
INP. +48VDC
40
INP. GND
OUT. +24VDC
OUT. +24VDC
22/29 221874
Prod A
20- 101
7,5A
F74
T-code
712, 713

A13
CABIN FUSE PANEL

919699-
Service Manual
7,5A
Date
2005-11-28
Sh. 21 23
20
Order number
227761-040
BT Europe AB
CHASSIS FUSE PANEL
OPTION
F64
17
X9:2
INP. GND
X1:1
X1:3
X1:4
X1:5
X1:6
INP. WARNING RELAY
X1:7
OUT. WARNING RELAY
X2:4
INP. DRIVE FORWARD (FORK DIRECTION)
X2:3
INP. +48VDC
X2:6
INP. DRIVE BACKWARDS
X2:5
INP. +48VDC
X2:12
INP. IN AISLE
X2:10
INP. +48VDC
X20
188
189
C
INP. SPEED REDUCTION PPS X131:31
OUT. (NPN) DRIVE FORWARD (FORK DIRECTION) X131:10
190
191
R20
820~E/5W
D
OUT. (NPN) DRIVE, BACKWARDS X131:24
192
R21
OUT. (NPN) IN AISLE X131:38
820~E/5W
193
R22
Date
2005-11-28
820~E/5W
17
BT Europe AB
Sh. 24
F
1
Order number
227761-040
INP. +48VDC POWER

919699-
Service Manual
X9:1
7,5A
40
8
A

A5
7
PPS ELECTRONIC CARD
A26
Sh. 22 25
A
Sh. 10 26
T-code
712, 713
20- 102
OPTION
OUT. (NPN) OVERRIDE PPS X131:22
PPS ELECTRONIC CARD

A26
194
R23
INP. PPS OVERRIDE SIGNAL
X1:14
INP. +48VDC
17
20- 103
24/29 221874
Prod A
F
1
F
8
T-code
712, 713

919699-
Service Manual
Sh. 23
X1:15
820~E/5W
Date
2005-11-28

A5
Order number
227761-040
BT Europe AB
OPTION

A5
Sh. 21 29
S12
28
205
S13
S14
X15
X26
207
Y55
X26
X13
C
Sh. 21
X15
29
S69
X26
X26
X13
151
154
INP. SPEED REDUCTION 1
X131:18INP.
SPEED REDUCTION 2
X131:32INP.
SPEED REDUCTION 3
X131:36OUT.
X130:40INP.
(NPN) PIVOT LOCK, LOCKING VALVE
PIVOT LOCK, LOCKED POSITION
S68
Sh. 23 26
40
X20
X15
X26
X13
153
X130:13INP.
PIVOT LOCK, RELEASED POSITION
X26
Date
2005-11-28
BT Europe AB
25/29 221874
Prod A
F
1
F
8
Order number
227761-040
PIVOT LOCKING DEVICE (IN AISLE)

919699-
Service Manual
206
X131:4
T-code
712, 713
20- 104
OPTION
110
115
114
INP. GND
40
115
INP. +48VDC
19
156
VIDEO SIGNAL 1
INP. +12VDC SUPPLY
INP. GND
Sh. 23
Sh. 25 27
CAMERA, FRONT
A52
F65
5A
210
X20
40
114
115
X30
X31
X31
X31
X31
X54
X54
X54
X54
X57
X57
X57
X57
INP. GND

A16
110
156
210
INP. +12VDC SUPPLY
256
X104:4
VIDEO SIGNAL 1
X104:3
X104:2
VIDEOSIGNAL 2
X104:1
20- 105
26/29 221874
Prod A
X30
X30
VIDEO SIGNAL 2
T-code
712, 713
256
X30

919699-
Service Manual
CHASSIS FUSE PANEL
Date
2005-11-28
CAMERA(S) WITH STD DISPLAY
OUT. GND (GALVANICALLY ISOLATED)
CAMERA, REAR
A51
114
OUT. +12VDC
VOLTAGE CONVERTER
A10
Order number
227761-040
BT Europe AB
SEAT HEATING (IN COLDSTORE)

A15
AUX EQUIPMENT CABIN PANEL

Sh. 22
Sh. 26 28
20
X16
X21
X29
F71
221
INP. +48VDC
40
X20
X15
X21
X29
X68
40
INP. GND
225
222
OUT +24VDC
BACK REST
S126
8
X63
223
E10
E11
224
Date
2005-11-28
4
2
X63
BT Europe AB
27/29 221874
Prod A
F
1
Order number
227761-040
SEAT
SEAT HEAT SWITCH

919699-
Service Manual
10A
OPTION
T-code
712, 713
20- 106
B
7
T-code
712, 713

919699-
C
C
Date
2005-11-28
Service Manual
F
28/29 221874
Prod A
7
6
5
4
3
2
20- 107
X69
X46
X68
X29
X21
X15
X20
40
Sh. 27
4
3
M
227
Order number
227761-040
OPTION
BT Europe AB
FAN POWER SWITCH
M
9
8
226
24
Sh. 11
RIGHT
M14
LEFT
M13
S96
X69
X46
X43
X56
A
COMFORT FANS IN CABIN
8
7
6
5
4
3
2
1
OPTION
COMPETITOR AISLE LAYOUT

A5
FORWARD DIRECTION 1
Sh. 25
28
X15
X24
S5
X24
X14
77
FORWARD DIRECTION 3
1
S139
X130:10INP.
IN AISLE SIGNAL 1
S7
X24
X14
78
FORWARD DIRECTION 4
1
S140
X130:24INP.
IN AISLE SIGNAL 2
S9
X24
X14
79
FORWARD DIRECTION 3
1
S137
X130:38INP. AISLE
END BRAKE 1
FORWARD DIRECTION 2
3
S123
X24
X14
201
FORWARD DIRECTION 4
1
S138
X130:2
Date
2005-11-28
BT Europe AB
29/29 221874
Prod A
F
1
Order number
227761-040
FORWARD DIRECTION 1

919699-
Service Manual
FORWARD DIRECTION 2
T-code
712, 713
20- 108

Component list
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
20.10 Component list

Symbol
Name/function
Electrical wiring diagram, page

712
713
Component
picture
A1/ACTL
Frequency converter, M1
A2/ACH
A4/FCU
Logic card, fork unit
10, 11, 12,

27
10, 11, 12
A5/MCU
Logic card, main computer card
1,2,5,6,7,9,
10,13,14,16
17,18,21,23
24, 25,30
1,2,5,6,7,9,
10,13,14,1
6,17,18,21,
23,24
25,29
A6
Display
15
15
A10
DC/DC converter, 48 V/12 V, camera
26
26
A11
DC/DC converter, 48 V/12 V
20
20
A12
22
22
A13
22
22
A14
Stereo/CD player
20
20
A15
28
A16/ICP
Control panel with integrated display
6,7,8,9,13,1
5,16,19,26,
27
6,7,8,9,13,
15,16,19,2
6,
A17
Thin client (PC), on-board terminal
19
19
A22
Keyboard
15
15
A25/XPS
USB hub
19
19
A26
Logic card PPS
23,24
23, 24
A31/
ACTR
A32/
DCHI
Transistor regulator, M4
A51
Camera back
26
26
A52
Camera in front
26
26
B1
Temperature sensor, M1
B2
B3
B4
Pressure sensor, steering accumulator
B5
Pressure sensor, pump pressure
13
13
BT Europe AB
Service Manual
20- 109

Component list
T-code
712, 713
Symbol

919699-
Name/function
Date
2005-11-28
Order number
227761-040

712
713
Component
picture
B6
Pressure sensor, auxiliary lifting system,

B cylinder
13
13
B7
Pressure sensor, hydraulic pressure lifting
12
12
E1
Cab illumination, left-hand side
E2
Cab illumination, right-hand side
E3
Work lights, left-hand side on roof
18
18
E4
Work lights, right-hand side on roof
18
18
E5
Work lights, left top light on cab
18
18
E6
Work lights, left lower light on cab
18
18
E7
Work lights, right top light on cab
18
18
E8
Work lights, right lower light on cab
18
18
E10
Heater in operator's seat, seat cushion
28
27
E11
Heater in operator's seat, backrest
28
27
F1
Drive motor fuse, left motor, 125 A
F2
Drive motor fuse, right motor, 125 A
F3
Pump motor fuse, cab lifting, 325 A
F4
Pump motor fuse, fork operation, 125 A
F60
Voltage feed fuse, switches, valves, horn

and ventilator fan motor, 10 A
F61
Voltage feed fuse, MCU, 5 A
F62
Operating fuse, K10 signal , 5 A
F63
Main fuse, cab electronics, 20 A
F64
Voltage feed fuse, PPS electronics, 7.5 A
23
23
F65
Voltage feed fuse, voltage converter A10,

5A
26
26
F66
Voltage feed fuse, auxiliary equipment

connector on chassis, 10 A
10
10
F67
Voltage feed fuse, ICP, 5 A
F68
Voltage feed fuse, cab relay K17, 7.5 A
F69
Voltage feed fuse, thin client (PC), 5 A
19
19
F70
Voltage feed fuse, work lights, 10 A
18
18
F71
Voltage feed fuse, optional cab-mounted

equipment, 10 A
8,28
8, 27
20- 110
Service Manual
BT Europe AB

Component list
Order number
227761-040
Symbol
Date
2005-11-28

919699-
Name/function
T-code
712, 713

712
713
Component
picture
F72
Voltage feed fuse, DC/DC converter, 7.5

A
20
20
F73

A
22
22
F74

A
22
22
F75
Voltage feed fuse, parking brake release,

5A
G1
Battery 48 V
H1
Horn
H2
Warning lamp
H3
Travel warning
21
21
H4
Left loudspeaker
20
20
H5
Right loudspeaker
20
20
H15
Flasher lamp, rear left
21
21
H16
Flasher lamp, rear right
21
21
H25
Flasher lamp, front left
21
21
H26
Flasher lamp, front right
21
21
K10
Main contactor
K17
Key relay, cab
K18
Voltage feed relay, chassis components
K19
Switching relay, rotation
12
12
M1
Left drive motor
M2
Right drive motor
M3
Pump motor, main lift
M4
Pump motor, initial lifting
M10
Pump motor fan
M12
Electric panel fan
M13
Cab ventilator left
29
28
M14
Cab ventilator right
29
28
M15
Thin client fan
19
19
M16
Fan in motor housing bonnet
BT Europe AB
Service Manual
20- 111

Component list
T-code
712, 713
Symbol

919699-
Name/function
Date
2005-11-28
Order number
227761-040

712
713
Component
picture
R1
Potentiometer, truck travel
R2
Potentiometer, fork controls
13
13
R7
Potentiometer, articulated centre angle
R8
Potentiometer, rotation angle
12
R9
Coupling resistor, K19
12
R20
Load rheostat
23
23
R21
Load rheostat
23
23
R22
Load rheostat
23
23
R23
Load rheostat
24
24
R91
Termination resistor, CAN 2
R99
Termination resistor, chassis service key
R100
R109
11
11
S4
Magneto switch, speed reduction at aisle

end 1, drive wheel direction
14
14
S5
Magneto switch, aisle detection 1, fork

direction
14,30
14,29
S6
Magneto switch, aisle detection 1, drive

wheel direction
14
14
S7
Magneto switch, aisle detection 2, fork

direction
14,30
14,29
S8
Magneto switch, aisle detection 2, drive

wheel direction
14
14
S9

end 1, fork direction
14,30
14,29
S12
Speed reduction switch 1.0 - 2.5 km/h
25
25
S13
Speed reduction switch 2, 2.5 - 4 km/h
25
25
S14
Speed reduction switch 3, 0 km/h (stopping)
25
25
S18
Right-hand sidemicro-switch, horn
S21
Emergency stop switch, cab
S22
Emergency stop switch, left side on chassis
S23
Emergency stop switch, right side on

chassis
S44
Micro-switch, cab lifting
13
13
20- 112
Service Manual
BT Europe AB

Component list
Order number
227761-040
Symbol
Date
2005-11-28

919699-
Name/function
T-code
712, 713

712
713
Component
picture
S48
Micro-switch, brakes
S50
Inductive sensor, traversing forks in home

position
11
11
S54
Photocell, aisle end stop 1
21
21
S62
Left-hand side micro-switch, horn
S68
Sensor, articulated centre unlocked
25
25
S69
Sensor, articulated centre locked
25
25
S70
Micro-switch, cab lowering
13
13
S71
Magneto switch, cab reference height
10
10
S72
Micro-switch, fork mode switching
13
13
S74
Micro-switch, clockwise rotation
13
13
S80
Micro-switch, counter-clockwise rotation
13
13
S81
Micro-switch, slack chain guard on mast,

left
S82
Micro-switch, slack chain guard on mast,

right
S83
Micro-switch, slack chain guard, cab's

left-hand side
11
11
S84
Micro-switch, slack chain guard, cab's

right-hand side
11
11
S87
Micro-switch, left gate
11
11
S88
Micro-switch, right gate
11
11
S93
Magneto switch, fork reference height
10
10
S96
Micro-switch, cab ventilator
29
28
S99
Micro-switch, work lights
18
18
S100
Dielectric detector, right handle
S101
Dielectric detector, left handle
S110
Photocell, aisle end stop 2
21
21
S120
Micro-switch, wire guidance requested
16
16
S123

end 2, fork direction
14
14,29
S124

end 2, drive wheel direction
14
14
126
Micro-switch, seat heater
28
27
S131
Micro-switch, parking brake release, M1
S132
Micro-switch, parking brake release, M2
BT Europe AB
Service Manual
20- 113

Component list
T-code
712, 713
Symbol

919699-
Name/function
Date
2005-11-28
Order number
227761-040

712
713
Component
picture
S133
Micro-switch, parking brake release
137
Magneto switch, end-of-aisle braking 1,

fork direction
30
29
138
Magneto switch, end-of-aisle braking 2,

fork direction
30
29
139
Magneto switch, aisle indication 1, fork

direction
30
29
140
Magneto switch, aisle indication 2, fork

direction
30
29
S156
Photocell, aisle detection 1
14
14
S172
Photocell, aisle ID 1
21
21
S173
21
21
S174
21
21
S178
Photocell, aisle detection 2
14
14
U1
Pulse transducer 1, steering with steering

wheel
U2
Pulse transducer 2, steering with steering

wheel
U9
Pulse transducer, fork lift height measurement unit
10
10
U10
Pulse transducer, cab lift height measurement unit
10
10
U11
Pulse transducer, left drive motor, M1
U12
Pulse transducer, cab lift pump motor, M3
U13
Pulse transducer, traversing movement
11
11
U14
Pulse transducer, right drive motor, M2
W1
Wire guidance antenna, fork direction
16
16
W2
Wire guidance antenna, drive wheel

direction
17
17
W5
Radio antenna
20
20
Y1
Magnet, parking brake, M1
Y2
Magnet, parking brake, M2
Y3
Proportional valve, steering right
Y4
Proportional valve, steering left
20- 114
Service Manual
BT Europe AB

Component list
Order number
227761-040
Symbol
Date
2005-11-28

919699-
Name/function
T-code
712, 713

712
713
Component
picture
Y5
Magnet, left-hand support leg brake
18
18
Y6
Magnet, right-hand support leg brake
18
18
Y7
Magnetic valve, steering pressure
Y8
Magnetic valve, traversing to right
12
12
Y9
Magnetic valve, traversing to left
12
12
Y10
Proportional valve, fork lowering
12
12
Y11
Magnetic valve, fork lift
12
12
Y16
Magnetic valve, one extra hydraulic function 1A
27
Y17
Magnetic valve, one extra hydraulic function 1B
27
Y18
Magnetic valve, two extra hydraulic functions 1A
27
Y19
Magnetic valve, two extra hydraulic functions 1B
27
Y21
Magnetic valve 1, cab lowering
13
13
Y25
Proportional valve, traversing
12
12
Y27
Proportional valve, counter-clockwise

rotation
12
Y28
Proportional valve, clockwise rotation
12
Y29
Magnetic valve 2, cab lowering
13
13
Y31
Magnetic valve, steering lock
Y55
Magnetic valve, articulated centre locking
25
25
BT Europe AB
Service Manual
20- 115

Component list
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
20.10.1 Placement of components

Picture 1
20- 116
Service Manual
BT Europe AB

Component list
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
Picture 2
BT Europe AB
Service Manual
20- 117

Component list
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Picture 3
20- 118
Service Manual
BT Europe AB

Component list
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
Picture 4
BT Europe AB
Service Manual
20- 119

Component list
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Picture 5
20- 120
Service Manual
BT Europe AB

Component list
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
Picture 6
BT Europe AB
Service Manual
20- 121

Component list
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Picture 7
20- 122
Service Manual
BT Europe AB

Component list
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
Picture 8
BT Europe AB
Service Manual
20- 123

Component list
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Picture 9
20- 124
Service Manual
BT Europe AB

Component list
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
20.10.2 Cabling contacts

Contact
number
Name/function/type
Placement on truck
X1
Battery connector
Battery housing
X10
Contact, emergency stop switch on chassis. 6-pin blue

JPT
Electric panel on chassis
X11
Contact, aisle transmitter. 6-pin grey JPT
X12
Contact, aisle ID and aisle end stop. 6-pin black JPT
X13
10-pin black JPT
X14
10-pin grey JPT
X15
10-pin blue JPT
X16
10-pin brown JPT
X17
Contact, warning buzzer (travel alarm). 2-pin Superseal
Spliced chassis cabling
X18
AUX contact, chassis. 2-pin black JPT
X19
Contact, battery measurement cabling. 4-pin black JPT
X20
Minus connection block. 21-pin JPT
X21
10-pin black JPT
Spliced under mast
X22
4-pin black JPT
Spliced under mast
X23
10-pin blue JPT
Spliced under mast
X24
Contact, aisle transmitter. 10-pin grey JPT
Spliced under mast
X25
Contact, aisle ID and aisle end stop. 10-pin brown JPT
Spliced under mast
X26
6-pin black JPT
Spliced under mast
X27
Remote control terminal. 3-pole Superseal
On main harness between

the electric panel on the
chassis and the MCU
X28
Aisle transmitter terminal. 6-pole grey JPT
Under the battery compartment
X29
14-pin CPC
Spliced in mast
X30
Contact, camera
Spliced at lower part of mast
X31
Contact, camera
Spliced in mast
X41
Contact, CAN service connector on chassis. 4-pin CPC
Rear chassis, right-hand side
X42
Contact, connection with mast. 4-pin black JPT
Electric panel in cab
X43
Contact, connection to control panel. 10-pin black JPT
X44
Contact, connection to control panel. 10-pin grey JPT
X45
Contact, CAN service connector in cab. 4-pin CPC
Left side of operator's chair
X46
Contact, fluorescent tubes. 2-pin black JPT
BT Europe AB
Service Manual
20- 125

Component list
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Contact
number
Name/function/type
Placement on truck
X47
Contact, fork unit connection. 6-pin brown JPT
X48
Contact, fork unit connection. 10-pin brown JPT
X49
Contact, valve plate connection. 10-pin blue JPT
X50
Contact, valve plate connection. 6-pin blue JPT
X51
Contact, left gate switch 4-pin brown JPT
X52
Contact, right gate switch. 4-pin blue JPT
X53
Contact, cab slack chain guard. 2-pin grey JPT
X54
Contact, camera connection. 7-pin CPC
X55
Contact, control panel. 19-pin CPC
Control panel arm
X56
Control panel arm
X57
Control panel arm
X58
Contact, fork lift reference switch. 4-pin grey JPT (Tcode 712)
Initial lifting unit
X59
Contact, fork lift pulse transducer. 4-pin brown JPT (Tcode 712)
X60
Contact, traversing pulse transducer. 4-pin blue JPT (Tcode 712)
X61
Contact, inductive sensor for traversing home position.

4-pin black JPT (T-code 712)
X62
Contact, rotation potentiometer. 3-pin Superseal (Tcode 712)
X63
Seat heater terminal. 2-pole Superseal
Behind the operator's seat
X64
Contact, left dead man's handle. 6-pin Ser. 040
Control panel
X65
Contact, emergency stop switch. 2-pin Poslock
Control panel
X66
Contact, right dead man's handle. 6-pin Ser. 040
Control panel
X67
Contact, auxiliary cabling to initial lifting unit.

3-pin Superseal (T-code 712)
X68
Contact, earth connection block in electric panel
X69
Contact, cab ventilator connection. 2-pin Superseal
Spliced in cab
X70
Contact, auxiliary hydraulic function. 4-pin Superseal

(T-code 712)
Spliced initial lifting unit
X71
Plus connection block, M10
X76
6-pin black JPT (T-code 713)
Under cabin, bottom fork unit
X77
6-pin grey JPT (T-code 713)
Under cabin, bottom fork unit
20- 126
Service Manual
BT Europe AB

Functional description, General
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
Contact
number
Name/function/type
Placement on truck
X78
6-pin grey JPT (T-code 713)
Front fork unit
X100
Contact, left-hand side. 20-pin Ser. 040
ICP
X101
Contact, standard. 12-pin Ser. 040
ICP
X102
Contact, Aux. 16-pin Ser. 040
ICP
X103
Contact, right-hand side. 20-pin Ser. 040
ICP
X104
Contact, camera 8-pin Ser. 040
ICP
X105
Contact, ICP keyboard
ICP
X106
RS-232
ICP
X107
Contact, ventilator fan
ICP
X108
Keypad 1
ICP
X109
Keypad 2
ICP
X110
Display
ICP
X111
RS-232
Thin client (PC)
X112
Modules
Thin client (PC)
X113
Power supply
Thin client (PC)
X130
42-pin grey
MCU
X131
42-pin black
MCU
X132
29-pin black
MCU
X140
6-pin Binder
XPS
X141
9-pin CPC
XPS
X142
8-pin Modular 1
XPS
X143
USB 1
XPS
X144
USB 2
XPS
X145
RS-232 no. 1
XPS
X146
RS-232 no. 2
XPS
X147
8-pin Modular 2
XPS
20.11 Functional description, General

The logic cards for the trucks contain microprocessors that detect
switch settings, control voltages, etc. and provide instructions for external electronic components, relays, valves, etc.
BT Europe AB
Service Manual
20- 127

Functional description, starting, driving, steering and braking
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
To safeguard all preset information in the electronic module when the

battery is disconnected, all information is stored in an EEPROM circuit
with non volatile. The MCU has a real time clock, which is powered by
an internal battery. Any faults detected by the microprocessor are
shown on the display.
The truck can be switched to three different operating modes:
Normal operating mode
Service mode
Emergency driving mode
Each of these modes is separately described in this document.
20.12 Functional description, starting,

driving, steering and braking
20.12.1 Battery connected, truck switched off
When the battery is connected, the MCU and ICP are powered up.
1. When the ICP receives +48 V via connector X101:3, the ICP
makes the following diagnostic checks:
Key relay status. No voltage on connector X101:6.
Communication verification with the MCU.
No contact ICP-MCU, the A6 display shows a warning triangle and
"waiting".
Communication ICP-MCU, the A6 displays shows the PIN log-in
box.
Conformity of firmware versions.
Comparison of the firmware versions in the MCU and ICP.
20- 128
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Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
2. When the MCU receives +48 V via connector X131:1, the MCU
makes the following diagnostic checks:
Truck and safety functions are initiated.
System parameters, truck parameters, calibration parameters and
back-up data are downloaded from the EEPROM.
If necessary, preset standard parameters are uploaded to the EEPROM.
Verification to ensure the chassis relay connectors are not closed,
no voltage on connector X131:6.
Voltage feed of +48 V to the capacitors in the ACTR, ACTL and ACH
via connector X131:15.
Switch-over to waiting state and ready for receipt of PIN code for operator log-in.
20.12.2 Log-in / Start-up

Log-in
The truck is started by entering a valid 4-digit PIN code via the keypad
A22 and then confirming the code by pressing the green [I] button.
When the PIN code is confirmed by pressing the [I] button, it is sent
from the ICP via CAN1 to the MCU to test its validity. If the code is valid,
it is assigned to one of ten operator parameter settings stored in the
MCU memory, and start-up commences.
The log-in process can be interrupted by depressing the [C] button.
If the PIN code is invalid, the log-in box on the display is cleared.
1. Verification/adjustment parameters
BT Europe AB
Parameter
no.
Function
Parameter
type
10, 20, etc.
PIN code for individual parameter settings for up to 10 different operators
Service
Service Manual
20- 129

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Start-up process
When a PIN code is entered, the following takes place (the picture
shows the various events during the start-up procedure):
1. The ICP sends the PIN code via CAN1 to the MCU.
2. The MCU checks that the K10 main contactor is not closed;
connector X131:15 has 0 V.
3. The battery voltage at MCU connectors X131:1 and X131:14 is
verified. Min. battery voltage 35.5 V.
4. The validity of the entered PIN code is verified against the PIN
codes stored in the MCU parameter memory. If the entered PIN
code matches one of the stored codes, the corresponding operator parameter setting (for up to 10 operators) is downloaded from the EEPROM.
The actual operator number is sent via CAN1 to the ICP.
5. If the PIN code is valid, the ICP switches on the key relay K17,
battery minus on connector X101:1, and commences with
continuous monitoring.
6. The ICP send the internal status to the MCU.
7. If the ICP does not report any faults, the MCU enters the startup mode.
8. The ICP verifies the MCU status via CAN1.
9. The MCU verifies the voltage on connector X131:5, +48 V, following activation of the key relay K17 and the emergency stop
switch S23 (ESO-in). Simultaneously, the capacitor voltage
level in the ACTR, ACTL and ACH, connector X131:15, is verified. Min. voltage 30 V.
10. The MCU commences communication with the motor controllers. The MCU verifies the status of the controllers and downloads parameters if necessary.
11. The MCU switches on the K10 main contactor, connector
X131:7 0 V (-), and then verifies the K10 status via connector
20- 130
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227761-040
Date
2005-11-28

919699-
T-code
712, 713
X131:15, +48 V.
Simultaneously, the chassis relays K18 receive minus feedback from connector 131:7 and closes; battery voltage of +48
V on connector X131:6.
12. The MCU commences communication routines with the FCU
and verifies the FCU firmware. The FCU receives a voltage of
+48 V from the key relay K17.
13. The MCU acknowledges correct start-up via CAN1 to the ICP.
14. The ICP verifies that the operator controls are in the neutral
positions and that all voltages are as presented in the table below.
Connector Control
code
Function
Voltage
X100:1
S80
Counterclockwise rotation
0V
X100:3
S74
Clockwise rotation
0V
X100:6
S100
Left dead-man switch
0V
X100:7
S62
Horn, left
0V
X100:11
R2
Left rocker switch
2.5V +- 0.5V
X103:1
S70
Cab lowering
0V
X103:3
S44
Cab lifting
0V
X103:6
S101
Right dead-man switch
0V
X103:7
S72
Operation shift button
0V
X103:9
S18
Horn, right
0V
X 103:11
R1
Drive rocker switch
2.5V +- 0.5V
X103:14
S48
Brake
0V
X103:15
S48
Brake
48 V
15. The ICP verifies with the MCU which option symbols should
be displayed on the A6 display.
16. The MCU provides the ICP with the symbols and the information to be displayed.
17. The A6 display switches to a display of the truck functions/operation.
18. Truck functions that correspond to the truck and operator parameter settings are activated.
Warnings during start-up

If the MCU or ICP detects an abnormal condition that is cause for a
warning (not a critical fault), then the warning symbol is displayed, however, the start-up procedure continues.
BT Europe AB
Service Manual
20- 131

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Critical faults during start-up

If the MCU detects a serious fault during the start-up procedure, it will
immediately interrupt the start-up procedure and an error code is sent
to the ICP.
If the ICP detects a serious internal ICP error, the ICP displays the error
code and the STOP symbol on the display. The error code is also sent
to the MCU where it is stored.
If the fault involves a serious hazard, the ICP will cut the minus feed
from connector X101:1 to the key relay K17.
NOTE!
Log-out must be done prior to a new log-in attempt.
20- 132
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Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
20.12.3 Log-out / Switch-off

Log-out
The truck is switched off by depressing the [O] button and keeping it
depressed for a few seconds. This will cause the operation mode on the
display to disappear and instead the log-in box is shown on the display.
If the log-out command is entered during normal truck operation, the
following takes place (the picture below shows the various events during the switch-off procedure).
MCU, ACTION
2
3
5
6
7
8
9
1.
2.
3.
4.
5.
6.
7.
8.
9.
BT Europe AB
1
4
The ICP sends the switch-off request to the MCU.

The MCU stops the trucks in a controlled manner.
When OK, the MCU sends an acknowledgement to the ICP.
The MCU sends the switch-off command to the motor controllers ACTR, ACTL, ACH and DCHI.
The ICP disconnects minus to the key relay K17, connector
X101:1.
Voltage feed to the K10 main contactor and chassis relay K18
is interrupted, and +48 V is no longer fed from the MCU connectors X131:5, X131:6 and X131:15.
Voltage feed of +48 V ESO to the motor controllers via cable 26
is also interrupted.
The MCU stores the back-up data, changed parameters and error code log in its EEPROM.
The system enters the standby state previously described in
the section on connected battery.
Service Manual
20- 133

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
20.12.4 Presence verification

Open cabin gates
If the cabin gates are open > 5 seconds at cabin heights < 1000 mm
and > 10 seconds at cabin heights > 1000 mm, the operator must
acknowledge his presence in the cabin.
Prior to any truck functions operating, the operator must acknowledge
his presence in the cabin as follows:
The displays shows the message DRIVER?.
- Actuate the right dead man's handle (S101) and the left dead
man's handle (S100).
The messages disappears from the display.
Closed cabin gates

Presence verification as described in the section Open cabin gates
needs only to be performed once after the gates have been closed.
20.12.5 Selecting the drive direction / Driving
The drive control R1 has a nominal voltage feed of +5 V from the ICP/
X103:12 connector via cable 122. R1 has a calibrated centre position.
See the calibration section. The nominal value is +2.5 V at the ICP/
X103:11 connector.
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227761-040
Date
2005-11-28

919699-
T-code
712, 713
Forward travel
To travel in the forwards direction, the drive control R1 is pressed to the
right causing a voltage increase at the ICP/X103:11 connector. The
adjustment range is 0 - +100% (corresponding to approx. +0.9 V from
the calibrated voltage value).
The current signal value is sent from the ICP to the MCU via CAN1.
When the speed control R1 is actuated, the signal on ICP/X103:11
increases by 15% (corresponding to approx. +0.13 V) and the MCU
releases the parking brake on the drive motors.
As the pressure on the drive control increases, the voltage feed from
R1 to ICP/X103:11 rises, causing a change in speed from 0 to 100%.
The MCU sends the command via CAN2 to the travel motor controllers
for a change in speed.
Reverse travel
To travel in the reverse direction, the drive control R1 is pressed to the
left causing a voltage decrease at the ICP/X103:11 connector. The
adjustment range is 0 - -100% (corresponding to approx. -0.9 V from
the calibrated voltage value).
The current signal value is sent from the ICP to the MCU via CAN1.
When the speed control R1 is actuated, the signal on ICP/X103:11
decreases by 15% (corresponding to approx. -0.13 V) and the MCU
releases the parking brake on the drive motors.
As the pressure on the drive control increases, the voltage feed from
R1 to ICP/X103:11 falls, causing a change in speed from 0 to 100%.
The MCU sends the command via CAN2 to the travel motor controllers
for a change in speed.
Motor control (ACTL, ACTR)

Truck travel relies on two AC motors and two AC motor controllers, the
ACTL and ACTR. The desired travel speed, acceleration and retardation depend on the values received from the drive control, the Optipace
system, the load and external safety conditions.
Speed is limited as a function of the current torque in the ACTx and follows a predefined speed/voltage curve.
The motor revolutions and rotational direction are separately controlled, M1 by the ACTL and M2 by the ACTR, relying on the information
received from the MCU via CAN2. The motor revolutions are also differentiated depending on the current steering angle.
Information sent from the MCU separately to each controller is as follows:
- Motor revolution set point
- Max. allowable torque
- Control information
BT Europe AB
Service Manual
20- 135

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
The AC controllers acknowledge with:

- Current motor revolutions
- Current torque
- Status information
The MCU also determines the local parameters in the motor controllers.
Current is fed through the ACTL fuse F1 and is converted to 3-phase
alternating current routed to M1 through the ACTR fuse F2 where it is
converted to 3-phase alternating and current subsequently sent to M2.
The drive motors revolutions are measured using the sensors U11(M1)
and U14 (M2).
The drive motor operating time is measured and stored in the MCU.
20.12.6 Emergency driving mode

NOTE!
Use of the emergency driving mode is recommended only when the
cabin is in the lowered position.
If the cabin cannot be lowered, use the emergency lowering valve on
the hydraulic block.
To access the emergency driving mode, depress one of the horn buttons and then log in as normal.
The ICP displays the info symbol and the text EMERGENCY.
In the emergency driving mode, the following operations are permitted:
steering, manual steering mode, forward/reverse travel at emergency
inching speed (very slow at 0.36 m/sec.) and lifting/lowering of the cab
and forks as well as lifting and lowering at reduced speed.
Warning
When the truck operates in the emergency driving mode, its normal,
logic safety features are disengaged.
Warning
In the emergency driving mode, the forks need not be in the home position.
In the emergency driving mode, pay attention to the fork position during driving, lifting and lowering.
To return the truck to the normal operation mode, log off/switch off the
truck and then perform new log-in/start-up.
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Date
2005-11-28

919699-
T-code
712, 713
20.12.7 Travel speeds

The truck has three travel speed ranges: full speed, half speed and
inching speed. The truck automatically switches between these three
speed ranges depending on the task at hand (i.e. outside or inside narrow aisle) as well as programmed speed reductions.
Full speed, half speed and inching speed can be reduced by 10-100%
through adjustment of the operator parameters .
Optipace
Optipace is a system that limits the maximum allowed travel speed at
any given time depending on the stability of the truck.
The Optipace system requests information from the various sub systems about the current travel speed, cabin height, weight of the goods
and the selected steering mode.
Optipace-related values for travel speed/cabin height can be adjusted
via the service parameters.
Other travel speed reductions

The travel speed is reduced to inching speed (2.5 km/h) when:
- The cabin is lifted above a set height or the lift height limiter is bypassed.
- Wire guidance is activated, but the truck is not locked on the wire.
- End-of-aisle speed reduction has been engaged according to the
parameter settings.
- The forks are not in the left or right home position.
If a travel speed reduction connector has engaged, the corresponding
speed will be reduced according to the set value for the corresponding
parameter.
BT Europe AB
Service Manual
20- 137

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
20- 138
Parameter
no.
Function
Parameter
type
2, 12, etc.
Max. travel speed
Operator
3, 13, etc.
Half speed
Operator
4, 14, etc.
Inching speed
Operator
103
Max. travel speed in rail-guided narrow aisle
Service
104
Max. travel speed in wire-guided narrow aisle
Service
105
Travel speed reduction
Service
106
Travel speed reduction 1
Service
107
Service
108
Service
109
Lifting height when OPTIPACE has

reduced speed to 2.5 km/h
Service
151
Locked/open operator parameters
Service
Service Manual
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
Travel speeds outside narrow aisles with forks in

the "home position"
The maximum allowed travel speed depends on the cabin height. See
the diagram.
1. The following travel speeds apply for driving outside narrow
aisles and with steering angles >10o. Note 1 in the travel speed
diagram.
- Cabin height <0.5 m = travel speed generally reduced to
max. 9.0 km/h (2.5 m/sec.).
- Cabin height >0.5 m but <1.2 m = travel speed is linearly reduced
from max. 9.0 km/h (2.5 m/sec.) to max. 4.0 km/h (1.11 m/sec.).
- Cabin height >1,2 m but <3.0 m = travel speed reduced to
max. 4.0 km/h (1.11 m/sec.).
- Cabin height >3.0 m = travel speed reduced to
max. 2.5 km/h (0.7 m/sec.).
- Forks not in "home position" = travel speed always
reduced to max. 2.5 km/h (0.7 m/sec.).
Travel speed
(km/h)
OUTSIDE NARROW AISLE
12.0
11.0
10.0
9.0
8.0
7.0
Not. 1
6.0
5.0
4.0
3.0
2.0
1.0
Not. 2
2.5
1.2
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
11.0
12.0
13.0
14.0
Cabin floor height

(m)
2. The following travel speeds apply for driving outside narrow

aisles and with steering angles >50o. Note 2 in the travel speed
diagram.
- Cabin height <0.5 m = travel speed generally reduced to
max. 4.0 km/h (1.11 m/sec.).
- Cabin height >0.5 m but <1.2 m = travel speed is linearly reduced
from max. 4.0 km/h (1.11 m/sec.) to max. 2.5 km/h (0.7 m/sec.).
max. 2.5 km/h (0.7 m/sec.).
BT Europe AB
Service Manual
20- 139

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
3. The following travel speeds apply for steering angles >10o but
<50o .
- Maximum travel speed according to item 1 is reduced by 25% for
each 10o increase in the steering angle until a steering angle of
50o has been reached.
Travel speeds for trucks in rail-guided narrow aisles

the diagram.
1. Trucks without support arm brakes:
- Cabin height <2.0 m = travel speed reduced to max. 10.0 km/h
(2.78 m/sec.).
- Cabin height >2.0 m but <11.0 m results in continuous OPTIPACE adjusted travel speed reduction that depends on required
stability and braking.
max. 2.5 km/h (0.7 m/sec.).
Travel speed
(km/h)
RAIL GUIDED WITHOUT WHEEL BRAKE

12.0
11.0
1500 kg load
10.0
9.0
8.0
7.0
6.0
5.0
4.0
3.0
2.0
2.5
1.0
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
11.0
12.0
13.0
14.0
Cabin floor height

(m)
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2. Trucks with support arm brakes:

The maximum allowed travel speed depends on the actual cabin height
and the load weight. See the diagram.
- Load weight 1,000 kg
Cabin height <2.0 m = travel speed reduced to max. 12.0 km/h
(3.33 m/sec.).
(3.06 m/sec.).
(2.78 m/sec.).
- Load weight 1,000 kg and 1,250 kg:
Cabin height >2.0 m but <11.5 m results in continuous OPTIPACE adjusted travel speed reduction that depends on required
Cabin height >11.5 m = travel speed reduced to
max. 2.5 km/h (0.7 m/sec.).
Cabin height >2.0 m but <11.0 m results in continuous OPTIPACE adjusted travel speed reduction that depends on required
Cabin height >11.0 m = travel speed reduced to
max. 2.5 km/h (0.7 m/sec.).
Travel speed
(km/h)
RAIL GUIDED WITH WHEEL BRAKE

1000 kg load
12.0
11.0
1250 kg load
1500 kg load
10.0
9.0
8.0
7.0
6.0
5.0
4.0
3.0
2.0
2.5
1.0
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
11.0
12.0
13.0
14.0
Cabin floor height

(m)
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Travel speeds for trucks in wire-guided narrow

aisles
the diagram.
- Cabin height <2.0 m = travel speed reduced to max. 10.0 km/h
(2.78 m/sec.).
- Cabin height >2.0 m but <11.0 m results in continuous OPTIPACE adjusted travel speed reduction that depends on required
max. 2.5 km/h (0.7 m/sec.).
Travel speed
(km/h)
WIRE GUIDED
12.0
11.0
1500 kg load
10.0
9.0
8.0
7.0
6.0
5.0
4.0
3.0
2.0
2.5
1.0
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
11.0
12.0
13.0
14.0
Cabin floor height

(m)
20.12.8 Steering
The truck uses electro-hydraulic steering with the steering wheel, which
is placed on the left side of the control panel, generating pulses that are
processed by the ICP microprocessor. The ICP sends information
about steering and steering speed response via CAN1 to the MCU. The
MCU adjusts steering by way of the proportional valves Y3 and Y4 for
distribution of the oil to both steering cylinders. The steering angle is
recorded by the MCU based on the actual voltage received from the
Steering angle potentiometer R7 at connector X130:4.
In order to be able to steer the truck, the hydraulic system must be pressurised. This is achieved using an accumulator installed in the steering
system. An analogue pressure sensor, B4 (0-5 V), monitors the steering accumulator pressure to ensure that the pressure is within the
allowed limits, 90-230 bar. If the steering pressure is lower than 120
bar, the MCU will start the pump motor M4, via the DCHI pump motor
controller, in order to charge the accumulator, through the routing valve
Y7, to 230 bar.
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The Y7 valve closes to avoid pressure loss in the accumulator when the
right dead man's handle (S101) is released.
In case of a fault in the steering system, Y7 closes, and the system is
accordingly disconnected from the accumulator causing maximum
braking of the truck through reversing. The Y31 routing valve also closes to block the negative side of the steering cylinders.
Safety monitoring
The steering system is continuously monitored in order to detect errors.
If a fault should occur in the steering system, the truck generates an
alarm by displaying an error code and displaying the STOP symbol on
the ICP display. Simultaneously, the truck is stopped in a controlled
manner through maximum reversal braking of both drive motors.
The steering system components are continuously monitored during
truck operation, and in case a fault occurs, the truck enters the error
mode.
1. The voltage feedto the pulse transducers U1 and U2 in the
steering wheel is monitored by the ICP microprocessor. If the
current level is too low, an error status is generated.
2. The ICP microprocessor compares the transducers U1 and
U2, and in case of a difference in the generated pulses, an error status is generated.
3. The steering angle potentiometer R7 is monitored with regard
to interruption and short-circuiting.
4. The proportional valves Y3 and Y4 used for steering are monitored with regard to interruption and short-circuiting.
5. The routing valves Y7 and Y31 used for steering are monitored
with regard to interruption and short-circuiting.
6. The hydraulic pressure of the steering accumulator is monitored, and an error status is generated if the pressure falls to
under 70 bar.
7. The pressure sensor B4 is monitored with regard to interruption and short-circuiting
NOTE!
See the section on error codes for an explanation of the truck's builtin safety logic and the error codes.
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Steering wheel
The steering wheel is made up of two independent pulse transducers,
i.e. transducer layers U1 and U2. The transducers are separately powered with a voltage of +15 VDC, U1 from the ICP connector X100:13
and U2 from connector X100:17. The transducers also have separate
minus feedbacks, U1 via ICP connector X100:16 and U2 via connector
X100:20.
When the steering wheel is turned, each transducer generate two signals, for channel A and B, which are 90o out of phase. U1 channel A on
ICP connector X100:14 and channel B on connector X100:15. U2
channel A on ICP connector X100:18 and channel B on connector
X100:19.
U1 CHAN. A (X100:14)
U1 CHAN. B (X100:15)
X100
U2 CHAN. A (X100:18)
U2 CHAN. B (X100:19)
The signals are compared by the ICP microprocessor to sense the

steering direction (channel A before B and vice versa) and the steering
speed response (number of pulses per time unit).
The ICP microprocessor monitors the voltage feed to the pulse transducers. If the current level is too low, an error status is generated.
Pulse transducer U1 is used for the steering function, while pulse transducer U2 is used as a safety reference. The ICP microprocessor compares both transducers, and in case of a difference in the generated
pulses, an error code is generated.
The ICP sends information about steering direction and steering speed
response via CAN1 to the MCU.
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While steering, the steering cylinders are controlled by proportional

valve Y3 or Y4, for steering to the right or left, respectively. The proportional valve coils are current-controlled, MCU X131:40 and MCU
X131:26, respectively. To be sure that the truck is actually turning, a
potentiometer, R7, has been installed. The potentiometer is fed with a
nominal voltage of +5 V. R1 has a calibrated centre position with a nominal value of 2.5 V on connector MCU/X130:4.
The characteristics of the proportional valves and the centre of the
steering angle potentiometer are measured using a calibration function
in the truck service mode. See the section on calibration for more
details.
The steering adjustment signals depend on which steering mode is currently selected on the truck. The selected steering mode rely on the signals received from the narrow aisle sensors and the wire-guidance programme logic. The truck can be in one of three different steering
modes.
Free driving mode

The pulses from U1 in the ICP steering wheel are used as control signals for manual steering in the free driving mode. The MCU processes
the information from the ICP, via CAN1, regarding the steering angle
and the steering response speed in order to offer smooth operation.
The steering response speed is reduced just before reaching the
mechanical end stops of the steering. This reduction in speed cannot
be adjusted.
Steering response can be adjusted in relation to the current travel
speed using the truck parameters.
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2005-11-28
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Parameter no.
Function
Parameter type
1, 11, etc.
Progressive steering
Operator
2. Steering indicator
The actual steering angle is sensed by the MCU via connector X130:4,
i.e. the current voltage value in relation to the calibrated centre position
value, and the MCU sends information about the actual steering angle
via CAN1 to the ICP. The ICP uses the truck symbol in the display to
roughly depict the selected steering angle.
Rail-guided narrow aisle mode

When entering a narrow aisle for rail guidance of the truck, the truck
must be straightened up and run straight in order for the narrow aisle
sensors to start operating. The displayed truck symbol should be
straight.
When the truck has entered the narrow aisle, the bistable magneto
switch is switched by the magnets in the narrow aisle floor, i.e. S5/S7 or
S6/S8. Alternatively photocells may be used, i.e. S156/ S178. A voltage
of +48 V is then received via MCU X130:10 and X130:24.
The truck automatically switches to the rail guided narrow aisle mode
and manual steering is disengaged when the aisle magneto switches
are switched on and the Steering angle is 3o or less. The narrow aisle
indication lights up in the ICP display.
In a rail-guided narrow aisle, the steering angle potentiometer R7 is
used for steering reference, and the MCU ignores all signals received
from the steering wheel pulse transducer. The steering system will
straighten up the truck to a steering angle of 0o, which is the calibrated
value of R7, and steering monitoring is taken over by the R7 potentiometer, which sends signals to the MCU about any corrections of deviation
from the selected angle when driving straight ahead.
When the trucks exits the narrow aisle, the aisle magneto switches are
switched off and the truck automatically enters the free driving mode
again.
Wire-guidance mode
Wire guidance is separately described. For details, see the section on
wire guidance.
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20.12.9 Braking
Braking of the truck is primarily achieved using both AC drive motors,
M1 and M2. Additionally, the truck may have been fitted with support
arm brakes, Y5 and Y6, positioned at the front support arm wheels.
Each drive motor is fitted with an electromechanical disc brake, Y1 and
Y2, which are used as a parking brake, emergency switch-off (ESO)
and in case of serious faults (see the section on error codes).
The maximum braking force is limited in the selected drive mode
depending on the stability of the truck, the selected drive mode and the
cabin height. When the truck brakes, the electronics regulates the
reversing power of the AC motors and the amount of support arm brake
application according to predefined slowdown curves. During braking,
the current generated by the AC motors is returned to the truck battery,
so-called regenerative braking.
The braking function always has higher priority than the travel functions.
Braking/slowdown is controlled in different ways:
- Automatic braking
- Reversing braking
- Braking with the brake button
- Releasing the right dead man's handle
- End-of-aisle slowdown/end-of-aisle stopping
- Personal protection system (PPS)
- Emergency switch-off
Safety monitoring
The components in the brake system are continuously monitored for
possible malfunction. If a fault should occur in the brake system, the
truck generates an alarm by displaying an error code and displaying the
STOP symbol on the ICP display. At the same time, the parking brakes
on both drive motors are applied to bring the truck to a complete stop.
The following components in the steering system are continuously
monitored during truck operation, and in case a fault occurs, the truck
enters the error mode.
1. The brake button micro-switch - both switches of the microswitch are compared by the ICP microprocessor. The signals
from both switches of the micro-switch must have opposite
status. If connector X103:14 is high, then connector X103:15
must be low, and vice versa.
2. When not applied, the parking brakes Y1 and Y2 are monitored
3. When applied, the support arm brakes Y5 and Y6 are monitored with regard to interruption and short-circuiting.
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4. The drive motor pulse transducers U11 and U14. While braking the drive motor speed reduction is monitored. If the drive
motor speed reduction does not correspond to the reduction
requested by the MCU, the parking brake is applied to stop the
truck.
NOTE!
Automatic braking
When the speed control R1 is partly or fully released, the drive motors
will brake the truck to the desired travel speed. The final speed
depends on the actual signal value received at ICP connector X103:11.
The ICP sends information about the signal value via CAN1 to the
MCU.
The MCU sends information about full motor braking according to
the predefined slowdown curves to the ACTL and ACTR via CAN2.
The ACTL and ACTR reduce the forwarding frequency in order that
the frequency becomes less than the frequency for the actual revolutions. In other words, a negative delay is achieved and the motors
will brake.
The ACTL and ACTR send information about the motor revolutions,
detected by the U11 and U14 sensors, via CAN2 to the MCU.
When the motor revolutions correspond to the travel speed requested by R1, the MCU will send information to the ACTL and ACTR via
CAN2 about the new, actual travel speed.
The braking force used for automatic braking can be adjusted using the
truck parameters and can also be deselected with the same parameter.
Adjustment range: 0-100%.
Parameter no.
Function
Parameter type
7, 17, etc.
Automatic braking
Operator
Reversing/Motor braking
When the operator changes the travel direction using the speed control
R1, the drive motors will brake the truck applying a braking force that
depends on the signal value received via ICP connector X103:11.
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Braking with the brake button (S48)

The brake button actuates the S48 micro-switch, which has two switches, one that is normally closed and one that is normally open.
When the brake button is depressed, the truck always brakes using the
maximum allowed braking force, however, still with consideration to the
stability of the truck.
When the operator depresses the brake button, the S48 microswitch is actuated. ICP connector X103:14 then goes high (+48 V)
while ICP connector X103:15 goes low (0 V).
The ICP sends information about thebraking request via CAN1 to
the MCU.
The MCU sends information about full motor braking according to
the predefined slowdown curves to the ACTL and ACTR via CAN2.
If the truck has been fitted with support arm wheel brakes, Y5 and
Y6, the MCU then adjusts the PWM current sent to the brakes in order that the combined braking force follows the predefined slowdown curves.
In this case, the braking force from the M1 and M2 drive motors will
be reduced.
The ACTL and ACTR reduce the forwarding frequency in order that
the frequency becomes less than the frequency for the actual revolutions. IN other words a negative delay is achieved and the motors
will brake.
The ACTL and ACTR send information about the motor revolutions,
detected by the U11 and U14 sensors, via CAN2 to the MCU.
If the operator keeps the brake button depressed, the truck will continue braking until it comes to a complete stop.
When the operator releases the brake button while the truck is still
travelling, the truck will continue motor braking until a new signal value is provided by R1 (reactuation).
Right dead man's handle released (S101)

When the right dead man's handle is deactuated/released, the truck
starts braking with full motor braking according to the predefined slowdown curves.
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End-of-aisle braking/End-of-aisle stopping

(options)
1. End-of-aisle braking
End-of-aisle braking is a customer option. The feature relies on twin
magneto switches to detect the magnets installed in the narrow aisle
floor.
Bistable magneto switches, S4/S9 and S123/S124, are installed on the
truck. Permanent magnets are installed in the narrow aisle floor.
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 the inching speed (2.5 km/h) the truck
must interrupt its travel and start to slow down. When the truck passes
the braking point, the warning buzzer in the ICP sounds for approx. 3
seconds.
When the travel speed equals inching speed or less, the truck will pass
the "braking point" without slowing down.
Slowdown is achieved by reversing the motors. When the truck travel
speed reaches zero or inching speed, depending on the parameter settings, slowdown is cancelled.
To continue to exit the narrow aisle, the speed control must be reactuated, i.e. it should be released and then actuated again. Reactuation
can be performed during the slowdown phase.
The maximum allowed travel speed permitted when exiting the narrow
aisle is half speed (4.0 km/h) until the truck has safely exited the narrow
aisle and the aislemagneto switches have been switched off.
If the truck enters the narrow aisle again without passing the aisle magnets, full narrow aisle travel speed is permitted.
2. End-of-aisle stopping
End-of-aisle stopping is a customer option, which stops the truck in the
aisle end zone, commonly "dead-end" narrow aisles with trucks both
entering and exiting.
The end-of-aisle stop feature only works together with end-of-aisle
braking.
The feature relies on twin photocells, S54 and S110, which detect
polarising reflections on the pillars of the racking. The reflection must
have a free line of sight across the entire stopping distance.
When the truck enters the stopping area, following slowdown, the truck
brakes to a complete stop by applying maximum allowed motor braking. Simultaneously the warning buzzer in the ICP sounds for approx. 3
seconds. Further travel in the same direction, against the obstruction, is
prevented.
If the truck enters the narrow aisle again, full narrow aisle travel speed
is permitted.
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Parameter no.
Function
Parameter
type
126
End-of-aisle braking
Service
127
End-of-aisle stopping
Service
Personal protection system (PPS)

The PPS system operates with slowdown/braking at two levels.
The first level with slowdown involves A26 closing the warning relay on
the logic card. Output A26/X1:7 goes high to +48 VDC and feeds voltage to MCU connector X131:31. Motor braking is applied and the
truck's travel speed slows down to inching speed (2.5 km/h).
The second level is complete stopping. A26 opens both safety relays,
and +48 VDC is removed from the A26 connectors X1:3 and X1:5. Also
the +48 V signal disappears at MCU connectors X131:3 and X131:17.
Maximum allowed motor braking is applied until the truck comes to a
complete stop.
The ICP displays the info symbol and the text AUTO STOP.
If the PPS override command is given (pushbutton under symbol), continued driving is allowed at inching speed for a duration of 10 seconds.
Emergency switch-off (ESO)

When one of the truck's emergency switch-off pushbuttons (S21, S22
or S23) is depressed, the voltage feed to chassis relay K18 is interrupted. When K18 opens, the voltage feed to Y1 and Y2 is interrupted, and
the parking brake is applied.
Also the K10 main contactor loses its voltage feed and opens. When
K10 and K18 have opened, the signal at MCU connectors X131:15 and
X131:6 is removed and the MCU processor stops sending command
information to ACTL, ACTR, ACH and DCHI.
Following emergency switch-off, the truck must be started anew
through log-in.
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Electrical description of the hydraulic functions
T-code
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919699-
Date
2005-11-28
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Parking brake
The parking brake is released when the left and/or right left dead man's
handle, S101 and/or S100 is actuated, and the speed control R1 is
actuated; the signal in ICP/X103:11 changes 15% from the calibrated
value. Also see the section on choosing the travel direction.
The parking brake is applied when the MCU detects travel speed as
zero, in the absence of CAN messages regarding pulses from U11
and U14 of the ACTL and ACTR, and when the speed control R1 is not
actuated; in this case the signal at ICP/X103:11 is equal to the calibrated value.
The parking brake is also applied with a delay of approx. 5 seconds
when the right dead man's handle (S101) is released.
20.13 Electrical description of the

hydraulic functions
The hydraulic functions of the truck are separated into two different
electrical systems: one system is used for cabin lifting and lowering and
is controlled by the MCU, while the other system covers the initial mast
functions, lifting/lowering, fork traversing and rotation through control
by the FCU. The cabin lift system relies on an AC pump motor, M3, and
its motor controller ACH, while the initial mast system relies on a DC
pump motor, M4, and its motor controller DCHI.
The cabin lift system has an auxiliary lifting system (ALS), which is a
closed system made up of one or two (depending on the Lifting height)
accumulators and a third lift cylinder. The purpose of the auxiliary lifting
system is to reduce energy consumption during cabin lifting. General
functioning of the auxiliary lifting system is not covered in detail in this
document. Only the pressure monitor function is explained. For a complete description of the ALS, see the hydraulic section of the manual, C
code 6000.
Here, we will fist describe allowed combined functions of the hydraulics, the general monitoring aspects and safety limits, upon which the
cabin lift system and initial mast system are dealt with.
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20.13.1 Allowed combined functions

As a result of the hydraulic and mechanical design of the truck, the following applies as to which hydraulic functions can be combined:
Cabin lifting/ Initial lifting/ Travers- Rotation Fork widening/ Fork

lowering
lowering
side-shifting
tilting
ing
Cabin lifting/
lowering
xxxxxxxx
Yes
No
No
No
No
Initial lifting/
lowering
Yes
xxxxxxxx
No
No
No
No
Traversing
No
No
xxxxxxxx
Yes
No
No
Rotation
No
No
Yes
xxxxxxxx
No
No
Fork widening/ No
side-shifting
No
No
No
xxxxxxxx
No
Fork tilting
No
No
No
No
xxxxxxxx
BT Europe AB
No
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20.13.2 Monitoring and functional limitations

Monitoring
When required, monitoring of each respective function is done in the
explanation of the function. In here, only the general monitoring functions for the hydraulic functions are described.
The following hydraulic function components are continuously monitored during truck operation, and in case a fault occurs, the truck enters
the error mode.
1. If the pump motor controllers ACH and DCHI or FCU detects
an error, an error code is sent to the MCU. The MCU blocks the
hydraulic functions and sends an error code to the ICP.
2. No hydraulic functions are allowed if CAN communication
with MCU is lost for more than 70 ms.
3. The MCU monitors the routing valves Y21 and Y29 for cabin
lifting with regard to interruption and short-circuiting.
4. The FCU monitors the proportional valve Y10 and the routing
valve Y11 for fork lifting/lowering with regard to interruption
and short-circuiting.
5. The FCU monitors the routing valves Y8 and Y9 as well as the
proportional valve Y25 for traversing with regard to interruption and short-circuiting.
6. The FCU monitors the proportional valves Y27 and Y28 for rotation with regard to interruption and short-circuiting.
NOTE!
Safety limitations
1. Cabin lifting/lowering is blocked in the following cases:
- Lifts made with low battery voltage.
- Lifting/lowering with open cabin gates above a programmed cabin height, < 3 m, set with parameter 102.
- Lifts exceeding 100 mm or 3 seconds when the slack chain
guards are engaged.
- Lowering if the slack chain guards are engaged.
- Lifts above a special height unless the bypass button has been
pressed.
- Lifts above a mechanical height, set with parameter 101.
- Lifting/lowering with manipulated dead man switches.
- Lifting/lowering without the right dead man's handle being actuated.
- Lifting/lowering without the left dead man's handle or the bypass
button being actuated in a narrow aisle.
- Lifting if the steering angle is >10o and the cabin height exceeds
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4.1 m.
- Lifting/lowering if the forks are not in the left or right home position.
NOTE:
The special function with cab lifting/lowering and forks set straight
ahead will bypass this limiter.
- Lifting/lowering if the ICP has detected an error in the cabin lift/

lowering switch during start-up.
2. Cabin lifting/lowering is reduced in the following cases:
- Close to a mechanical end stop.
- Close to a special height.
3. Initial lifting/lowering is blocked in the following cases:
- The ICP has detected an error in the switch button during startup.
4. Initial lifting is blocked in the following cases:
- The steering angle >10o and the cabin height exceeds 4.1 m.
5. Horizontal fork movements, traversing and rotation are
blocked in the following cases:
- The travel speed exceeds the inching speed (2.5 km/h).
- Cabin lifting or cabin lowering is engaged.
- The steering angle >10o and the cabin height exceeds 4.1 m.
- The ICP has detected an error in the switch button or the rotation
switch during start-up.
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20.13.3 Slack chain guard

The four lifting chains for cabin lifting are monitored by two pairs of
mechanical switches, S81/S82, connected in series and situated at the
bottom of mast. These are connected to MCU/X131:30 and S83/S84
on the cab, which in turn are connected to FCU/040
The slack chain guards (switches) monitor correct tensioning of the
cabin lift chains. If one of the chains become slack, one of the slack
chain guards opens. If S81 or S82 opens, this is detected by the MCU
through +48 V on the X131:30 connector, and the MCU subsequently
prevents cabin lowering movement.
If S83 or S84 opens, this is detected by the FCU through +48 V on the
040 connector, and the FCU subsequently sends a message about the
open slack chain guard via CAN1 to the MCU, which then prevents the
lowering movement.
Lifting movement of 100 mm or max. 3 seconds is allowed.
20.13.4 Height measurement

The height measurement feature measures the lifting height from the
lowest (floor) level to the highest fork position.
The height is measured using 2-phase pulse transducers built into ball
bearings. The transducers supply two pulse trains with a 90o phase offset, each phase generating 32 pulses per revolution.
The truck has two pulse transducers, U9 and U10, for height measurement. U9 is connected to the FCU and measures the fork height for initial lifting, while U10 is connected to the MCU and measures the cabin
height on the main mast.
A reference switch, S93, is used to calibrate the initial height measurement. Each time S93 passes the magnet, height measurement for initial lifting is calibrated to the value set in parameter 411. Measurement
of initial lifting commences when the height reference switch, S93, for
the first time after log-in passes the magnet installed on the initial mast.
A reference switch, S71, is used to calibrate the cabin height measurement. Each time S71 passes the magnets, height measurement for the
cabin height is calibrated to the value set in parameter 176. Measurement of cabin lifting commences when the height reference switch,
S71, for the first time after log-in passes the magnet installed on the initial mast.
When the forks are lifted, the pulse transducer U9 supplies pulses to
the FCU. This information is sent via CAN1 to the MCU, which records
the height information in a height register.
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The MCU records the actual cabin height, i.e. pulses from U10 during
cabin lifting, in another height register. The MCU calculates the current
fork lifting height and sends the current lifting height via CAN1 to the
FCU and, depending on the setting of parameter 160, the fork lifting
height or cabin height to the ICP for display on the display panel.
Upon log-out from or switch-off of the truck, the current height information is stored in the MCU EEPROM. During subsequent log-in or startup, the stored information is sent to the FCU.
Parameter no. Function
Parameter type
160
Height display method
Service
176
Height reference, cabin lifting
Service
411
Height reference, initial lifting
Service
Safety monitoring
To immediately detect any fault, height measurement is continuously
monitored during lifting and lowering. If a fault should occur, the truck
generates an alarm by displaying an error code and displaying the
WARNING symbol on the ICP display.
The following monitoring activities are covered by the height measurement system.
1. Pulse transducer U9. Presence of pulses and pulse direction
in relation to the function command are monitored. In case of
a fault, initial lifting is blocked and the travel speed is reduced
to inching speed (2.5 km/h).
2. Pulse transducer U10. Pulse speed and pulse direction in relation to expected lifting speed (pump motor speed) and function commands are monitored. In case of a fault, cabin lifting
is blocked and the travel speed is reduced to inching speed
(2.5 km/h).
3. The fork height on the initial mast is verified against the S93
reference height when S93 passes the magnet. If the height
deviates and is not within acceptable margins, initial lifting is
blocked and the travel speed is reduced to inching speed (2.5
km/h).
4. The cabin height is verified against the S71 reference height
when S71 passes the magnet. If the height deviates and is not
within acceptable margins, cabin lifting is blocked and the
travel speed is reduced to inching speed (2.5 km/h).
NOTE!
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20.13.5 Cabin lifting

To enable cabin lifting, the fork unit must first be returned to its home
position. Cabin lifting uses two speeds, which are achieved by depressing one of the two pushbuttons on the underside of the right dead man's
handle.
Lifting starts by first depressing the front pushbutton, S44. When S44 is
closed, connector ICP/X103:3 receives +48 V. The ICP sends information about the closed state of S44 via CAN1 to the MCU. The MCU
interprets this information as a command for cabin lifting/low travel
speed and sends a command for 60% pump motor revolutions, M3, to
the ACH via CAN2. M3 starts operating and the ACH adjusts the revolutions to the requested rpm. The M3 revolutions are measured using a
sensor, U12, and the actual value is returned via ACH/CAN2 to the
MCU.
S70
S44
If the rear pushbutton is depressed, S70 closes and connector ICP/

X103:1 also receives +48 V. The ICP sends information about S70 also
being closed via CAN1 to the MCU. The MCU sends a command to the
ACH to increase the adjustment of M3 to 100% pump motor revolutions. The rev increase is monitored by the MCU via ACH and U12.
Cabin lifting can be programmed with an electric lifting stop when the
pump motor stops. The maximum height is set with parameter 101.
Close to the maximum lifting height, the MCU will request a reduction of
the lifting speed to achieve smooth stopping.
To be able to lift the cabin above 3.0 m, the cabin gates must always be
closed. The micro-switches S87 and S88 monitor this state. It is possible to use parameter 102 to set a lower height at which the gates must
be kept closed.
If the battery guard has detected a remaining battery capacity level of
20% or less, cabin lifting will be prevented.
20- 158
Parameter no.
Function
Parameter
type
101
Max. cabin height
Service
102
Gate height
Service
Service Manual
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
Safety monitoring
The components in the cabin lifting system are continuously monitored
for possible malfunction. If a fault should occur in the lifting system, the
WARNING symbol on the ICP display.
At the same time cabin lifting is blocked and the travel speed is reduced
to inching speed (2.5 km/h).
The following components in the lifting system are continuously monitored during truck operation, and in case a fault occurs, the truck enters
the error mode.
1. If the ACH pump motor regulator detects a fault, an error code
is sent to the MCU. The MCU blocks the lifting function and
sends an error code to the ICP.
with the MCU is lost for more than 70 ms.
3. The M3 pump motor is monitored with regard to its operating
temperature.
4. The U12 pulse transducer in M3 is monitored with regard to interruptions in the transducer circuit, pulse frequency and
pulse direction.
5. The ACH pump motor regulator internally monitors the operating temperature, voltage level, current level and communication.
6. The height sensor U10, pulse speed and pulse direction in relation to expected lifting speed (pump motor speed) and function commands are monitored.
7. The hydraulic pressure in the lifting system is monitored via
the B5 pressure sensor.
8. The pressure in the auxiliary lifting system (ALS) is monitored
via the B6 pressure sensor.
NOTE!
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2005-11-28
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227761-040
20.13.6 Special height (lift limiter function)

A total of eight special heights can be programmed using the parameters: one parameter for travel outside narrow aisle and seven parameters for travel in narrow aisles.
Close to the programmed special height, the MCU will request a reduction of the lifting speed to achieve smooth stopping.
To continue lifting the cabin above a special height, the bypass command must be issued. This is achieved by keeping the pushbutton corresponding to the bypass symbol on the display depressed.
10:40
00:00
00:07
+
_
When the pushbutton is depressed in a narrow aisle, it replaces the left

dead man's handle, S100.
20- 160
Parameter
no.
Function
Parameter
type
110
Lift height limit outside narrow aisle
Service
112
Lift height limit 1 in narrow aisle
Service
113
Service
114
Service
115
Service
116
Service
117
Service
118
Service
Service Manual
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
20.13.7 Cabin lowering

To enable cabin lowering, the fork unit must first be returned to its home
position. During cabin lifting, the torque in M3 is used to brake the
hydraulic pump, thus generating current that is returned to the truck
battery, so-called regenerative lowering.
The operator can vary the lowering speed in two steps by depressing
the two pushbuttons on the underside of the right dead man's handle.
This causes a change in the braking torque in M3.
Prior to the lowering movement commencing, the lifting cycle is briefly
used to build up sufficient torque in M3 and sufficient hydraulic pressure
on the rear side of the lowering valves Y21 and Y29. The torque in M3
is used to brake the hydraulic pump.
Lowering starts by first depressing the rear pushbutton, S70. When S70
is closed, connector ICP/X103:1 receives +48 V. The ICP sends information about the closed state of S70 via CAN1 to the MCU.
The MCU interprets this information as a command for cabin lowering
and sends a command for generating hydraulic pressure to the ACH to
start M3 for lifting. The pressure sensor B5 detects the pump pressure
and the signal is received by the MCU via connector X130:3.
When the signal reaches the allowed level, the MCU sends a command
to the ACH to switch the rotational direction of M3, for 40% pump motor
revolutions, and for minus feedback to the lowering valves Y21 and
Y29 via connector X131:8. The ACH adjusts the revolutions in accordance with the requested revolutions. The M3 revolutions are measured
using a sensor, U12, and the actual value is returned via ACH/CAN2 to
the MCU.
S70
S44
If the front pushbutton is also depressed, S44 closes and connector

ICP/X103:3 also receives +48V. The ICP sends information about S44
also being closed via CAN1 to the MCU. The MCU sends a command
to the ACH to increase the adjustment of M3 to 100% pump motor revolutions. The rev increase is monitored by the MCU via ACH and U12.
The lowering speed is adjusted by the MCU/ACH in order to maintain
constant speed in disregard of the load.
When the cabin's bottom position is reached, the MCU requests
increased motor braking, and the braking torque increases to reduce
the lowering speed and thus achieve soft landing.
To be able to lower the cabin above 3.0 m, the cabin gates must always
be closed. The micro-switches S87 and S88 monitor this state. It is possible to use parameter 102 to set a lower height at which the gates must
be kept closed.
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T-code
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919699-
Date
2005-11-28
Order number
227761-040
Safety monitoring
The components in the cabin lowering system are continuously monitored for possible malfunction. If a fault should occur in the lifting system, the truck generates an alarm by displaying an error code and displaying the WARNING symbol on the ICP display.
At the same time cabin lowering is blocked and the travel speed is
reduced to inching speed (2.5 km/h).
The following components in the lifting system are continuously monitored during truck operation, and in case a fault occurs, the truck enters
the error mode.
1. If the ACH pump motor regulator detects a fault, an error code
is sent to the MCU. The MCU blocks the lowering function and
3. The MCU monitors the routing valves Y21 and Y29 with regard
to interruption and short-circuiting.
4. The M3 pump motor is monitored with regard to its operating
temperature.
5. The U12 pulse transducer in M3 is monitored with regard to interruptions in the transducer circuit, pulse frequency and
pulse direction.
6. The ACH pump motor regulator internally monitors the operating temperature, voltage level, current level and communication.
7. The height sensor U10, pulse speed and pulse direction in relation to expected lowering speed (pump motor speed) and
function commands are monitored.
9. The pressure in the auxiliary lifting system (ALS) is monitored
via the B6 pressure sensor.
NOTE!
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20.13.8 Special function with cab lifting/

lowering and forks set straight ahead
This function is intended for pallet handling at different levels when the
forks are set straight ahead.
Cab lifting/lowering is allowed when the forks are in the 90o home position pointing straight ahead, during which time the fork symbol in the
display lights with a steady yellow light in the straight ahead position.
Travel speed is reduced to max. inching speed (2.5 km/h).
BT Europe AB
Parameter
no.
Function
Parameter
type
161
Allows cab lifting/lowering with

forks in the straight ahead home
position
Service
Service Manual
20- 163

Turret head unit (T-code 712)
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
20.14 Turret head unit (T-code 712)

The movements of the turret head unit are adjusted and monitored by
the FCU. The FCU receives its input signals over CAN1 from the ICP
via the MCU, and the output signals are sent to the hydraulic valves and
the MCU for control of the M4 DC pump motor via the DCHI controller.
The FCU must control and monitor the following functions:
- Traversing of the forks, manual operation.
- Rotation of the forks, manual operation.
- Fork lifting/lowering, manual operation.
- Automatic fork rotation.
- Extra hydraulic functions (max. two extra hydraulic functions are
available).
- Position sensors, rotation and traversing.
- Height measurement, fork lifting.
- Weight of the load.
To activate the fork unit, the right "dead man's handle" (S101) must be
actuated, and in narrow aisles, the left "dead man's handle" (S100)
must also be actuated.
The maximum speeds for traversing, rotation and lifting/lowering as
well as weighing of the load can be learned by the truck and are
adjustable/settable in the calibration mode. For more details, see the
section on calibration.
Lifting, lowering, traversing and rotation have higher priority than the
commands for extra functions.
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Safety monitoring
The components in the turret head fork system are continuously monitored for possible malfunction. If a fault should occur in the system, the
STOP symbol on the ICP display.
At the same time the current fork movement is blocked and the travel
speed is reduced to inching speed (2.5 km/h), or, alternatively, the fork
movement speed is reduced to the speed for maximum load.
The following components in the turret head fork system are continuously monitored during truck operation, and in case a fault occurs, the
truck enters the error mode.
1. If the DCHI pump motor regulator detects a fault, an error code
is sent to the MCU. The MCU blocks the fork function and
3. The FCU monitors the routing valves Y8, Y9 and Y11 with regard to interruption and short-circuiting.
4. The FCU monitors the proportional valves Y10, Y25 and Y28
5. The height sensor U10, pulse speed and pulse direction in relation to expected lowering speed (pump motor speed) and
function commands are monitored.
7. The B7 pressure sensor is monitored with regard to interruptions in the circuit.
8. The U13 pulse transducer used for traversing is monitored
with regard to interruptions in the transducer circuit, pulse
frequency and pulse direction.
9. The R8 rotation potentiometer is monitored with regard to interruptions in the circuit and the charge level.
NOTE!
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2005-11-28
Order number
227761-040
Automatic switching of the turret head fork unit's

functions
Depending on the current travel mode, the MCU automatically switches
between allowed fork movements in a turret head unit with multiple
functions.
The truck can be in one of two different travel modes.
1. Travel mode Truck moving = travel speed >0.5 km/h
(>0.14 m/sec.)
The MCU only allows vertical fork movements, e.g. fork lifting/
lowering, fork tilting. Horizontal fork movements are blocked.
2. Travel mode Truck stopped = travel speed <0.5 km/h (<0.14
m/s)
The MCU selects the default function for horizontal fork

movement, e.g. traversing, rotation.
To enable vertical fork movements, the operator must issue a
shift command.
The function for both travel modes is described for each turret head fork
function.
Fork lifting/lowering
1. Fork lifting/lowering in the Truck moving travel mode
The MCU has selected fork lifting/lowering as the default function on
the R2 rocker switch.
R2
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Date
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2. Fork lifting/lowering in the Truck stopped" travel mode

To access the lifting/lowering function when the truck is at standstill, it is
necessary to first depress the function shift button S72; +48 V at connector ICP/X103:7. When lifting/lowering starts, the button can be
released.
R2
S72
3. Functional description of fork lifting

The rocker switch R2 has a nominal voltage feed of +5 V from the ICP/
X100:11 connector.
To lift the forks, the R2 switch should be pressed to the left. The voltage
then falls in connector ICP/X100:11. The adjustment range is 0 - -100%
(corresponding to approx. -0.9 V from the calibrated voltage value).
The current signal value is sent from the ICP to the MCU via CAN1 to
check whether fork lifting is allowed. The signal value is also sent via
CAN1 to the FCU. The FCU then waits for acknowledgement from the
MCU as to whether fork lifting is allowed.
When the R2 switch is actuated, the signal at ICP/X100:11 decreases
by 15% (corresponding to approx. -0.13 V), and the FCU requests the
MCU to start the pump motor M4 via DCHI. At the same time, the FCU
supplies +48 V on connector 005, the routing valve Y11 opens, and a
PWM voltage of 0-24 V on connector 016 is applied to the proportional
valve Y25 to adjust the lifting speed. The opening time for Y25 follows a
start ramp function, which is adjustable using parameter 406, in order to
adapt the lifting acceleration of the forks.
The more the R2 switch is actuated, the higher the voltage applied at
the ICP/X100:11 and the FCU accordingly changes the PWM voltage to
Y25 in relation to the current R2 signal level, i.e. a lifting speed of 0
100%. At the same time, the FCU sends a request to the MCU for adaptation of the pump motor revolutions. The MCU adjusts the DCHI to the
requested M4 setting. The maximum lifting speed is 0.30 m/sec. without any load and 0.25 m/sec. with maximum load.
Close to the programmed lifting height (mechanical stop), the lifting
movement is braked in order to achieve gentle stopping. The braking
ramp can be adjusted using parameter 407.
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2005-11-28
Order number
227761-040
When R2 is released to the neutral position, i.e. the calibrated value,

the proportional valve Y25 closes, i.e. the ramp set with parameter 407,
before the routing valve Y11 closes.
4. Functional description of fork lowering
X100:11 connector.
To lower the forks, the R2 switch should be pressed to the right. The
voltage then increases in connector ICP/X100:11. The adjustment
range is 0 - +100% (corresponding to approx. +0.9 V from the calibrated voltage value).
check whether fork lowering is allowed. The signal value is also sent via
MCU as to whether fork lowering is allowed.
When the R2 switch is actuated, the signal atICP/X100:11 increases by
15% (corresponding to approx. +0.13V) and the FCU applies a PWM
voltage of 0-24 V on connector 031 to the proportional valve Y10 in
order to adjust the lowering speed. The opening time for Y10 follows a
adapt the lowering acceleration of the forks.
The more the R2 switch is actuated, the lower the voltage applied at the
ICP/X100:11 and the FCU accordingly changes the PWM voltage to
Y10 in relation to the current R2 signal level, i.e. a lowering speed of 0
100%. The maximum lowering speed is 0.30 m/sec. in disregard of the
load.
Close to the bottom of the initial mast (mechanical stop), the lowering
When the R2 switch is released to the neutral position, i.e. the calibrated value, proportional valve Y10 closes, i.e. the ramp set with parameter 409.
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Parameter
no.
Function
Parameter
type
400
Piston stroke, fork lifting
Service
406
Acceleration ramp, lifting
Service
407
Braking ramp, lifting
Service
408
Acceleration ramp, lowering
Service
409
Braking ramp, lowering
Service
414
Max. lift speed
Service
415
Max. lowering speed
Service
Measuring the load weight

The weight of the load is measured using the pressure sensor B7 in the
fork lifting system. It senses the hydraulic pressure in the initial cylinder
circuit. The B7 sensor receives a voltage of +5 V from the FCU connector 002, and according to the weight of the load, a voltage of +0.5 V (0
bar) to +5 V (250 bar) is obtained in the FCU at connector 014.
The FCU calculates the current weight of the load, based on the voltage
at connectors 014, and it sends this information to the MCU via CAN1.
The MCU subsequently sends the information to the ICP via CAN1.
The weight of the load is shown on the ICP display with a margin of tolerance of 20 kg.
The display indication range is 200 kg - 1,500 kg.
The FCU uses the information about the weight of the load to limit the
maximum speed of traversing and rotation movement, and the MCU
uses the information about the weight of the load to adapt maximum
travel speed and braking force of the truck.
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Date
2005-11-28
Order number
227761-040
Side shifting/traversing of the forks

1. Traversing in the Truck moving travel mode
Fork traversing is blocked during truck travel.
If traversing movement has commenced prior to the truck starting to
travel, the traversing is allowed as long as the travel speed does not
exceed inching speed (2.5 km/h).
2. Traversing in the Truck stopped" travel mode
The MCU has selected fork traversing as the default function on the R2
rocker switch.
R2
3. Functional description
X100:11 connector.
To make the forks move laterally, i.e. traversing, to the left or right, the
left rocker switch, R2 should be pressed to the left or right.
To traverse to the right, the R2 switch should be pressed to the right.
The voltage then increases in connector ICP/X100:11. The adjustment
To traverse to the left, the R2 switch should be pressed to the left. The
voltage then falls in connector ICP/X100:11. The adjustment range is 0
- -100% (corresponding to approx. -0.9 V from the calibrated voltage
value).
check whether traversing is allowed. If traversing is allowed, i.e. the
truck is in the Truck stopped mode, the MCU sends the signal value
via CAN1 to the FCU.
When the R2 switch is actuated, the signal on ICP/X100:11 increases/
decreases by 15% (corresponding to approx. +0.13 V/-0.13 V), and the
FCU requests the MCU to start the pump motor M4 via DCHI.
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When traversing to the right, the FCU supplies +48 V at connector 004,
and routing valve Y8 opens, while when traversing to the left +48 V is
supplied at connector 017, and the routing valve Y9 opens. At the same
time the FCU applies a PWM voltage of 0-24 V on connector 016 to the
proportional valve Y25 in order to adjust the traversing movement
speed. The opening time for Y25 follows a start ramp function, which is
adjustable using parameter 402, in order to adapt the traversing acceleration of the forks.
Y25 in relation to the current R2 signal level, i.e. a traversing speed of
0100%. At the same time, the FCU sends a request to the MCU for
adaptation of the pump motor revolutions. The MCU adjusts the DCHI
to the requested M4 setting.
The traversing speed is automatically adapted from min. 0.18-0.4 m/
sec. depending on the current weight of the load (signal from B7) and
the cabin height.
Traversing movement is measured using a two-channel pulse sensor,
U13. U13 receives +15 V from the FCU at connector 028 and it supplies
two pulse trains which are 90 phase offset. The voltage level is approx.
+7.5 V per channel at max. traversing speed at FCU connectors 008
and 009.
Close to the traversing end stop, the speed is braked to achieve gentle
stopping. The braking ramp can be adjusted using parameter 403. The
current piston stroke can be programmed using parameter 401.
An inductive sensor, S50, detectsthe metallic end plates at the end
stops of the traversing movement. S50 closes and supplies a +15 V signal at connector FCU/010.
When R2 is released to its neutral position, i.e. the calibrated value, the
proportional valve Y25 closes before the routing valves closes. Braking
depends on how quickly R2 is released to the neutral position.
If the forks are in the home position when logging out/switching off the
truck, the position is stored in the MCU. When later starting the truck
again, the information is sent back to the FCU.
If the forks are not in the home position when truck is started, or if the
MCU was unable to store the home position, the system has no information about the traversing position. In this system state, only inching
speed is allowed for truck travel and fork movement. To achieve full
speed, the home position needs to be recalibrated.
To calibrate the home position, traversing must be done against the
mechanical stop, with the forks turned inwards, for a brief interval.
The left home position is used as a the traversing home position.
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2005-11-28
Order number
227761-040
Parameter no.
Function
Parameter type
401
Stroke length
Service
402
Acceleration ramp, start
Service
403
Braking ramp, end stop
Service
412
Max. traversing speed
Service
Fork rotation
1. Fork rotation in the Truck moving travel mode
Fork rotation is blocked during truck travel.
If rotation movement has commenced prior to the truck starting to travel, the rotation is allowed as long as the travel speed does not exceed
inching speed (2.5 km/h).
2. Fork rotation in the Truck stopped" travel mode
The MCU has selected fork rotation as the default function for the S74
and S80 pushbuttons.
S74
S80
S72
3. Functional description, General

Fork rotation uses two speeds, which are achieved by depressing one
of the two pushbuttons on the underside of the left dead man's handle.
The rotation speed for 180o rotation is automatically adapted, 6.0-10 m/
sec., depending on the current weight of the load (signal from B7) and
the cabin height.
The rotation angle of the forks is measured using a potentiometer, R8,
which is placed at the top of the fork unit. The potentiometer receives
+5 V and its end stop position value is learned in the calibration mode.
Close to the rotation end stop, the speed is braked to achieve gentle
stopping. The braking ramp can be adjusted using parameter 405.
The home position for full rotation clockwise is used as the rotation
home position.
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4. Functional description, clockwise rotation (right)

Clockwise rotation, to the right, is started by pushing the front pushbutton, S74. When S74 is closed, connector ICP/X100:3 receives +48 V.
The ICP sends information about S74 being closed to the MCU, and the
MCU verifies whether fork rotation is allowed. If rotation is allowed, i.e.
the truck is in the Truck stopped mode, the MCU sends the signal value via CAN1 to the FCU. The FCU requests the MCU to start the pump
motor M4 via DCHI.
The MCU sends a command for 60% pump motor revolutions, in M4, to
the DCHI via CAN2. The M4 starts operating and the DCHI adjusts the
revolutions to the requested rpm.
At the same time, the FCU supplies a PWM voltage (0-24 V) at connector 003, via the K18 relay (switches in neutral position), to the Y28 proportional valve to adjust the rotation speed, max. 50% of the calibrated
adjustable using parameter 404, in order to adapt the rotational acceleration of the forks.
If the rear pushbutton is depressed, S80 closes and connector ICP/
being closed via CAN1 to the MCU. The MCU sends this information to
the FCU, which then increases the PWM voltage to Y28. The voltage
increase follows a start ramp (parameter 404) until 100% rotation
speed has been reached.
5. Functional description, counterclockwise rotation (left)
Fork rotation uses two speeds, which are achieved by depressing one
of the two pushbuttons on the underside of the left dead man's handle.
Counterclockwise rotation, to the left, is started by pushing the rear
pushbutton, S80. When S80 is closed, connector ICP/X100:3 receives
+48 V. The ICP sends information about S80 being closed to the MCU,
and the MCU verifies whether fork rotation is allowed. If rotation is
allowed, i.e. the truck is in the Truck stopped mode, the MCU sends
the signal value via CAN1 to the FCU. The FCU requests the MCU to
start the pump motor M4 via DCHI.
The FCU supplies +48 V at connector 006 to relay K18, and K18 then
closes the circuit for FCU PWM voltage (0-24 V) at connector 003 to
proportional valve Y27 in order to adjust the rotation speed, max. 50%
of the calibrated speed. The opening time for Y27 follows a start ramp
function, which is adjustable using parameter 404, in order to adapt the
rotational acceleration of the forks.
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If the front pushbutton is depressed, S74 closes and connector ICP/

being closed via CAN1 to the MCU. The MCU sends this information to
the FCU, which then increases the PWM voltage to Y27. The voltage
increase follows a start ramp (parameter 404) until 100% rotation
Parameter
no.
Function
Parameter
type
404
Service
405
Service
413
Rotation speed, high speed range
Service
416
Rotation speed, low speed range
Service
417
Height-dependent speed reduction
Service
20.14.1 Auto rotation

Auto rotation is a function in which the forks traverse and rotate automatically according to a pre-programmed geometric course. This geometric course generates optimum traversing movement in relation to
the rotational change. The traversing and rotation speeds are individually and automatically adapted in order that the centre position between
the forks should trace the programmed geometric course.
Two types of auto rotation can be requested: 180 degree rotation and
90 degree rotation. The functions covered by auto rotation, i.e. fork
rotation and fork traversing, have functions and ramps according to the
above descriptions for rotation and traversing of the forks.
The auto rotation functions can be activated using the parameters in
the service mode. For more information, see the section "Verification/
adjustment parameters".
Auto rotation is selected by keeping the pushbutton under the auto rotation symbol on the ICP display depressed. If both auto rotation angles
have been set with the parameters, two symbols are displayed. This
switches the truck computer to the auto rotation mode. Information
about requested auto rotation movement is then sent from the ICP via
CAN1 to the FCU via the MCU.
The direction of movement is selected with the R2 rocker switch.
Depending on the position of R2, a low or high auto rotation speed is
achieved. The speeds can be separately adjusted using the truck
parameters. Auto rotation only works if the forks are in the left or right
home position.
NOTE!
The auto rotation function follows the traversing direction.
It is possible to vary the auto rotation start angle, i.e. the rotation angle
prior to allowing traversing to start.
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The rotation position and speed is measured using potentiometer R8.

The traversing speed is measured using the sensor U13. The pump
motor M4 operates at fixed revolutions.
1. 180o auto rotation
10:40
00:00
00:07
+
_
When the pushbutton under the 180o display symbol is depressed and
the R2 rocker switch is actuated, the forks rotate through the full rotation stroke and also traverse through the full stroke.
2.
90 auto rotation stopping straight ahead
10:40
00:00
00:07
+
_
When the pushbutton under the 90o display symbol is depressed and
the R2 rocker switch is actuated, auto rotation stops with the forks in the
straight-ahead position and the forks only traverse half a stroke.
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2005-11-28
Order number
227761-040
Parameter
no.
Function
Parameter
type
132
Auto rotation activation, 180
Service
133
Auto rotation activation, 90
Service
418
Auto rotation speed, low speed
Service
419
Auto rotation speed, high speed
Service
420
Setting the angle at which traversing is allowed to start
Service
421
Monitoring consistency with the

programmed geometric course
Service
20.14.2 Miscellaneous electrical functions

Warning lamp
The warning lamp, H2, at the rear of the truck lights when the right dead
man's handle, S101, is engaged. The MCU sends minus feedback to
H2 at connector X131:21. This is an LED type lamp with a blinking frequency of 2 Hz.
Personal protection system (PPS)

The truck has been prepared for connection to a personal protection
system, e.g. TBM.
PPS sends braking commands to the MCU for stopping or speed
reduction at connector MCU/X131:3, X131:17 and X131:31.
PPS receives information about the truck travel status from the MCU:
travel direction at connector MCU/X131:10 (forward) and X131:24
(reverse), narrow aisle mode at connector MCU/X131:38 and bypass at
connector MCU/X131:22.
Regarding connection to the PPS, see electrical wiring diagram 23.
For a complete description of the internal PPS functions, please refer to
the instructions from the supplier of the system mounted on the truck.
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20.14.3 Narrow aisle ID system

The ID system is designed to automatically control the seven (7) programmable lift height limits.
ID system operation is controlled by parameter 111 for multi-level stopping or single-level stopping.
Three photocell detectors, S172, S173 and S174, are installed on the
truck mast. The photocells read a binary code, on reflecting tape, when
entering the narrow aisle but before passing the aisle transmitter. The
three photocells can provide up to a total of seven (7) binary codes to
the MCU. These codes control the lift height limiter.
The codes determine the lift height limits according to the table below
and depending on the set value of parameter 111.
Binary
code
Combination
of photocell
detectors
Active MCU inputs
Lift height limit no.:
S172
X130:41
1-7
S173
X131:2
2-7
S172 + S173
X130:41 + X131:2
3-7
S174
X131:16
4-7
S172 + S174
X130:41 + X131:16
5-7
S173 + S174
X131:2 + X131:16
6-7
S172 + S173 +
S174
X130:41 + X131:2 +
X131:16
Parameter value 1 Parameter value 2
Example of parameter value 1:

Binary code 5.
Results in lift height limit no. 5, 6 and 7.
When set to bypass or stop according to the configuration parameters for each lift height limit.
Example of parameter value 2:

Binary code 5.
Results in lift height limit no. 5.
When set to bypass or stop according to the configuration parameters for each lift height limit.
NOTE:
Lift height limit 1 must always be used for the lowest lift height.
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2005-11-28
Order number
227761-040
20.14.4 Alternative narrow aisle system

The truck can be adapted for different narrow aisle systems (BT, Jungheinrich/Dambach) and aisle detection by using wire guidance.
Parameter
no.
Function
Parameter
type
144
Narrow aisle system
Service
144:11
BT narrow aisle layout
Service
144:22
Jungheinrich/Dambach narrow
aisle layout
Service
144:91
Aisle detection when locked on

wire,
BT EOA magnets
Service
144:92

wire,
Jungheinrich/Dambach EOA
magnets
Service
Narrow aisle type

Type 1) BT layout
To set the truck to the narrow aisle mode, four bistable magneto
switches have been mounted under the truck, S5/S7 on the front chassis (fork direction) and S6/S8 on the rear chassis (drive wheel direction). Both switches, in the S5/S7 or S6/S8 pair, must be switched on in
order to set the truck to the narrow aisle mode.
Type 2) Jungheinrich/Dambach layout
switches have been mounted under the truck on the front chassis (fork
direction) S5/S7 and S139/S140. Both switches, in the S5/S7 pair (travel in fork direction) or S139/S140 pair (travel in drive wheel direction),
must be activated in order to set to the truck to the narrow aisle mode.
Type 3) Narrow aisle detection using the wire (no magnets used for
aisle detection)
When the truck has locked onto the wire, it is regarded as set to the narrow aisle mode. The narrow aisle indicator lights up in the ICP display
as a confirmation.
Truck without end-of-aisle braking:
The maximum travel speed is limited to 8 km/h.
It is only possible to switch off wire guidance when the current travel
speed is zero, in which case manual steering will be reengaged.
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Truck equipped with end-of-aisle braking:

When the truck enters the narrow aisle and passes the end-of-aisle
braking magnet, the signal from these switches goes high. The truck is
now travelling in the "aisle centre" zone with a maximum travel speed of
10 km/h permitted.
It is not possible to switch off wire guidance when the truck is in the centre zone of the narrow aisle.
NOTE:
The S9/S123 and S137/S138 sensors are mono-stable magneto
switches to match the magnets in a Jungheinrich/Dambach layout.
BT Europe AB
Service Manual
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Shuttle fork unit (t-code 713)
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
20.15 Shuttle fork unit (t-code 713)

The movements of the shuttle forks are adjusted and monitored by the
FCU. The FCU receives its input signals over CAN1 from the ICP via
the MCU and the output signals are sent to the hydraulic valves and the
MCU for control of the M4DC pump motor via the DCHI controller.
The FCU must control and monitor the following functions:
Traversing of the forks
Fork lifting/lowering
To activate the fork unit the right dead mans handle (S101) must be
actuated, and in narrow aisles, the left dead mans handle (S100)
must also be actuated.
The maximum speeds for traversing and lifting/lowering as well as
weighing of the load can be learned by the truck and are adjustable/
settable in the calibration mode. For more details, see the section on
calibration. Lift, low and traversing have higher priority than the optional
function command.
20.15.1 Traversing of the forks

Fork traversing is blocked during truck travel.
The MCU has selected fork traversing as the default function on the R2
rocker switch.
R2
Functional description
X100:11 connector.
To make the forks move laterally, i.e. traversing, to the left or right, the
left rocker switch, R2 should be pressed to the left or right.
To traverse to the right, the R2 switch should be pressed to the right.
The voltage then increases in connector ICP/X100:11. The adjustment
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Date
2005-11-28

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712, 713
To traverse to the left, the R2 switch should be pressed to the left. The
voltage then falls in connector ICP/X100:11. The adjustment range is 0
- -100% (corresponding to approx. -0.9 V from the calibrated voltage
value).
check whether traversing is allowed. If traversing is allowed, i.e. the
truck is in the Truck stopped mode, the MCU sends the signal value
via CAN1 to the FCU.
When the R2 switch is actuated, the signal on ICP/X100:11 increases/
decreases by 15% (corresponding to approx. +0.13 V/-0.13 V), and the
FCU requests the MCU to start the pump motor M4 via DCHI.
When traversing to the right, the FCU supplies +48 V at connector 004,
and routing valve Y8 opens, while when traversing to the left +48 V is
supplied at connector 017, and the routing valve Y9 opens. At the same
time the FCU applies a PWM voltage of 0-24 V on connector 016 to the
proportional valve Y25 in order to adjust the traversing movement
adjustable using parameter 402, in order to adapt the traversing acceleration of the forks.
Y25 in relation to the current R2 signal level, i.e. a traversing speed of
0100%. At the same time, the FCU sends a request to the MCU for
adaptation of the pump motor revolutions. The MCU adjusts the DCHI
to the requested M4 setting.
The traversing speed is automatically adapted from min. 0.18-0.4 m/
sec. depending on the current weight of the load (signal from B7) and
the cabin height.
Traversing movement is measured using a two-channel pulse sensor,
U13. U13 receives +15 V from the FCU at connector 028 and it supplies
two pulse trains which are 90 phase offset. The voltage level is approx.
+7.5 V per channel at max. traversing speed at FCU connectors 008
and 009.
Close to the traversing end stop, the speed is braked to achieve gentle
stopping. The braking ramp can be adjusted using parameter 403. The
overall traverse fork stroke lenght is set when calibrating traverse. The
traverse stroke lenght can be limited by using parameter 429.
An inductive sensor, S50, detects the metallic plate at the center stop of
the traversing movement. S50 closes and supplies a +15 V signal at
connector FCU/010.
When R2 is released to its neutral position, i.e. the calibrated value, the
proportional valve Y25 closes before the routing valves closes. Braking
depends on how quickly R2 is released to the neutral position.
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Date
2005-11-28
Order number
227761-040
If the forks are in the home position when logging out/switching off the
truck, the position is stored in the MCU. When later starting the truck
again, the information is sent back to the FCU.
If the forks are not in the home position when truck is started, or if the
MCU was unable to store the home position, the system has no information about the traversing position. In this system state, only inching
speed is allowed for truck travel and fork movement. To achieve full
speed, the home position needs to be recalibrated.
To calibrate the home position, traversing must be positioned at the
centre position.
Parameter no.
Function
Parameter type
402
Service
403
Service
412
Service
20.15.2 Fork lifting/lowering

S74
S80
S72
Lifting
The MCU has selected fork lifting as the default function for the S74
pushbutton and fork lowering for the S80 pushbutton. Movement
speeds are specified to lifting 0,25 m/s without load and 0,20 m/s with
maximum load. Movement speeds are specified to lowering 0,30 m/s.
Lifting is started by pushing the lift pushbutton S74. When S74 is
closed, connector ICP/X100:3 receives +48 V. The ICP sends information about S74 being closed to the MCU, and the MCU verifies whether
lifting is allowed. If lifting is allowed the MCU sends the signal value via
CAN1 to the FCU. The FCU requests the MCU to start the pump motor
When the S74 switch is actuated, the signal at ICP/X100:11 decreases
by 15% (corresponding to approx. -0.13 V), and the FCU requests the
MCU to start the pump motor M4 via DCHI. At the same time, the FCU
supplies +48 V on connector 005, the routing valve Y11 opens, and a
PWM voltage of 0-24 V on connector 016 is applied to the proportional
valve Y25 to adjust the lifting speed. The opening time for Y25 follows a
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Date
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adapt the lifting acceleration of the forks.
The more the S74 switch is actuated, the higher the voltage applied at
Y25 in relation to the current S74 signal level, i.e. a lifting speed of 0
100%. At the same time, the FCU sends a request to the MCU for adaptation of the pump motor revolutions. The MCU adjusts the DCHI to the
requested M4 setting. The maximum lifting speed is 0,25 m/sec. without any load and 0.20 m/sec. with maximum load.
If also S80 is depressed S80 closes and connector ICP/X100:1 also
receives +48 V. The ICP sends information about S80 also being
closed via CAN1 to the MCU. The MCU sends this information to the
FCU, which then increases the PWM voltage to Y25. The voltage
increase follows a start ramp (parameter 404) until 100% lifting speed
has been reached.
Lowering
Lowering, is started by pushing the rear pushbutton, S80. When S80 is
closed, connector ICP/X100:1 receives +48 V. The ICP sends information about S80 being closed to the MCU, and the MCU verifies whether
fork lowering is allowed. If lowering is allowed, the MCU sends the signal value via CAN1 to the FCU.
check whether fork lowering is allowed. The signal value is also sent via
MCU as to whether fork lowering is allowed.
When the S80 switch is actuated, the signal at ICP/X100:11 increases
by 15% (corresponding to approx. +0.13V) and the FCU applies a
PWM voltage of 0-24 V on connector 031 to the proportional valve Y10
in order to adjust the lowering speed. The opening time for Y10 follows
a start ramp function, which is adjustable using parameter 408, in order
to adapt the lowering acceleration of the forks.
The more the S80 switch is actuated, the lower the voltage applied at
Y10 in relation to the current S80 signal level, i.e. a lowering speed of
0100%. The maximum lowering speed is 0.30 m/sec. in disregard of
the load.
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T-code
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919699-
Date
2005-11-28
Order number
227761-040
If also S74 is depressed, S74 closes and connector ICP/X100:1 also

receives +48 V. The ICP sends information about S74 also being
closed via CAN1 to the MCU. The MCU sends this information to the
FCU, which then increases the PWM voltage to Y10. The voltage
increase follows a start ramp (parameter 404) until 100% lowering
Close to the bottom of the initial mast (mechanical stop), the lowering
When the S80 is released i.e. the calibrated value, proportional valve
Y10 closes, i.e. the ramp set with parameter 409.
Parameter
no.
Function
Parameter
type
406
Lift acc. ramp slope
Service
407
Lift end ramp slope
Service
408
Low acc. ramp slope
Service
409
Low end ramp slope
Service
414
Lift top speed
Service
415
Low top speed
Service
418
Lower end speed
Service
Measuring the load weight

The weight of the load is measured using the pressure sensor B7 in the
fork lifting system. It senses the hydraulic pressure in the initial cylinder
circuit. The B7 sensor receives a voltage of +5 V from the FCU connector 002, and according to the weight of the load, a voltage of +0.5 V (0
bar) to +5 V (250 bar) is obtained in the FCU at connector 014.
The FCU calculates the current weight of the load, based on the voltage
at connectors 014, and it sends this information to the MCU via CAN1.
The MCU subsequently sends the information to the ICP via CAN1.
The weight of the load is shown on the ICP display with a margin of tolerance of 20 kg.
The FCU uses the information about the weight of the load to limit the
maximum speed of traversing and rotation movement, and the MCU
uses the information about the weight of the load to adapt maximum
travel speed and braking force of the truck.
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Wire guidance
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
20.16 Wire guidance

20.16.1 General
The wire guidance system is an option that can be added to the truck's
electrical control system.
The standard truck system uses the logics and control system of the
main logic card.
Additional components required to make the wire guidance system
complete include the WG filter card, an antenna mounted on the front
chassis and another antenna on the rear chassis.
Error messages relating to the wire guidance system are stored in the
MCU error code register and are sent via CAN1 to the ICP for display in
the display panel.
See the section on error codes.
The system has a learning function and automatically adapts to the frequency and amplitude of the wire.
Frequencies within a range of 1 to 10 kHz and amplitudes in the range
of 14 mA to 1900 mA RMS are covered.
20.16.2 Wire guidance components

MCU
The WG filter card is fully integrated in the MCU, however, MCUs prepared for wire guidance have a special order number in order to distinguish them from the standard MCU. See the Quality Parts booklet.
Following installation of a new MCU, it is necessary to download the
firmware, to set the parameters and perform calibration. See the section on calibration and parameters.
Antennas, W1 and W2
Two antennas are installed on the truck: W1 in the fork direction and
W2 in the steering wheel direction.
It is important that the antennas are installed on the truck's centre line
(+/- 5 mm) and are mounted in the correct direction.
To eliminate external interference of the antenna signals, the antennas
are connected via a shielded wire with 9 conductors.
BT Europe AB
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Wire guidance
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
W1
50 mm
W2
Each antenna consists of four coils, which detect the magnetic field of
the cable buried in the ground. The signals from the coils are amplified
by a pre amp card in the antenna and are later processed by the MCU
filter card.
The nominal antenna mounting height is 50 mm above floor level.
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Order number
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Date
2005-11-28

919699-
T-code
712, 713
Installing a new antenna

1. Front antenna W1
Lift up the cabin to gain access to the antenna.
Remove the protection plates around the antenna.
Loosen the antenna cable.
Loosen the antenna from the mounting plate.
Install a new antenna on the mounting plate.
Verify the antenna height with a 50 mm spacer and make the necessary adjustments.
Connect the antenna cable.
2. Rear antenna W2
Open the battery cover and remove the battery to gain access to the
antenna.
Loosen the antenna cable.
Unscrew the complete antenna mount assembly from the chassis.
Install a new antenna on the mount assembly, and then reinstall the
assembly on the truck.
Use a 50 mm spacer to determine the correct antenna height and
tighten the mounting bolts.
Connect the antenna cable.
NOTE!
Following installation of a new antenna, the antenna offset must be
recalibrated. For more details, see the section on calibration.
Steering angle sensor R7
R7
R7 is actively used in the wire guidance mode since the steering angle
value is continuously used by the MCU to calculate optimum wire tracking.
The angle sensor's basic settings for steering straight and straight articulated centre are determined in the calibration mode, while in the
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Service Manual
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Wire guidance
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Learn offset mode, the truck 'learns' angle deviations in the wire guidance adjustment mode. For more details, see the section on calibration.
Activation switch
In the operator's cabin, on the left side of the ICP, there is a switch,
S120, used for wire guidance. This must be engaged prior to entering a
narrow aisle.
Narrow aisle mode
S120
The truck can be adapted for different narrow aisle systems (BT, Jungheinrich/Dambach) and aisle detection by using wire guidance.
Parameter
no.
Function
Parameter
type
144
Narrow aisle system
Service
144:11
BT narrow aisle layout
Service
144:22
Jungheinrich/Dambach narrow
aisle layout
Service
144:91

wire,
BT EOA magnets
Service
144:92

wire,
Jungheinrich/Dambach EOA
magnets
Service
Narrow aisle type

Type 1) BT layout
switches have been mounted under the truck, S5/S7 on the front chassis (fork direction) and S6/S8 on the rear chassis (drive wheel direction). Both switches, in the S5/S7 or S6/S8 pair, must be switched on in
order to set the truck to the narrow aisle mode.
Type 2) Jungheinrich/Dambach layout
switches have been mounted under the truck on the front chassis (fork
direction) S5/S7 and S139/S140. Both switches, in the S5/S7 pair (travel in fork direction) or S139/S140 pair (travel in drive wheel direction),
must be activated in order to set to the truck to the narrow aisle mode.
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Wire guidance
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
Type 3) Narrow aisle detection using the wire (no magnets used for
aisle detection)
When the truck has locked onto the wire, it is regarded as set to the narrow aisle mode. The narrow aisle indicator lights up in the ICP display
as a confirmation.
Truck without end-of-aisle braking:
The maximum travel speed is limited to 8 km/h.
It is only possible to switch off wire guidance when the current travel
speed is zero, in which case manual steering will be reengaged.
Truck equipped with end-of-aisle braking:
When the truck enters the narrow aisle and passes the end-of-aisle
braking magnet, the signal from these switches goes high. The truck is
now travelling in the "aisle centre" zone with a maximum travel speed of
10 km/h permitted.
It is not possible to switch off wire guidance when the truck is in the centre zone of the narrow aisle.
NOTE:
The S9/S123 and S137/S138 sensors are mono-stable magneto
switches to match the magnets in a Jungheinrich/Dambach layout.
BT Europe AB
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Wire guidance
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
20.16.3 Functional description

The wire guidance system has three basic operation modes:
the Run mode, Service mode and Learn mode.
The Service mode is used to set the parameters for setting the limit values of the wire guidance system. See the section on parameters.
Learn mode is used by the truck to learn the control signals in the
wire guidance system. See the section on calibration.
Run mode
The Run mode is the normal operating mode and is selected by
default when the truck is started.
The MCU operates in the manual and auto operating modes. Switching
from the manual mode to the auto mode is controlled by a signal pulse
from S120.
In the auto mode, there are three operating states: Seeking wire, Tracking wire and Locked on wire.
Seeking wire: The operator steers the truck manually towards the wire
with a max. angle of approx. 20. When the W1 or W2 antenna
approaches the wire, the operator depresses the S120 switch to
request wire guidance. The ICP then detects +48 V at connector
X100:9, and it sends a message to the MCU about wire guidance having been requested. The WG logics of the MCU starts seeking the wire.
The wire indication (the dashed line under the truck symbol in the display) lights and starts blinking.
10:40
00:00
00:07
<20o
The maximum speed while Seeking wire is 2.5 km/h (i.e.. inching
speed) in both the fork and drive wheel direction. The maximum
approach angle in both directions is 20.
Tracking wire: The MCU has detected the wire via the antennas. The
display indication is still blinking.
When the first antenna detects the magnetic field, a signal is sent from
J1:2 / J1:3 to the MCU connector X132/23/X132:4 or alternatively
X132:29/X132:10, and the MCU switches to the auto mode. The MCU
now switches from manual steering to auto steering and steers based
on the antenna signal strength.
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Wire guidance
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
The MCU adjusts the steering set point based on the information
received from the steering angle sensor, i.e. potentiometer R7, until
both truck antennas are right above the wire and the articulated centre
stands straight.
Locked on wire: The truck is right above the wire with both antennas.
The wire indication in the display lights steadily.
The truck now steers automatically in the 2-antenna mode. The truck
adjusts the steering in order to maintain the signal level in the antenna
coils, which the system has "learned" in the Learn mode. Deviations in
the angle and lateral direction are continuously calculated based on the
signal levels of the antenna coils and steering angle sensor.
When the truck is locked on the wire and runs in the narrow aisle, wire
guidance cannot be switched off. The MCU ignores all messages from
the ICP after it has received the signal from S120.
The maximum speed allowed when the truck is locked on the wire is
10.0 km/h (full speed) in both directions in narrow aisles. Outside narrow aisles, when the truck is locked on the wire, the speed is reduced.
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Display
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
20.17 Display
The display can be set to different display modes: normal, information
and service mode. Here, we describe the functionality for the normal
mode and the information mode. How to use the service mode is
described in the sections on calibration, parameter setting and error
code handling.
20.17.1 Normal mode

In the normal mode, different symbols are displayed depending on the
current use of the truck.
10:40
00:00
00:07
+
_
1. Pop-up symbols
This display area shows various graphics depicting the fork function
(horizontal/vertical movement) of the left controller as well as for controls with corresponding pushbutton functions. It also shows symbols
and a code in case of an error.
2. Narrow aisle indication
This indicates that the truck is travelling in a narrow aisle.
On a wire guided truck, the dashed line symbol blinks when the truck is
seeking the wire. When the truck has locked on the wire, the symbol
lights constantly.
3. Truck symbol
This shows the home position of the forks. The fork symbol blinks when
the forks are not in the home position.
When driving outside a narrow aisle, the truck symbol shows the Steering angle in increments of 15o.
20- 192
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BT Europe AB

Display
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
4. Clock
This shows the time in hours and minutes using the 24-hour format.
The time is obtained from the real-time clock in the MCU and the display is updated each time log-in or start-up takes place.
5. Weight of the load
The current weight of the load is displayed in kilograms (kg), with a margin of tolerance of 20 kg.
6. Height
This displays the current height in centimetres.
The display can be changed using the parameters to show the fork
height or the cabin height.
7. Battery status
This displays the battery charge state in eight segments, corresponding
to a charge level of 0-100%.
The display can be adapted to different battery sizes using the parameters.
8. Pushbutton option and corresponding symbols
These show the functionality for installed optional functions that are
operated with the ICP pushbuttons. The function of the pushbuttons are
verified by the MCU upon log-in.
The ICP can accommodate the following option functions:
- Automatic fork rotation (90 and 180 degrees)
- Fork widening
- Side shifting of the forks
- Lift height limitation, incl. bypass
- Camera(s)
BT Europe AB
Service Manual
20- 193

Display
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
9. Protection and blocking messages

10:40
GATES
00:00
00:07
If the MCU blocks use of the truck, a text messages and an information
symbol (i) are displayed and the ICP buzzer also sounds. The following
messages can be displayed:
Text message
Meaning
"DRIVER ?"
No operator in truck
DEADMAN
The left and/or right dead man's handle is not

actuated when required
"GATES"
Cabin gates not closed at the required height

set by the parameters
"OVERRIDE"
The bypass command has been requested
"STABILITY"
The function is blocked because of truck stability
"AUTO BRAKE"
Auto braking has been applied as a result of

the PPS or end-of-aisle braking
"AUTO STOP"
Auto stop has been applied as a result of the

PPS or end-of-aisle stopping
"CHAIN ?"
The slack chain guard has been engaged
"EMERGENCY"
Emergency driving mode
The message disappears from the display when the cause for the same
has been remedied.
20- 194
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BT Europe AB

Display
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
20.17.2 Information mode

When the information button [I] is depressed, the display switches to
the information mode.
In this mode, certain truck data and navigation symbols associated with
the option function pushbuttons are displayed. It is possible to select
other functions (modes) from this state. For more details, see item 4.
1
10:40
PACK:
ICP:
MCU:
FCU:
A:
B:
C:
D:
E:
S:
500h
400h
200h
80h
120h
99h
XXXXXX-XXX
XXXXXX-XXX
XXXXXX-XXX
XXXXXX-XXX
+
_
5
1. Logged in operator
The operator number corresponding to the log-in PIN code is displayed
(1-10).
If the service key is connected in CAN1, operator number 1 is active.
2. Setting the correct time
Set the clock by entering the correct time using the keys on the keypad.
Once a new time has been set, press the [ON] key to confirm the
change.This will cause the change to be stored in the MCU RAM.
To store the change in the MCU's EEPROM, the truck must be switched
off (i.e. log-out).
BT Europe AB
Service Manual
20- 195

Display
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
3. Hour meter
Six different hour meters can be displayed.
Timer
A
Total operating time, i.e. logged in time
Total actual operating hours for the hydraulics and/or

drive functions
Actual drive motor hours
Actual pump motor hours, cabin lifting
Actual pump motor hours, fork unit
Service counter, hours remaining until next required service intervention
All the hour meters are shown at the same time in the display in information mode.
The service counter [S] is activated in the same manner as the B hour
meter, however, the hours count down from a start value set with the
parameters (par. 150). The hours count down to 0. Zero service hours
are indicated in the display when logging in with this warning information. Restart of the service counter is done by resetting the parameters
to the selected service interval.
4. Node information
This shows the firmware version order numbers of the installed
firmware package and the separate firmware versions of the CAN
nodes (ICP, MCU, FCU).
5. Navigation buttons
Another function (mode) can be selected by depressing the pushbutton
under the corresponding symbol.
The following modes can be selected:
- Operator parameters, depicted by a blue human being symbol.
See the section on parameters.
- Truck parameters, depicted by a green truck symbol. See the
section on parameters.
- Error code register, depicted by a red E100 symbol. See the section on troubleshooting.
- Calibration, depicted by an orange potentiometer symbol. For
more details, see the section on calibration.
- Service, depicted by a black tool symbol. See the section on service.
NOTE!
If the service key is not connected to CAN1, only the operator parameter symbol is displayed.
To return to the normal mode, depress the [C] button.
20- 196
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BT Europe AB

Calibration Turret Head (t-code 712)
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
20.18 Calibration Turret Head

(t-code 712)
20.18.1 Calibration mode
Enter the calibration mode as explained in section 14.2.
The calibration mode allows calibration and adjustment of the various
truck functions. It uses a navigation menu allowing easy selection of
desired functions.
In the calibration mode, the following function keys on the keyboard are
used to navigate through the menus:
[UP] = Go up
[DOWN] = Go down
[+] = Expand the menu
[-] = Minimise the menu
[ON] = Select
The system has the following calibration functions:
"CONTROLS" = Calibration of the left and right ICP controls.
"STEERING" = Calibration of the MCU steering system.
"WIRE" = Calibration of the MCU wire guidance steering system.
"FORKS" = Calibration of the FCU turret head fork unit functions.
"WEIGHT" = Calibration of the weight indication system.
"PRESSURE" = Calibration of the accumulator pressure in the B cylinder system.
Select the item to be calibrated with [UP]/[DOWN].
Start calibration by pressing [ON] and follow the instructions for the
selected calibration function.
When calibration starts, Working is displayed and the buzzer
sounds briefly.
When calibration is complete, Ready is displayed.
If calibration fails, a status code is displayed (see the relevant calibration function for more details), and the buzzer sounds a long
tone.
General status code for MCU calibrations:
BT Europe AB
Status
code
Error type
Description
Truck, not inactive
The truck function is active upon

start-up of the calibration function
Service Manual
20- 197

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Calibration of the ICP controls - CONTROLS

Select CONTROLS.
Press [ON].
Move the fork control, R2, to the rightmost position.
Keep the control in position until the ICP buzzer sounds
Move the fork control, R2, directly from the rightmost position to the
leftmost position.
Move the fork control to the neutral position.
Wait until the ICP buzzer sounds
Move the speed control, R1, to the rightmost position.
Move the speed control, R1, directly from the rightmost position to
the leftmost position.
Move the speed control to the neutral position.
Wait until the ICP buzzer sounds
When Ready is displayed, calibration has been completed for both
controls.
Switch off the truck to save the new calibration.
Warning/Note:
Do not hold the right dead man's handle.
The truck is in operating condition throughout the calibration mode.
The following status codes may appear during calibration of the controls.
20- 198
Status
code
Error description
The speed control is outside the allowed limits.
The fork control is outside the allowed limits.
Service Manual
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
Calibration of steering - STEERING

There are two calibration functions for calibrating the steering system:
Calibration of the centre position of the articulated centre (straight
steering) and the proportional valves of the steering system as well as
the end stops of the articulated centre potentiometer.
1. Calibration of the articulated centre potentiometer
Calibration of the articulated centre potentiometer is probably the most
important calibration function. If this calibration is incorrect, this will
affect truck behaviour in wire guided as well as rail guided narrow
aisles.
Set the truck chassis straight.
Please make sure that the truck's articulated centre is completely
straight.
Select STEERING.
Select PIVOT.
Press [ON].
The following status message may be displayed:
Status
code
Error type
Description
Calibration of the arti- The sensor signal is outside

culated centre poten- the allowed limits when the
tiometer failed
articulate centre is set
straight
2. Calibration of steering
Calibration of the steering system requires a large open area. When
calibration starts, the truck will make full steering manoeuvres by itself.
Set the truck straight.
Select STEERING.
Select VALVES.
Press [ON].
Turn the steering wheel at relatively high speed and steer right until
the buzzer sounds.
The truck will turn fully to the left and the buzzer sounds.
The truck will turn fully to the right and the buzzer sounds.
The truck now returns to straight articulated centre.
Once Ready is displayed, the calibration is ready.
BT Europe AB
Service Manual
20- 199

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Calibration of wire guidance - WIRE

There are two calibration functions for calibrating the wire guidance
system: "Learn offset" and "Learn frequency".
1. Learn Offset
OFFSET calibration is an automatic function.
Calibration of the antenna offsets is done continuously while travelling
at a speed in excess of 4.0 km/h and in both travel directions when
locked onto the wire.
NOTE:
The calibration function OFFSET via the ICP display has been
switched off.
If an attempt is made to activate this function, the message WORKING is displayed for the entire duration and no calibration is made.
2. Learn frequency
Frequency learning is only required if parameter 165 has been set to
Other frequency, i.e. parameter value 2.
Proceed as follows:
Check whether parameter 165 has been set to 0 or 1.
Set the truck straight (centred) above the wire.
Enter the calibration mode and select WIRE.
Select FREQUENCY.
Press [ON].
Switch on wire guidance with the wire guidance switch.
Change parameter 165 to "2" once the frequency has been learned.
Drive the truck on the wire to fine calibrate OFFSET.
The following status codes may appear during calibration of the frequency.
20- 200
Status
code
Error type
Description
Calibration of the frequency failed
The signal level from the

wire is too low.
Service Manual
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
Calibration of the turret head fork unit functions FORKS

Calibration of the turret head fork unit functions is made separately,
except for traversing and lifting, which need to be calibrated together
because they share the same proportional valve.
1. Counter-clockwise rotation
Turn the forks clockwise all the way to the inside stop.
Select FORKS.
Select CCW.
Press [ON].
Perform a complete counter-clockwise rotation of the forks.
When the buzzer sounds, the calibration is ready.
When the control is released, Ready is displayed.
The following status codes may appear during calibration of counterclockwise rotation.
Status code
Error description
110
Rotation CW hysteresis
111
Rotation CW max. speed
112
Min. angle
2. Clockwise rotation
Turn the forks counter-clockwise all the way to the inside stop.
Select FORKS.
Select CW.
Press [ON].
Perform a complete clockwise rotation of the forks.
BT Europe AB
Service Manual
20- 201

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
The following status codes may appear during calibration of clockwise

rotation.
Status code
Error description
113
Rotation CCW hysteresis
114
Rotation CW max. speed
115
Max. angle
3. Calibration of traversing/lifting, TRAV/LIFT

Set the turret head fork unit to the home position on the left.
Select FORKS.
Select TRAV/LIFT.
Press [ON].
Traverse the fork unit all the way to the rightmost position.
(NOTE:Low speed at the end of the traversing movement). Push the
fork unit against the end stop until the ICP buzzer sounds.
Traverse the fork unit back to the left end stop. Push the fork unit
against the end stop until the ICP buzzer sounds.
Press the Shift button.
Lift the forks until they slow down and the ICP buzzer sounds.
Ready is displayed when the control is released, and calibration is
then complete.
The following status codes may appear during calibration of traversing/
lifting.
Status
code
Error type
116
Calibration of travers- The hysteresis for proporing/lifting failed

tional valve Y25 could not be
found.
Traversing max.
Max. traversing speed was
speed
not achieved.
Calibration of the
Could not calculate the tratravel length failed
versing travel length.
Max. lift speed
Max. lifting speed was not
achieved.
117
118
119
20- 202
Service Manual
Description
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
4. Fork lowering - LOWER

Lift the forks to at least 2/3 of the initial lift height.
Select FORKS.
Select LOWER.
Press [ON].
Press the fork control, R2, to lower the forks.
The forks will be lifted until they reach the mechanical stop.
Continue depressing the fork control, R2, to lower the forks.
Lowering commences.
Continue depressing the control for lowering the forks until the forks
have reached the bottom mechanical stop.
The following status codes may appear during calibration of the lowering function.
Status
code
Error type
120
Calibration of the low- The hysteresis for proporering function failed tional valve Y10 could not be
found.
Max. lowering speed Max. fork lowering speed was
not achieved.
Calibration of the
Could not calculate the initial
travel length failed
lift travel length.
121
122
Description
Calibration of weight indication - WEIGHT

In order to calibrate the weight indication, a load with a known weight
is required. The weight should be more than 1,000 kg but not exceed
1,600 kg.
Place the load/weight on the floor in the set-off position (i.e. ultra-reversed position).
Traverse back to the opposite home position.
Enter the parameter settings mode, and set parameter 410 to the
weight of the load.
Enter the calibration mode.
Select WEIGHT.
Press [ON].
Lift the forks, without any load, until the buzzer sounds.
Lower the forks until the buzzer sounds.
Traverse outwards in order to pick up the goods.
BT Europe AB
Service Manual
20- 203

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Lift the forks, with the load, and keep them in position until the buzzer sounds.
Lower the forks to the bottom-most position.
Release the control.
Status code
Error description
122
Reference weight = 0
Calibration of B cylinder pressure - PRESSURE

Drain all oil from the accumulator by opening the manual valve (2)
on the valve plate.
Close the valve (2) when no more oil comes out.
B5
Open the manual valve (1) on the pressure side.

1

Select PRESSURE.
Press [ON].
The accumulator will then be automatically charged by the hydraulic
DC pump.
When the buzzer sounds, the accumulator pressure is correct at 250
bar.
Close the valve (1).
The following status message may be displayed:
20- 204
Status
code
Error type
Description
Calibration of the B
cylinder pressure
failed
Hydraulic pressure does not

increase
Service Manual
BT Europe AB

Calibration Shuttle fork (t-code 713)
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
20.19 Calibration Shuttle fork

(t-code 713)
20.19.1 Calibration of Shuttle fork
Calibration of the shuttle fork unit functions is made separately, except
for traversing and lifting, which need to be calibrated together because
they share the same proportional valve.
5. Calibration of traversing/lifting, TRAV/LIFT
Set the fork unit to the left end stop.
Select FORKS.
Select TRAV/LIFT.
Press [ON].
Traverse the fork unit all the way to the rightmost position.
(NOTE:Low speed at the end of the traversing movement). Push the
fork unit against the end stop until the ICP buzzer sounds.
Traverse the fork unit back to the left end stop. Push the fork unit
against the end stop until the ICP buzzer sounds.
Press S74
Lift the forks until they slow down and the ICP buzzer sounds.
Ready is displayed when the control is released, and calibration is
then complete.
6. Fork lowering - LOWER
Lift the forks to at least 2/3 of the initial lift height.
Select FORKS.
Select LOWER.
Press [ON].
Press the fork control, S80, to lower the forks.
The forks will be lifted until they reach the mechanical stop.
Continue depressing the fork control, S80, to lower the forks.
Lowering commences.
Continue depressing the control for lowering the forks until the forks
have reached the bottom mechanical stop.
BT Europe AB
Service Manual
20- 205

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Calibration of weight indication - WEIGHT

In order to calibrate the weight indicator it is necessary to calibrate
without and with load on the forks because of the friction in the initial
lift cylinders. A load with a known weight is required. The weight
should be more than 500 kg but not exceed 1400 kg. Place the load/
weight on the floor in the set-off position (i.e. ultra-reversed position).
Traverse back to the opposite home position.
Enter the parameter settings mode, and set parameter 410 to the
weight of the load.
Select WEIGHT.
Press [ON].
Lift the forks, without any load, until the buzzer sounds.
Lower the forks until the buzzer sounds.
Traverse outwards in order to pick up the goods.
Lift the forks, with the load, and keep them in position until the buzzer sounds.
Lower the forks to the bottom-most position.
Release the control.
20- 206
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BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
Learn status codes FCU

FCU specific codes for learn forks (traverse/lift,lower) and learn weight
system:
BT Europe AB
Code
Abstract
Description
116
Traverse/lift failed
117
Traverse failed
118
119
Position sensor
failed
Lift failed
120
Lower failed
121
Lower failed
122
Height sensor failed
123
Weight error
Havent found the traverse/lift

hysteresis
Havent reached the traverse
maximum speed
Couldnt count hte traverse
stroke length
Havent reached the lift maximum speed
Havent found the lower hysteresis
Havent reached the lower maximum speed
Couldnt count the minimum
height and the lift stroke height
The reference weight is zero,
when start the weight calibration
Service Manual
20- 207

Parameters
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
20.20 Parameters
Parameters are the tools BT uses to adapt the truck to specific customer applications, such as adaptation of speeds, lifting limits and integration of the optional functions.
The truck has different parameter categories:
1. Operator parameters
These cover parameter numbers 1-100
Up to 10 different sets of operator parameters per truck can be programmed: operator 1-10. Each operator set contains nine parameters.
Each operator parameter set is protected by a four-digit log-in code.
The operator parameters can be set 'open', allowing the logged in
operator to change his own parameters, or 'protected', preventing
parameters from being changed unless they are accessed via the
service mode.
The operator parameters are stored in the MCU.
2. Truck parameters
The truck parameters are grouped depending on which logic card
they belong to.
MCU parameters no. 1 - 229
FCU parameters no. 400 - 475
ICP parameters no. 500 - 549
The MCU stores the general truck parameters and the wire guidance parameters.
The FCU stores parameters related to the turret head fork unit.
The ICP stores internal ICP parameters.
The MCU and FCU also contain parameters, which display the
learned values from the calibration features. Learned values can be
adjusted in the parameter mode.
NOTE!
Truck behaviour.
When changing truck-specific parameters, the running characteristics of the truck will change.
Do not change any parameters unless you possess the necessary
skills to do so.
20- 208
Service Manual
BT Europe AB

Parameters
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
20.20.1 Accessing parameters

The parameters can be changed via the ICP keyboard when set to the
information mode.
Operator parameters (service key not inserted)

1
A:
B:
C:
D:
E:
S:
500h
400h
200h
80h
120h
99h
ICP: XXXXXX-XXX
MCU: XXXXXX-XXX
FCU: XXXXXX-XXX
Enter the ICP information mode by pressing the information key [I].
Press the Operator soft-key that is displayed.
The display will change to the operator parameter mode (1).
1 STEER PROG.
+
_
5
3
Up to ten parameters, i.e. operator parameters for the logged in operator, can be changed/displayed.
Select a parameter with the [UP] / [DOWN] keys and change the value with [+] / [-] (2).
To abort, press the [C] key (3).
To reset the selected parameter to the default value, press the [FACTORY] soft-key (4).
When a parameter has been changed, press the [ON] key to confirm
the change (5). This will cause the change to be stored in the MCU
RAM.
To store changed parameters in the MCU's EEPROM, the truck
must be switched off (i.e. log-out).
The next time the truck is switched on (log-in) the new parameter set
will be used.
To enable adjustment of the tenth parameter, i.e. the PIN code, the
service key must be used.
BT Europe AB
Service Manual
20- 209

Parameters
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
20.20.2 Operator parameters (operators 1-10)

No.
Parameter type
Unit
Min.
Max.
Def.
value
Remarks
Progressive steering
10
60
30
In increments of 10
Travel speed,
max.speed
10
100
100
In increments of 10
100% = 9 km/h
Travel speed, half

speed
10
100
100
In increments of 10
100% = 4 km/h
Travel speed, low

speed
10
100
100
In increments of 10
100% = 2.5 km/h
Acceleration
10
100
100
In increments of 10
Travel speed in nar- %

row aisle, max. speed
30
100
80
In increments of 10
100% equals the value set
in parameter 104
Auto braking
100
80
In increments of 10
0 = no auto braking
Not used
100
10
Not used
100
10
10
Pin code
0000
9999
5807
5807 = default PIN code

set at factory
Parameter 1
The higher the value entered, the less the steering wheel needs to be
turned between the end steering positions.
The value 60 provides steering with no progressive steering (i.e.
reduced sensitivity at higher speeds).
Parameter 2
Use this parameter to set the maximum travel speed outside narrow
aisles.
Parameter 3
Use this parameter to set the maximum travel speed in the half-speed
area.
Parameter 4
Use this parameter to set the maximum travel speed in the low-speed
area, i.e. inching speed.
20- 210
Service Manual
BT Europe AB

Parameters
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
Parameter 5
The lower the value entered, the more time it will take for the truck to
reach maximum speed.
Parameter 6
Use this parameter to set the maximum travel speed in narrow aisles.
The absolute maximum speed depends on the value set in parameter
104.
Parameter 7
Use this parameter to set the force applied when the truck brakes, i.e.
when the speed control is released and it returns to the neutral position.
Parameter 10
The service key must be used when this parameter needs to be
changed.
In the operator parameter mode, only the parameter value is displayed.
PIN codes for 10 different operators can be programmed. Select the
PIN code via the ICP keyboard.
The PIN code for operator 1 is set to no. 1 in the default setting.
NOTE!
The PIN code for operator 1 should be changed to another 4-digit
code to prevent unauthorised operation of the truck.
Operators 2-10 have not been defined. By default, these parameter values are set to 0000.
BT Europe AB
Service Manual
20- 211

Parameters
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
20.20.3 Truck parameters

1
A:
B:
C:
D:
E:
S:
500h
400h
200h
80h
120h
99h
ICP: XXXXXX-XXX
MCU: XXXXXX-XXX
FCU: XXXXXX-XXX
Connect the service key to CAN1.

Start the truck. When the service key has been connected it is not
necessary to enter a code. Simply press the start key [ON].
Enter the ICP information mode by pressing the information key [I].
The "Driver" soft-key and "Truck" soft-key are displayed together
with the other operational modes.
Press the soft-key next to the truck symbol to enter the truck parameter mode. (1).
All truck parameters are now available, including all ten operator
parameters.
Operator no. 1: parameter 1-10, operator no. 2: parameter 11-20,
operator no. 3: parameter 21-30, etc.
PARAMETER
101
MIN/MAX
VALUE
860
1500
+
_
7
5
6
Select the desired parameter with the [UP] / [DOWN] keys (2).
When [UP] / [DOWN] is kept depressed, the parameter numbers advance in increments of 20.
Change a parameter value using [+] / [-] (3).
When [+] / [-] is kept depressed, the parameter value increases/decreases in increments of 20.
It is also possible to directly enter a new value using the keypad (4).
To abort, press the [C] key (5).
To reset the selected parameter to the default value, depress the
[FACTORY] soft-key (6).
When a parameter has been changed, press the [ON] key to confirm
the change. The parameter value then changes colour (7). This will
cause the change to be stored in the MCU RAM.
20- 212
Service Manual
BT Europe AB

Parameters
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
All parameters that need to be changed can be changed before all

changes are saved.
To store changed parameters in the MCU's EEPROM, the truck
must be switched off (i.e. log-out).
The next time the truck is switched on (log-in) the new parameter set
will be used.
NOTE!
Truck behaviour.
When changing truck-specific parameters, the running characteristics of the truck will change.
Do not change any parameters unless you possess the necessary
skills to do so.
BT Europe AB
Service Manual
20- 213

Parameters
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
20.20.4 MCU parameters

Basic truck parameters: Number 101-160
Wire guidance parameters: Number 165-171
Parameters for calibrated values: Number 186-233
Basic parameters
No.
Parameter type
Unit
Min.
Max.
Def.
value
Remarks
101
Max. cabin height
cm
1500
1000
Max. cabin floor height

In increments of 1
102
Cabin gate height
cm
300
50
Max. cabin floor height with

open gates.
In increments of 1
103
Reference height for

cabin lifts
mm
1200
680
Cabin height when reference

sensor changes status
In increments of 1
104
Max. speed in narrow %

aisle
10
100
100
Max. speed in mech. aisle

100% = 12 km/h
Max. speed in wire aisle
100% = 10 km/h
In increments of 1
105
Not used
106
Speed limit 1
100
100
SpeedRed1 input
Digital input X131:4
100%=value of parameter 104
107
Speed limit 2
100
100
SpeedRed2 input
Digital input X131:18
108
Speed limit3
100
100
SpeedRed3 input
Digital input x131:32
109
Optipace height in
narrow aisle
cm
200
200
Cab height when the Optipace function has reduced

the travel speed to low speed
In increments of 1
110
Lift height limiter outside narrow aisle
cm
1500
1500
In increments of 1
20- 214
Service Manual
BT Europe AB

Parameters
Order number
227761-040
Date
2005-11-28
No.
Parameter type
111

919699-
Min.
Max.
Def.
value
Remarks
Narrow aisle ID sensors
Number of photocell sensors

used for narrow aisle ID controlled lift height limiting
0: no sensor
1: Multi-level stopping
2: Single-level stopping
112
Lift height limitation 1 cm
1500
1500
Lift height limitation 1 in narrow aisle

In increments of 1
113
1500
1500

In increments of 1
114
1500
1500

In increments of 1
115
1500
1500

In increments of 1
116
1500
1500

In increments of 1
117
1500
1500

In increments of 1
118
1500
1500

In increments of 1
119
Configuration of lift
height limitation 1
1010
3131
1010
See the parameter explanations
120
height limitation 2
1010
3131
1010
121
height limitation 3
1010
3131
1010
122
height limitation 4
1010
3131
1010
123
height limitation 5
1010
3131
1010
124
height limitation 6
1010
3131
1010
BT Europe AB
Unit
T-code
712, 713
Service Manual
20- 215

Parameters
T-code
712, 713

919699-
No.
Parameter type
125
Order number
227761-040
Min.
Max.
Def.
value
Remarks
height limitation 7
1010
3131
1010
126
Final speed, end-ofaisle braking
The truck speed after completed slowdown:

0: 0 km/h, with audible braking
1: low speed, max. 2.5 km/h
(0,7 m/s), with audible alert
2: 0 km/h, no audible alert
3: low speed, max. 2.5 km/h
(0.7 m/s), no audible alert
127
End-of-aisle stopping
0: Not connected
1: End-of-aisle stopping, with
audible alert
2: End-of-aisle stopping, no
audible alert
128
Battery size
20
12
Selects the battery size/type;

increasing the value allows
deeper discharge of battery.
See the table under parameter explanations.
129
Fork unit type
0: Turret head forks

1: Shuttle fork
130
Telescoping forks
0: No telescoping forks
1: Telescoping forks
131
Half-pallet handling
0: No half-pallet handling
1: Half-pallet handling
132
Auto rotation 180
0: No 180 auto rotation

1: 180 auto rotation
133
Auto rotation 90
0: No 90 auto rotation
1: 90 auto rotation
134
Fork tilting
0: No fork tilting
1: Fork tilting
135
Fork widening
0: No fork widening
1: Fork widening
136
Sideshift
0: No sideshift
1: Sideshift
137
Personal Protection
System
0: No PPS installed
1: PPS installed
20- 216
Unit
Date
2005-11-28
Service Manual
BT Europe AB

Parameters
Order number
227761-040
Date
2005-11-28
No.
Parameter type
138

919699-
Unit
T-code
712, 713
Min.
Max.
Def.
value
Remarks
Truck functions,
status outputs
10
Status output functions for

truck functions.
139
Flashers
0: No flashers
1: Flashers
140
Support arm brakes
0: No support arm brakes

1: Support arm brakes
141
Narrow aisle mode
0: Rail guidance
1: Wire guidance
142
Camera function
33
XY setting
X = setting of number of cameras
0: No camera
1: Only rear-mounted camera
2: Only front-mounted camera
3: Cameras at both front and
back
Y = Camera switching setting
0: No automatic camera
switching
1: Automatic selection of rearview camera
2: Automatic selection of
front-view camera
3: Automatic switching of
rear-view/front-view camera
143
Travel alert; truck

moving
BT Europe AB
Service Manual
1515
XY setting
X = Setting of truck moving
alert.
X = Setting of cab moving
alert.
0: No alert
>0: Alert connected
20- 217

Parameters
T-code
712, 713

919699-
No.
Parameter type
144
Order number
227761-040
Min.
Max.
Def.
value
Remarks
Narrow aisle system
11
92
11
Setup [XY]
X = aisle indication system:
1: AI magnet layout (BT) bistable, or with photo cell (only
with rail guidance)
2: AI magnet layout (JH) bistable
3-8: not used
9: AI wire guidance
Y =aisle end braking system:
1: AEB magnet layout (BT) bistable
2: AEB magnet layout (JH)
mono stable
145
Extra hydraulic function 1
0: Not connected
1: Engaged
146
Extra hydraulic function 2
0: Not connected
1: Engaged
147
Reserved, option 3
Not used
148
Reserved, option 4
Not used
149
Reserved, option 5
Not used
150
Service interval
2000
0: No service counter
>0: Set to 9999 at next startup..
151
Operator access to
operator parameters
0: Operator parameters
locked
1: Operator parameters can
be changed by logged in
operator
152
Selection of error
code log 1
100
0: Digital outputs 1-6

1: B cylinder pressure
2: Lifting pressure
3: Steering accumulator pressure
4: Steering angle
5: Battery, current consumption
153
Selection of error
code log 2
100
0: Digital outputs 1-16

1: Digital inputs 11-25
2: Battery, voltage
154
Clock, year
00
99
155
Clock, month
12
20- 218
Unit
Date
2005-11-28
Service Manual
BT Europe AB

Parameters
Order number
227761-040
Date
2005-11-28
No.
Parameter type
156
Clock, day
157
Lift height limit, special
158

919699-
Unit
T-code
712, 713
Min.
Max.
Def.
value
31
1500
1500
Special lift height limit

affected by digital input 24
(X131:33)
Special function
10
Special function affected by

digital input 6 (X130:39) in the
narrow aisle.
0: Not connected
1: Automatic selection of half
pallet handling (bi-stable
magneto switches)
2: Automatic selection of half
pallet handling (photocell
detectors)
159
Height pre-selection
0: Height pre-selection not

active
1: Height pre-selection is programmable
2: Height pre-selection is not
programmable
160
Height display
Height displayed.
0: Current fork height
1: Current cabin height
161
Cab lifting, forks set

straight ahead
0: No function
1: Cab lifting/lowering with
forks set 90o straight ahead
162
Jungheinrich layout
reset
0: No function
1: Jungheinrich layout reset
163
CabinLowerLimit
1200
0: no function
1: Cabin lower limit
cm
mm
Remarks
Parameter 101
Use this parameter to set the electrical stop for max. cabin lifting height.
Parameter 102
Use this parameter to set the cabin height at which the gates must be
closed in order to enable lifting/lowering of the cabin and truck travel.
Parameter 103
Use this parameter to set the current cabin lift height when the height
reference sensor S71 changes status.
BT Europe AB
Service Manual
20- 219

Parameters
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Parameter 104
Use this parameter to set the maximum allowed travel speed in the narrow aisle mode.The max. travel speed is dependent on the setting of
parameter 141.
Max. speed in rail guided narrow aisle. 100% = 12 km/h
Max. speed in wire guided narrow aisle. 100% = 10 km/h
The change in speed is proportional to the speeds indicated above.
Parameter 105
Not used.
Parameter 106
SpeedRed1 input. Digtal input X131:4. 100%=value of parameter 104
Parameter 107
SpeedRed2 input. Digital input X131:18. 100%=value of parameter
104.
Parameter 108
SpeedRed3 input. Digital input X131:32. 100% = value of parameter
104.
Parameter 109
Use this parameter to set the lifting height at which the travel speed is
reduced to low speed (2.5 km/h) according to the truck's OPTIPACE
system.
Parameter 110
Use this parameter to set lift height limitation outside narrow aisles.
Parameter 111
Use this parameter to activate the narrow aisle ID system.
The ID system affects the lift height limits 1-7 according to the functional
description.
Parameter 112
Use this parameter to set lift height limitation 1 in narrow aisles. Limitations can be set using parameter 119.
Parameter 113
20- 220
Service Manual
BT Europe AB

Parameters
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
Parameter 114
Parameter 115
Parameter 116
Parameter 117
Parameter 118
Parameter 119 - 125

Parameters 119-125 are configuration parameters used for the lift
height limitations in narrow aisles, i.e. parameters 112-118.
Configuration is done by first entering a four-digit password, where the
password governs the lift height limitation behaviour, as shown in the
table below.
Configuration code Effect on lift height limitation function

1010
Lift height limitation not engaged.
1110
Lift height limitation engaged but bypass

possible.
3110
Lift height limitation engaged with forced

stop. Bypass not possible.
Parameter 126
Use this parameter to set the truck travel speed following completed
end-of-aisle braking, stopping or low speed.
It is possible to select end-of-aisle braking with, or without, an audible
alert.
The low speed is according to the setting of operator parameter 4.
BT Europe AB
Service Manual
20- 221

Parameters
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Parameter 127
Use this parameter to select end-of-aisle stopping for blind narrow
aisles.
It is possible to select end-of-aisle stopping with, or without, an audible
alert.
End-of-aisle stopping only works in conjunction with end-of-aisle braking.
Parameter 128
NOTE!
Upon release of these instructions, no test data was available.
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 breaking 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 (min. specific gravity 1.14)
The specific gravity may vary depending on the battery used.
Value
Function
Battery (Ah)
1
2
3
4
5
6
7
8
9
10
11
Slightly discharged
12
13
1200 Ah
Considerably discharged
14
15
20- 222
Service Manual
BT Europe AB

Parameters
Order number
227761-040
Date
2005-11-28

919699-
Value
Function
T-code
712, 713
Battery (Ah)
16
17
18
19
20
WARNING!
Correct parameter setting.
The battery could suffer permanent damage.
If parameters are set higher than recommended, this will cause overdischarge of the batteries resulting in battery destruction.
Parameter 129
Use this parameter to select which type of fork unit is fitted on the truck.
The default parameter depends on the type of fitted fork unit.
NOTE!
Do not change.
Parameter 130
Use this parameter to activate the optional telescoping fork function.
Parameter 131
Use this parameter to activate the optional half-pallet handling function.
Parameter 132
Use this parameter to activate the optional 180o auto rotate function.
Parameter 133
Use this parameter to activate the optional 90o auto rotate function.
Parameter 134
Use this parameter to activate the optional fork tilt function.
Parameter 135
Use this parameter to activate the optional fork widening function.
Parameter 136
Use this parameter to activate the optional sideshift function.
BT Europe AB
Service Manual
20- 223

Parameters
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Parameter 137
Use this parameter to activate the truck logic for the on-board Personal
Protection System (PPS).
Parameter 138
Use this parameter to define the functions of the three MCU outputs,
X131:10, X131:24 and X131:38. The output signals are used by logical
units to record certain truck functions.
Parameter value 0:
Signals adapted to the PPS system (TBM or similar)
- Output 1: Forward travel
Output 2: Reverse travel
Output 3: In narrow aisle
Parameter value 1:
Signals adapted to TLS (DavisDerby or similar)
- Output 1: Forward/reverse travel
Output 2: Cab lifting/lowering
Output 3: Turret head fork unit/initial lifting
Parameter set 2: Not used.
Parameter 139
Use this parameter to activate the optional flasher function.
Parameter 140
Use this parameter to activate the optional support arm brake function.
Parameter 141
Parameter 141 is used to set the narrow aisle mode of the truck.
Parameter value 0:
Narrow aisle mode set to rail guidance. Wire guidance is disengaged.
Parameter value 1:
When the parameter is to 1, operation and control via wire guidance is
engaged.
Parameter 142
Use this parameter to activate the optional integrated camera system
and which camera picture should be displayed.
This parameter uses a two-digit value [XY] to allow greater selection
freedom of the camera setting.
The X value (1st digit) determines the number of cameras used:
- Parameter value 0: No camera.
- Parameter value 1: One rear-mounted camera.
- Parameter value 2: One front-mounted camera.
20- 224
Service Manual
BT Europe AB

Parameters
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
- Parameter value 3: Two cameras, mounted at the front and back.

The Y value (2nd digit) determines camera switching:
- Parameter value 0: Only manual camera switching via the ICP
panel.
- Parameter value 1: Automatic camera selection when reversing.
- Parameter value 2: Automatic camera selection when travelling
forwards.
- Parameter value 3: Automatic camera selection depending on
the travel direction.
BT Europe AB
Service Manual
20- 225

Parameters
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Parameter 143
When the parameter is set to >0 the alert signal for the truck moving is
activated.
This parameter uses a two-digit value [XY] to allow greater selection
freedom of the movement alert.
The X value (1st + 2nd digit) determines the truck travel setting according to the table:
Travel in the drive

wheel direction
outside a narrow
aisle
Travel in the fork

direction outside
a narrow aisle
Travel in the drive

wheel direction in
a narrow aisle
Travel in the fork

direction in a narrow aisle
00
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
20- 226
Service Manual
BT Europe AB

Parameters
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
The Y value (3rd + 4th digit) determines the cab movement setting
according to the table:
Cab lowering outside narrow aisle
Cab lifting outside narrow aisle
Cab lowering in
narrow aisle
Cab lifting in narrow aisle
00
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
Parameter 144
Use this parameter to select alternative narrow aisle systems/layouts.
Parameter 144 configures these systems as [xy] for a total of six different combinations:
X = aisle indication system:
Parameter value 1: AI magnet layout (BT) bi-stable, or with photo cell
(only with rail guidance)
Parameter value 2: AI magnet layout (JH) bi-stable
Parameter value 3-8: not used
Parameter value 9: AI wire guidance
Y =aisle end braking system:
Parameter vaule 1: AEB magnet layout (BT) bi-stable
Paramter value 2: AEB magnet layout (JH) mono stable
General functionality of the aisle end braking system:
When the truck exits from a narrow aisle, the aisle end braking command is issued when at least one of the two sensors detects the
BT Europe AB
Service Manual
20- 227

Parameters
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
presence of an aisle end braking magnet. The truck brakes and

comes to a complete stop when the current travel speed exceeds 0
km/h.
Parameter 145
Use this parameter to activate the optional extra hydraulic function 1.
Parameter 146
Use this parameter to activate the optional extra hydraulic function 2.
Not used
Parameter 147
Not used
Parameter 148
Not used
Parameter 149
Not used
Parameter 150
Use this parameter to define the service interval for the truck. The buzzer sounds and code 2:005 is displayed when the service counter reaches zero. The counter shows the time that has passed since the last
service intervention.
Reset the counter by entering the required operational hours until the
next service intervention under this parameter. Defalult value of service
timer interval is set to 0 which means that service timer is switched off
by default.
Parameter 151
Use this parameter to define whether or not operator parameters are
allowed to be changed by the operator.
Parameter value 0:
The operator can only view the parameter settings and cannot change
them.
Parameter value 1:
The operator can also change the parameter settings.
20- 228
Service Manual
BT Europe AB

Parameters
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
Parameter 152
Error log registration, option 1.
Using this parameter, it is possible to obtain extended information about
the current status for a selected function when the corresponding error
code is recorded. This extended information can be used for troubleshooting.
The following functions can be selected for extended information:
Parameter value 0: MCU digital inputs 1-6.(default)
Parameter value 1: B cylinder pressure, sensor B6.
Parameter value 2: Initial lift pressure, sensor B7.
Parameter value 3: Steering accumulator pressure, sensor B4.
Parameter value 4: Articulated centre potentiometer, sensor R7.
Parameter value 5: Instantaneous battery current consumption
Parameter 153
Error code registration, option 2.
Using this parameter, it is possible to obtain extended information about
the current status for a selected function when the corresponding error
code is recorded. This extended information can be used for troubleshooting.
The following functions can be selected for extended information:
Parameter value 0: MCU digital outputs 1-16.(default)
Parameter value 1: MCU digital inputs 11-25.
Parameter value 2: Instantaneous battery voltage
Parameter 154 - 156

Use parameters 154-156 to adjust the calendar in the truck. The set
year, month and day are used on the ICP display and when recording
an error in the error code log.
Parameter 157
Use this parameter to set a special lift height limit, which is activated by
a detector connected to digital input 24 (connector X131:33).
The special lift height limit is only active when travelling in narrow
aisles.
BT Europe AB
Service Manual
20- 229

Parameters
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Parameter 158
Use this parameter to activate various special functions (used for special truck designs).
The special function is activated via detector signals received on digital
input 6 (X130:39) while travelling in narrow aisles.
- Parameter set 1: Automatic selection of half pallet handling with
bi-stable magneto switch control.
- Parameter set 2: Automatic selection of half pallet handling with
photocell control.
Parameter 159
Use this parameter to activate the optional height pre-selection function.
- Parameter value 1:
Height pre-selection is active and is open for programming via the
information menu on the display.
Height pre-selection is active, but programming via the information menu is blocked
Parameter 160
Use this parameter to select whether to display the fork lift height or
cabin lift height on the ICP.
The cabin lift height display can be used as a guide when adjusting the
lift height limiter.
Parameter 161
Use this parameter to activate the cab lifting/lowering function with
forks set straight ahead.
Parameter 162
Use this parameter to automatically reset the truck status to truck outside narrow aisle when logging in, i.e. parameter value 1. In order for
the auto reset to operate correctly, parameter 144 must be set to
parameter value 2 or 4.
Parameter 163
This parameter defines the cabin lower limit. Lift limit override softkey
symbol pops up close to limit height and this softkey shall be used to
enable further cabin lowering.
20- 230
Service Manual
BT Europe AB

Parameters
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
20.20.5 Wire guidance parameters:

No.
Parameter type
Unit
Min.
Max.
Def.
value
Remarks
165
Frequency
Selected frequency
0: 5.2 kHz
1: 6.25 kHz
2: Another frequency in
increments of 1
166
Antenna
Angle, slowing down
Degrees 0
(x 10)
20
In increments of 1
167
Antenna
Angle, stopping
Degrees 0
(x 10)
40
20
In increments of 1
168
Antenna
Side, slowing down
Inches
(x 10)
16
In increments of 1
169
Antenna
Side, stopping
Inches
(x 10)
30
12
In increments of 1
170
Steering angle slow

down zone
Degrees 0
13
0,15 degrees per step
171
Virtual displacement
slow down zone
mm
25
15
Parameter 165
Use this parameter to select the wire frequency and amplitude.
Depending on the selected frequency used, to obtain the correct reference signal, the current in the wire must correspond with the values
presented in the table below.
Parameter value
kHz
mA RMS
5.2
90
6.25
75
1 - 10
14 - 1900
Remarks
See below
Parameter value 2:
In order for the truck to learn other frequencies, the product of Amp*Hz
must remain 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) * 7,500 Hz = 593 A*Hz
BT Europe AB
Service Manual
20- 231

Parameters
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Parameter 166
Use this parameter to set the antenna angle at which the truck's direction in relation to the wire should cause a slowdown of the speed.
This parameter value must be less than that set in parameter 167.
NOTE!
The unit of this parameter is degrees.
The parameter value is set in increments of 0.1 degree.
Parameter 167
Use this parameter to set the antenna angle at which the truck's direction in relation to the wire should cause emergency braking.
This parameter value must exceed that set in parameter 166.

NOTE!
The unit of this parameter is degrees.
The parameter value is set in increments of 0.1 degree.
Parameter 168
Use this parameter to set the antenna distance from the wire at which
the speed should be slowed down.
This parameter value must be less than that set in parameter 169.
NOTE!
The unit of this parameter is inches.1 inch = 25.4 mm
The parameter value is set in increments of 0.1x1 inch = 2.54 mm
Parameter 169
Use this parameter to set the antenna distance from the wire at which
the truck should commence emergency braking (truck has lost the
wire).
This parameter value must exceed that set in parameter 168.
NOTE!
The unit of this parameter is inches.1 inch = 25.4 mm
The parameter value is set in increments of 0.1x1 inch = 2.54 mm
NOTE!
The values of Parameter 166-169 must be checked manually when updating truck with package 213017-013
20- 232
Service Manual
BT Europe AB

Parameters
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
Parameter 170
This parameter set the steering angle slow down zone value 0-13 (0,15
degrees per step) Default value 7 (1 degree) Steering angle stop zone
constant 13 (2 degrees) gives error code 5:139.
Parameter 171
This parameter sets virtual point displacement slow down zone, Value
0-25 mm. Default vaule is 15 (mm). Virtual displacement stop zone constant 25 (mm) gives error code 5:140.
Note!
When uppdating the truck with package 213017-013 the parameters
170-171 have to be modified/checked manually.
BT Europe AB
Service Manual
20- 233

Parameters
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Learned calibration values, steering

WARNING!
Do not change the calibrated values unless you are 100% sure of what
you are doing.
Changing these calibrated values can make it impossible to drive the
truck.
No.
Parameter type
Unit
Min.
Max.
Def.
value
Remarks
186
Straight centre,
potentiometer value
Data
1023
500
In increments of 1
187
End stop, clockwise

Data
steering, potentiometer value
1023
100
In increments of 1
188
End stop, counterclockwise steering,

potentiometer value
Data
1023
900
In increments of 1
189
Steering right,
start current
Data
1023
In increments of 1
190
Steering right,
start PWM
Data
1023
120
In increments of 1
191
Steering right, start

voltage
Data
1023
850
In increments of 1
192
Steering left,
start current
Data
1023
In increments of 1
193
Steering left,
start PWM
Data
1023
120
In increments of 1
194
Steering left, start

voltage
Data
1023
850
In increments of 1
The parameter values for the steering calibration data can be used as
information in case of problems relating to unsatisfactory steering on
the truck.
Data outside the min. or max. range indicates that something is wrong.
The various parameters can be used to trace in which part of the steering system a given error can be located.
The parameter values can also be used to verify the calibration function.
Parameter 186
Use this parameter to change the calibrated voltage value of the articulated centre potentiometer with a straight centre.
20- 234
Service Manual
BT Europe AB

Parameters
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
Parameter 187
Use this parameter to change the calibrated voltage value for the articulated centre potentiometer at max. clockwise steering (right).
Parameter 188
Use this parameter to change the calibrated voltage value for the articulated centre potentiometer at max. counter-clockwise steering (left).
Parameter 189
Use this parameter to change the calibrated start current for steering to
the right.
Parameter 190
Use this parameter to change the calibrated start PWM for steering to
the right.
This can eliminate possible jerks in the steering movement.
Parameter 191
This parameter displays the recorded instantaneous battery voltage
when calibrating steering to the right.
The recorded value is used to compensate for fluctuating battery voltage during operation to ensure steering is the same in disregard of the
voltage level.
NOTE:
The saved parameter value must not be 0 (zero).
Parameter 192
Use this parameter to change the calibrated start current for steering to
the left.
Parameter 193
Use this parameter to change the calibrated start PWM for steering to
the left.
This can eliminate possible jerks in the steering movement.
BT Europe AB
Service Manual
20- 235

Parameters
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Parameter 194
This parameter displays the recorded instantaneous battery voltage
when calibrating steering to the left.
The recorded value is used to compensate for fluctuating battery voltage during operation to ensure steering is the same in disregard of the
voltage level.
NOTE:
The saved parameter value must not be 0 (zero).
20- 236
Service Manual
BT Europe AB

Parameters
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
Learned calibration data, wire guidance

WARNING!
you are doing.
Changing these calibrated values can make it impossible to drive the
truck on the wire.
No.
Parameter type
Unit
Min.
Max.
Def.
value
218
Reference signal,
antenna in load direction
Data
1000
219
Reference signal,
antenna in drive unit
direction
Data
1000
Remarks
220
Not used
221
Not used
222
Not used
223
Filter mode
Data
100
224
Filter frequency
Data
100
225
Clock frequency
Data
100
226
Antenna gain
Data
1000
227
Learned wire guidance Data
228
Filter Q value
Data
100
229
Learned frequency
Data
32767
The parameter values for wire guidance can be used as information in

case of problems relating to trucks not following the wire satisfactorily.
The various parameters can be used to trace in which part of the wire
guidance system a given error can be located.
NOTE:
When the standard wire guidance settings, 6.25 kHz and 5.2 kHz, are
used, the standard calibration data value is displayed.
To enable adjustment of the calibration data and subsequent activation on the truck, parameter value 165 must be set to 2 (i.e. another
frequency)
BT Europe AB
Service Manual
20- 237

Parameters
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
20.20.6 FCU parameters (t-code 712)

Basic parameters of the turret head fork unit: Number 400-420
Parameters for calibrated values: Number 450-477
Basic parameters, turret head fork unit

No.
Parameter type
Unit
Min.
Max.
Def.
value
400
Rated load
kg
1500
1500
401
Arm length
mm
500
1500
500
402
Acceleration ramp, traversing
10
In increments of 1
1 = Hard
10 = Soft
403
Slowdown ramp, traversing
10
In increments of 1
1 = Hard
10 = Soft
404
Acceleration ramp,
rotation
10
In increments of 1
1 = Hard
10 = Soft
405
Slowdown ramp, rotation
10
In increments of 1
1 = Hard
10 = Soft
406
Acceleration ramp, initial lift
10
In increments of 1
1 = Hard
10 = Soft
407
Slowdown ramp, initial

lift
10
In increments of 1
1 = Hard
10 = Soft
408
Acceleration ramp, initial lowering
10
In increments of 1
1 = Hard
10 = Soft
409
Slowdown ramp, initial

lowering
10
In increments of 1
1 = Hard
10 = Soft
410
Calibration weight
kg
1000
1600
411
Reference height,
initial lift
mm
100
50
Fork height when reference

sensor changes status
In increments of 1
412
Traversing speed
100
100

In increments of 1
413
Rotation speed, high

speed
100
100
Max. speed in high-speed

area
In increments of 1
20- 238
Service Manual
Remarks
BT Europe AB

Parameters
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
No.
Parameter type
Unit
Min.
Max.
Def.
value
Remarks
414
Lifting speed, initial lift
100
100
Max. lifting speed

In increments of 1
415
Lowering speed, initial

lift
100
100
Max. lowering speed.

In increments of 1
416
Rotation speed, low

speed
100
50
Max. speed in low speed

area. In increments of 1
417
Height-dependent rota- %
tion speed
100
100
Rotation speed above ICP

level
418
Lowering speed, bottom end stop
100
60
In increments of 1
419
Start angle, auto rotation
degrees
10
In increments of 1
420
Auto rotation speed,

high speed
100
100
Max. speed in high-speed

area
In increments of 1
421
Auto rotation speed,

low speed
50
50
Max. speed in low speed

area. In increments of 1
422
Tilt speed
100
100
In increments of 1
423
Fork widening speed
50
100
100
In increments of 1
424
Traversing speed
100
100
In increments of 1
425
Fork telescoping speed %
50
100
100
In increments of 1
426
Speed of extra hydraulic function 1
100
100
In increments of 1
427
Speed of extra hydraulic function 2
100
100
In increments of 1
428
Travel length, half pallet mm
200
3000
200
In increments of 1
Parameter 400
Use this parameter to set the rated load, according to the name plate, in
the electronic overload warning module.
Parameter 401
Use this parameter to set the physical reach of the arm in the truck's
electronic module.
The fork movement speed is automatically adapted according to the
setting of this parameter.
Parameter 402
Use this parameter to set how hard/soft traversing should accelerate.
BT Europe AB
Service Manual
20- 239

Parameters
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Parameter 403
Use this parameter to set how hard/soft traversing should slow down.
Parameter 404
Use this parameter to set how hard/soft rotational movement should
accelerate.
Parameter 405
Use this parameter to set how hard/soft rotational movement should
slow down.
Parameter 406
Use this parameter to set how hard/soft initial lift lifting movement
should accelerate.
Parameter 407
Use this parameter to set how hard/soft initial lift lifting movement
should slow down.
Parameter 408
Use this parameter to set how hard/soft initial lift lowering movement
should accelerate.
Parameter 409
Use this parameter to set how hard/soft initial lift lowering movement
should slow down.
Parameter 410
Use this parameter to set the known weight of a load and use this for
calibration of the weight indication feature.
The parameter will be reset to zero once calibration has been completed.
Parameter 411
Use this parameter to set the fork height at which the reference detector
changes status.
Parameter 412
Use this parameter to set the maximum allowed traversing speed.
Parameter 413
Use this parameter to set the maximum allowed rotation speed in the
high speed area.
20- 240
Service Manual
BT Europe AB

Parameters
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
Parameter 414
Use this parameter to set the maximum allowed fork lifting speed.
Parameter 415
Use this parameter to set the maximum allowed fork lowering speed.
Parameter 416
Use this parameter to set the maximum allowed rotation speed in the
low speed area.
Parameter 417
Use this parameter to reduce the rotation speed when forks are lifted
above the ICP height.
Parameter 418
Use this parameter to set how hard/soft the lowering function should
slow down close to the bottom end stop.
Parameter 419
Use this parameter to determine at which rotation angle traversing
movement should be allowed during auto rotation.
Parameter 420
Use this parameter to set the maximum allowed auto rotation speed in
the high speed area.
Parameter 421
Use this parameter to set the maximum allowed auto rotation speed in
the low speed area.
Parameter 422
Use this parameter to set the maximum allowed fork tilt speed.
Parameter 423
Use this parameter to set the maximum allowed fork widening speed.
Parameter 424
Use this parameter to set the maximum allowed fork traversing speed.
Parameter 425
Use this parameter to set the maximum allowed fork telescoping
speed.
BT Europe AB
Service Manual
20- 241

Parameters
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Parameter 426
Use this parameter to set the maximum allowed speed for extra hydraulic function 1.
Parameter 427
Use this parameter to set the maximum allowed speed for extra hydraulic function 2.
Parameter 428
Use this parameter to set the travel length for half pallet handling.
Learned calibration data, turret head fork unit

WARNING!
you are doing.
Changing calibrated values could render the turret head fork unit inoperative.
No.
Parameter type
Unit
Min.
Max.
Def.
value
Remarks
450
Max. rotation angle
Data
150
255
199
End stop, counter-clockwise

rotation
451
Min. rotation angle
Data
100
19
End stop, clockwise rotation
452
Clockwise rotation,
PWM hysteresis
Data
5000
15000
7200
Pulling position Y28
453
Clockwise rotation,
start current
Data
255
101
Learned current value
454
Clockwise rotation,
max. current
Data
255
159
455
Clockwise rotation,
max. PWM
Data
255
35
Y28 fully open
456
Counter-clockwise
Data
rotation, PWM hysteresis
5000
15000
7200
457
Counter-clockwise
rotation, start current
Data
255
98
458
Counter-clockwise
rotation, max. current
Data
255
153
459
Counter-clockwise
rotation, max. PWM
Data
255
35
Y27 fully open
460
Traversing/Lift, PWM
hysteresis
Data
2000
10000
2736
20- 242
Service Manual
BT Europe AB

Parameters
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
No.
Parameter type
Unit
Min.
Max.
Def.
value
Remarks
461
Traversing/Lift, start
current
Data
255
28
462
Traversing/Lift, max.
current
Data
255
62
463
Traversing, max. PWM Data
255
47
Y25 fully open for traversing
464
Lift, max. PWM
Data
255
71
Y25 fully open for fork lifting
465
Traversing, travel
length
Data
1200
560
1 pulse/2.5 mm
Learned number of pulses
466
Lowering, PWM hyster- Data

esis
10000
1776
467
Lowering, start current
Data
255
35
468
Lowering, max. current Data
255
122
469
Lowering, max. PWM
Data
255
87
Y10 fully open
470
Initial lift, travel length
Data
1000
500
1 pulse/4.0 mm
Learned number of pulses
471
Min. height
Data
200
17
472
Lifting load, K value
Data
10000
106
Calibration value
473
Lifting load, m value
Data
10000
464
Calibration value
474
Holding load, K value
Data
10000
115
Calibration value
475
Holding load, m value
Data
10000
458
Calibration value
476
Lowering load, K value Data
10000
116
Calibration value
477
Lowering load, m value Data
10000
454
Calibration value
The parameter values for the turret head fork unit's calibration data can
be used as information in case of problems relating to unsatisfactory
functioning of the turret head fork unit.
The various parameters can be used to trace in which part of the turret
head fork unit system a given error can be located.
Parameter 450
Use this parameter to change the calibrated voltage value for the turret
head fork unit at max. counter-clockwise steering (left).
BT Europe AB
Service Manual
20- 243

Parameters
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Parameter 451
Use this parameter to change the calibrated voltage value for the turret
head fork unit at max. clockwise steering (right).
Parameter 452
Use this parameter to change the calibrated pulling position of proportional valve Y28.
This affects the amount of jerking movement during clockwise rotation.
Parameter 453
Use this parameter to change the calibrated start current of Y28.
This affects the amount of jerking movement during clockwise rotation.
Parameter 454
Use this parameter to change the calibrated max. current of Y28.
This affects clockwise rotation speed.
Parameter 455
Use this parameter to change the calibrated max. PWM of Y28.
This affects clockwise rotation speed.
Parameter 456
This affects the amount of jerking movement during counter-clockwise
rotation.
Parameter 457
This affects the amount of jerking movement during counter-clockwise
rotation.
Parameter 458
This affects counter-clockwise rotation speed.
Parameter 459
This affects counter-clockwise rotation speed.
Parameter 460
20- 244
Service Manual
BT Europe AB

Parameters
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
This affects the amount of jerking movement during traversing/lifting

movement.
Parameter 461
This affects the amount of jerking movement during traversing/lifting
movement.
Parameter 462
This affects the traversing/lifting speed.
Parameter 463
Use this parameter to change the calibrated max. PWM of Y25 for traversing.
This affects the traversing speed.
Parameter 464
Use this parameter to change the calibrated max. PWM of Y25 for fork
lifting.
This affects the lifting speed.
Parameter 465
This parameter is used to verify the data setting of the traversing travel
length.
For information only.
Parameter 466
This can eliminate possible jerks in the lowering movement.
Parameter 467
This can eliminate possible jerks in the lowering movement.
Parameter 468
This affects the lowering speed.
Parameter 469
This affects the lowering speed.
BT Europe AB
Service Manual
20- 245

Parameters
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Parameter 470
This parameter is used to verify the data setting of the initial lift.
Parameter 471
This parameter is used to verify the data setting of the initial lift minimum height.
Parameter 472
This parameter is used to verify the weight indication K value when a
load is lifted.
Parameter 473
This parameter is used to verify the weight indication m value when a
load is lifted.
Parameter 474
load is held in place during initial lifting.
Parameter 475
load is held in place during initial lifting.
Parameter 476
load is lowered.
Parameter 477
load is lowered.
20- 246
Service Manual
BT Europe AB

Parameters Shuttle fork (t-code 713)
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
20.21 Parameters Shuttle fork

(t-code 713)
20.21.1 Service Parameters (t-code 713)
No
Name
Unit
Min
Max
Default
Description
400
Classified
weight
kg
1250
1250
Classified weight
401
Boom length
mm
500
1500
500
Boom length from

cabin
402
Traverse acc.
ramp slope
10
1:Hard, 10:Soft
403
Traverse end
ramp slope
10
1:Hard, 10:Soft
404
Not used
405
Not used
406
Lift acc. ramp

slope
10
1:Hard, 10:Soft
407
Lift end ramp

slope
10
1:Hard, 10:Soft
408
Low acc. ramp

slope
10
1:Hard, 10:Soft
409
Low end ramp

slope
10
1:Hard, 10:Soft
410
Calibration
weight
kg
500
1400
Weight of calibration
load - returns to 0
after calibration
411
Initial reference
height
mm
1000
570
Fork height when ref.

sensor switches
412
Traverse top
speed
100
100
Max traverse speed
413
Not used
414
Lift top speed
100
100
Max lift speed
415
Low top speed
100
100
Max lower speed
416
Not used
417
Not used
BT Europe AB
Service Manual
20- 247

T-code
712, 713

919699-
Date
2005-11-28
No
Name
Unit
Min
Max
Default
Description
418
Lower end
speed
100
35
Valve opening at bottom
419-425
20- 248
Order number
227761-040
Not used
426
One extra function speed
100
100
Max one extra speed
427
Two extra function speed
100
100
Max two extra speed
428
Half pallet
stroke limit
mm
500
3000
500
Trav. stroke at half

pallet
429
SF Stroke limit
mm
500
3000
Traverse stroke limitation
449
TestPar449
1000
0
Not used
Service Manual
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
20.21.2 Learned data (t-code 713)

No:
Name:
Unit
Min
Max
Default:
450-459
Not used
460
Traverse/Lift start
Data
10000
3072
461
Traverse lift start

current
Data
255
41
462
Traverse/lift max
current
Data
255
58
463
Traverse max
Data
255
40
464
Lift max
Data
255
36
465
Traverse stroke
length
Data
3000
1062
466
Lower start
Data
10000
2160
467
Lower start current
Data
255
50
468
Lower max current
Data
255
124
469
Lower max
Data
255
72
470
Lift stroke height
Data
1000
377
471
Min height
Data
500
210
472
Lift weight K-value
Data
10
500
158
473
Lift weight m-value
Data
10
1000
747
474
Stand weight Kvalue
Data
10
500
163
475
Stand weight mvalue
Data
10
1000
742
476
Low weight Kvalue
Data
10
500
181
477
Low weight mvalue
Data
10
1000
764
478
1 pulse/3,2mm
1 pulse/2.0mm
Not used
499
BT Europe AB
Description:
Service Manual
10000
Not used
20- 249

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
20.21.3 ICP parameters

No.
Parameter type
Unit
Min.
Max.
Def.
value
500
Display brightness
100
100
501
Key beep confirmation
0 = Off
1 = On
502
Digital output 1
0 = Off
1 = On
503
Digital output 2
0 = Off
1 = On
504
Digital output 3
0 = Off
1 = On
505
Digital output 4
0 = Off
1 = On
506
Not used
100
507
Time for automatic log-off
20
508
Neutral range, fork control, R2
25
50
25
509
Neutral range, speed control, R1
25
50
25
510
Screensaver
Minutes
60
10
530
Camera 1, input data size

of X dimension
Pixels
1000
640
531

of Y dimension
Pixels
1000
480
532
Camera 1, input data offset of X dimension
Pixels
1000
50
533
Camera 1, input data offset of Y dimension
Pixels
1000
50
534
Camera 1, display size of

X dimension
Pixels
1000
320
535

Y dimension
Pixels
1000
240
536
Camera 1, position of display area of X dimension
Pixels
1000
20- 250
Minutes
Service Manual
Remarks
0: No automatic log-off
1-20: Time in minutes for
automatic log-off
0: Screensaver switched
off
>0: Time until screensaver is activated
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
No.
Parameter type
Unit
Min.
Max.
Def.
value
537
Camera 1, position of display area of Y dimension
Pixels
1000
538
Camera 1, reduction ratio

of X dimension
Pixels
1000
539

of Y dimension
Pixels
1000
540

of X dimension
Pixels
1000
640
541

of Y dimension
Pixels
1000
480
542
Camera 2, input data offset of X dimension
Pixels
1000
50
543
Camera 2, input data offset of Y dimension
Pixels
1000
50
544

X dimension
Pixels
1000
320
545

Y dimension
Pixels
1000
240
546
Camera 2, position of display area of X dimension
Pixels
1000
547
Camera 2, position of display area of Y dimension
Pixels
1000
548

of X dimension
Pixels
1000
549

of Y dimension
Pixels
1000
Remarks
Parameter 500
Use this parameter to change the display brightness.
Parameter 501
Use this parameter to switch on/off the key beep when depressing keys
on the ICP.
Parameter 502 - 505

Use these parameters to activate the digital ICP outputs for optional
features.
BT Europe AB
Service Manual
20- 251

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Parameter 507
Use this parameter to set/adjust the time for automatic log-off when the
truck is inactive.
Parameter 508
Use this parameter to adjust the voltage level for the neutral range in
relation to the calibrated fork control voltage.
Parameter value 25: = +/-0.12 V neutral voltage
Parameter 509
Use this parameter to adjust the voltage level for the neutral range in
relation to the calibrated speed control voltage.
Parameter 510
Use this parameter to adjust the activation time of the ICP display
screensaver. The time is set in minutes.
Parameter value 0: The screensaver is switched off and the display will
light all the time.
NOTE:
To ensure proper display function when working at temperatures under +10oC, set parameter 510 to the 0 value
Parameter 530 - 539

Use these parameters to adapt the camera picture on video input 1
when using another camera than a BT specified camera.
Parameter 540 - 549

Use these parameters to adapt the camera picture on video input 2
when using another camera than a BT specified camera.
20- 252
Service Manual
BT Europe AB

Warning and error codes
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
20.22 Warning and error codes

20.22.1 Error handling
All electronic modules send status reports to the MCU error handling
module. The MCU is able to limit the operation of certain function,
switch off malfunctioning units/functions and to switch off the entire
truck. Depending on the seriousness of an error, each electronic module is able to take its own countermeasures.
Errors are classified into two levels of seriousness:
3:523
10:40
00:00
00:07
Warning: Warnings are displayed with a yellow warning symbol.

The malfunctioning unit will either be switched off or its malfunctioning mode will become limited.
In case the error cause disappears, warnings can recover by themselves.
Error: Errors are displayed with a red stop symbol.
All truck functions will be switched off.
Error cannot recover by themselves. Log-out and subsequent log-in
by the operator is required.
When an error occurs, the buzzer sounds and a code with a corresponding symbol is displayed at the upper left corner of the display.
The code consists of a group number and a detailed code. The group
number indicates the subsystem of the truck where the error has
occurred.
WARNING!
Do not ignore error indications.
This could jeopardise truck safety.
Always inspect all truck functions prior to starting up the truck.
Error grouping
Errors are generally grouped into six different function groups as indicated below:
1. Group 1: ICP
Internal errors and communication errors detected by the

ICP.
2. Group 2: MCU
Internal errors and communication errors detected by the

MCU.
3. Group 3: Travel system
Travel operation errors and other errors detected by the

ACTx.
4. Group 4: Cabin lift/lowering system
Cabin lift/lowering operation errors and other errors detected

by the ACH.
BT Europe AB
Service Manual
20- 253

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
5. Group 5: Steering system
Steering system errors, errors detected by the wire guidance

electronic modules and errors detected by the DCHI.
6. Group 6: Initial lift and turret head fork unit systems
Errors detected by the FCU.
Error recording
Error codes (both warning and error codes) are registered and stored in
the MCU memory when the operator logs out. If an error occurs while a
warning condition is in progress, only the error code is stored.
The error code history can be viewed on the display via the information
mode, symbolised by a red [E100] symbol.
The following data is stored in the error code log:
- Log entry number
- Error code [group and detailed code]
- Date and time of registration
- All hour counters [A, B, C, D, E, S]
- Battery discharge status [%]
- Travel speed [km/h]
- Cabin lift height [mm]
- Hydraulic pressure, cabin lift system [bar]
- Hydraulic pressure, initial lift system [bar]
- Temperatures in the AC chopper amps [ C]
- 2 optional values (selected with parameters 152 and 153 in the
MCU)
To select the log entry number, use the [UP]/[DOWN] keys.
The error code log can be deleted by pressing the soft-key next to the
waste basket symbol. Confirm by pressing the green OK key (green
check mark) or cancel by pressing the cancel key (red cross).
The MCU features a green LED that shows the internal status of the
MCU. The LED lights continuously when the status is OK and blinks
whenever an error (in group 2) occurs.
20- 254
Service Manual
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
20.22.2 Safety logics

To maintain safety in case of the various errors and events, the measures listed in the table below are taken:
M = Measure by MCU
I = Measure by ICP
Steering disengaged
Hydraulics of
turret head fork unit/initial lift
blocked
Main contactor opened
Reversing braking with

drive motors
Keypad not working M
Steering error
Wire guidance error
Drive controller
error
Cabin lift controller

error
Initial lift/fork turret

head control error
Critical error in ICP
M
M
Non-critical error in
ICP
Critical error in
MCU
M, I
M
MCU
Critical error in FCU
FCU
BT Europe AB
Affected function blocked

(see error code list)
Cabin lift function blocked
Emergency Switch- M
Off switch (ESO)
engaged
Measure:
Parking brake engaged
Event:
Key relay opened
F = Measure by FCU
Service Manual
20- 255

Parking brake engaged
Cabin lift function blocked
Steering disengaged
Hydraulics of
turret head fork unit/initial lift
blocked
Main contactor opened
Reversing braking with

drive motors
Order number
227761-040
Measure:
Event:
Date
2005-11-28
Error in CAN 1
Error in CAN 2
End-of-aisle braking/stopping
Personal Safety
System
Right dead man's

handle released
Left dead man's

handle released
Brake button
engaged
Steering wheel
error
20- 256
Affected function blocked

(see error code list)

919699-
Key relay opened
T-code
712, 713
M
M
Service Manual
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
20.23 Warning and error codes

20.23.1 ICP, code group 1
ICP warning codes
BT Europe AB
Code:
1: 001
Error type:
BTVM communication warning
Description:
Communication with BTVM has been lost.
Measure:
Check whether the BTVM application is running.

Check the communications settings in the BTVM.
Inspect the RS-232 cabling.
Code:
1:002
Error type:
BTVM version, compatibility warning
Description:
The BTVM and ICP display versions do not correspond.

The BTVM does not support certain display functions
used by the ICP, and vice versa.
Measure:
Check to make sure that the same firmware versions are

used.
Code:
1:003
Error type:
Slight version deviation, compatibility warning
Description:
Slight deviation in compatibility between the MCU and

ICP firmware versions. The MCU does not support certain functions used by the ICP, and vice versa.
Measure:

used.
Code:
1:004
Error type:
Display version, compatibility warning
Description:
The MCU and ICP display versions do not correspond.

The MCU does not support certain display functions
used by the ICP, and vice versa.
Measure:

used.
Service Manual
20- 257

T-code
712, 713
20- 258

919699-
Date
2005-11-28
Order number
227761-040
Code:
1:005
Error type:
High temperature, warning
Description:
The temperature in the ICP housing has reached the

upper limit.
Measure:
Check for correct operation of the M15 cooling fan.

Install a cooling fan.
Code:
1:006
Error type:
Low temperature, warning
Description:
The temperature in the ICP housing has reached the

lower limit.
Measure:
If the truck is fitted with a cooling fan, disconnect the fan.
Code:
1:007
Error type:
CAN 1 bus off, warning
Description:
The CAN module error counter has reached the warning

level due to a transmission error.
Measure:
Inspect the CAN 1 cabling.

Inspect the termination resistor.
Inspect the other CAN 1 nodes.
Code:
1:008
Error type:
Preselected parameters, warning
Description:
Default parameters were loaded due to different firmware

versions having been downloaded.
Measure:
Check that all parameters have been set as desired.

Note! To remove the warning, disconnect and reconnect
battery voltage.
Service Manual
BT Europe AB

Order number
227761-040
BT Europe AB
Date
2005-11-28

919699-
T-code
712, 713
Code:
1:009
Error type:
Calibration of controls, warning
Description:
The left and right controls are missing a calibrated value.

This code is also generated if a control error (511-512)
has occurred during a previous log-in.
Measure:
Calibrate the controls.
Code:
1:010
Error type:
Digital output 1, short-circuit warning
Description:
A short-circuit has been detected on digital output 1.
Measure:
Check the X101:12 output.
Code:
1:011
Error type:
Description:
Measure:
Code:
1:012
Error type:
Description:
Measure:
Code:
1:013
Error type:
Description:
Measure:
Service Manual
20- 259

T-code
712, 713
20- 260

919699-
Date
2005-11-28
Order number
227761-040
Code:
1:014
Error type:
Key relay output, short-circuit warning
Description:
A short-circuit has been detected on the digital output for

key relay K17.
Measure:
Code:
1:015
Error type:
Digital output 1, interruption warning
Description:
No load on digital output 1 (Y19).
Measure:
Inspect output X101:12 and check parameter 502.

Inspect the valve coil and cabling.
Code:
1:016
Error type:
Description:
No load on digital output 2 (Y18).
Measure:

Inspect the valve coil and cabling.
Code:
1:017
Error type:
Description:
No load on digital output 3.
Measure:
Code:
1:018
Error type:
Description:
No load on digital output 4.
Measure:
Service Manual
BT Europe AB

Order number
227761-040
BT Europe AB
Date
2005-11-28

919699-
T-code
712, 713
Code:
1:019
Error type:
Wire guidance switch, warning
Description:
The wire guidance switch has been detected as high during the log-in procedure.
Measure:
Code:
1:020
Error type:
Horn switch, warning
Description:
One of the horn switches has been detected as high during the log-in procedure.
Measure:
Inspect outputs X100:7 and X103:9.
Code:
1:021
Error type:
Shift function switch, warning
Description:
The shift function switch has been detected as high during the log-in procedure.
Measure:
Code:
1:022
Error type:
Cabin lift switch, warning
Description:
The cabin lift switch has been detected as high during

the log-in procedure.
Measure:
Code:
1:023
Error type:
Cabin lowering switch, warning
Description:
The cabin lowering switch has been detected as high

during the log-in procedure.
Measure:
Service Manual
20- 261

T-code
712, 713
20- 262

919699-
Date
2005-11-28
Order number
227761-040
Code:
1:024
Error type:
Counter-clockwise rotation switch, warning
Description:
The counter-clockwise rotation switch has been detected

as high during the log-in procedure.
Measure:
Code:
1:025
Error type:
Clockwise rotation switch, warning
Description:
The clockwise rotation switch has been detected as high

during the log-in procedure.
Measure:
Code:
1:026
Error type:
Right dead man's handle switch, warning
Description:
The right dead man's handle switch has been detected

as high during the log-in procedure.
Measure:
Code:
1:027
Error type:
Left dead man's handle switch, warning
Description:
The left dead man's handle switch has been detected as

high during the log-in procedure.
Measure:
Code:
1:028
Error type:
RS-232 parity warning
Description:
A parity control error (communication error) has been

detected in the RS-232 interface.
Measure:

Service Manual
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
Code:
1:029
Error type:
RS-232 protocol warning
Description:
A protocol error (communication error) has been

detected in the RS-232 interface.
Measure:
Code:
1:030
Error type:
RS-232 overload warning
Description:
An overload error (communication error) has been

detected in the RS-232 interface. Data received by the
ICP has not been completely handled by the ICP prior to
receipt of new data (data was lost).
Measure:

ICP error codes
BT Europe AB
Code:
1:500
Error type:
Considerable version deviation, compatibility warning
Description:
Large deviation in compatibility between the MCU and

ICP firmware versions. Communication cannot be considered safe.
Measure:

used.
Code:
1:501
Error type:
+5 V outside tolerance limits
Description:
5 V voltage feed of external sensors outside given tolerances.
Measure:
Check the X102:10 input.

Check for any external overload (sensors).
Inspect the circuit for short-circuits.
Check the ICP voltage feed value.
Service Manual
20- 263

T-code
712, 713
20- 264

919699-
Date
2005-11-28
Order number
227761-040
Code:
1:502
Error type:
Description:
Measure:

Code:
1:503
Error type:
+9.5 V outside tolerance limits
Description:
9.5 V voltage feed of TFT display outside given tolerances.
Measure:
Inspect the flat cable connecting the display.

Code:
1:504
Error type:
Steering pulse transducers, voltage feed error
Description:
Current that flows through the steering pulse transducers

1 and/or 2 has been detected as too lower during normal
operation.
Measure:
Check inputs X100:13 and X100:16.

Inspect the pulse transducers in the steering wheel.
Code:
1:505
Error type:
Steering pulse transducers, differentiation error
Description:
A difference in the signal value between the steering

pulse transducer 1 and/or steering pulse transducer 2
was detected during normal operation.
Measure:

Service Manual
BT Europe AB

Order number
227761-040
BT Europe AB
Date
2005-11-28

919699-
T-code
712, 713
Code:
1:506
Error type:
Key relay, short-circuit error
Description:
Key relay K17 was detected as closed when it was

expected to be open.
Measure:

Inspect the key relay K17.
Code:
1:507
Error type:
Key relay, interruption error
Description:
Key relay K17 was detected as open when it was

expected to be closed.
Measure:

Inspect the key relay K17.
Code:
1:508
Error type:
CAN, PDO error
Description:
Cyclic messages from the MCU interrupted for more than

60 ms.
These messages should be received by the ICP every
20 ms.
Measure:
Check the mast cabling.

Inspect the other Check CAN1 nodes.
Code:
1:509
Error type:
CAN, bus off error
Description:
The CAN module error counter has reached the error

Measure:

Service Manual
20- 265

T-code
712, 713
20- 266

919699-
Date
2005-11-28
Order number
227761-040
Code:
1:510
Error type:
Right rocker switch, error
Description:
The right rocker switch has been detected to be outside

the neutral position tolerance limit during start-up or outside the allowed operating area during normal operation.
Measure:

Check the calibrated value for the right rocker switch R1.
Code:
1:511
Error type:
Left rocker switch, error
Description:
The left rocker switch has been detected to be outside

the neutral position tolerance limit during start-up or outside the allowed operating area during normal operation.
Measure:

Check the calibrated value for the left rocker switch R2.
Code:
1:512
Error type:
Brake button, error
Description:
One of both break button switches has been detected

not to have opposite status.
Measure:

Inspect the brake switch S48
Code:
1:513
Error type:
Brake button, start-up error
Description:
One of both break button switches has been detected to

have incorrect signal level during the start-up procedure.
Measure:

Inspect the brake switch S48
Service Manual
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
Code:
1:514
Error type:
Abnormal steering speed
Description:
The measured time between two pulses received from

the steering wheel's pulse transducer is too short (steering request is too quick).
Measure:
Perform the following check at normal steering speed:

20.23.2 MCU, code group 2

MCU warning codes
Note:
Code 001-099 is stored in the error code log, but will not result in any
operational limitations.
BT Europe AB
Code:
2:001
Error type:
Memory checksum error, warning.
Description:
The checksum of the MCU memory is wrong.
Measure:
In case of repeated warnings, restarting the truck may

rectify the error.
Code:
2:002
Error type:
Description:
Default parameters have been downloaded to the MCU.
Measure:
Code:
2:003
Error type:
Description:

Measure:

Service Manual
20- 267

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Code:
2:004
Error type:
Description:

Measure:

Code:
2:005
Error type:
Service counter, warning
Description:
The service counter timer indicates that the set service

interval has been reached.
Measure:
Following complete service, use parameter 150 to set

the new time until the next service intervention. Default
value is set to 0 which means that the service timer is
switched off by default.
Note:
Code 100-499 is stored in the error code log and the following measures are taken: Cabin lifting/lowering is blocked, the truck will be
braked and stop through reversing of the motor and steering will be
disengaged.
20- 268
Code:
2:100
Error type:
FCU CAN PDO error
Description:
The FCU has not acknowledged the PDO message during the past 70 ms.
Measure:
Check to make sure that the FCU connection is OK.

Inspect the mast cabling.
Code:
2:101
Error type:
FCU start-up error
Description:
The FCU does not respond during start-up of the truck.
Measure:
Check to make sure that the key relay is on.

Check to make sure that the FCU connection is OK.
Inspect the mast cabling.
Service Manual
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
Code:
2:103
Error type:
ACH CAN PDO error
Description:
The ACH has not acknowledged the PDO message during the past 70 ms.
Measure:
Check to make sure that the ACH connection is OK.

Inspect the rear chassis CAN cabling.
MCU error codes

Measures:
All truck movements will be stopped as a result of the the main contactor K10 opening.
BT Europe AB
Code:
2:500
Error type:
Digital output 3 short-circuited
Description:
The output to the main contactor (K10) and the chassis

relay (K18) is short-circuited.
Measure:
Inspect the main contactor (K10) coil.

Inspect the chassis relay (K18) coil.
Inspect the connection plugs and cabling.
Check the voltage feed.
The MCU could be defective.
Code:
2:501
Error type:
Digital output 3 interruption
Description:
The output to the main contactor (K10) and the chassis

relay (K18) has been interrupted.
Measure:
Inspect the main contactor (K10) coil.

Service Manual
20- 269

T-code
712, 713
20- 270

919699-
Date
2005-11-28
Order number
227761-040
Code:
2:502
Error type:
Chassis relay open
Description:
The chassis relay (K18) status indicates that the relay is

open when the truck is in the normal operating mode.
Measure:

Check the fuse F60.
Code:
2:503
Error type:
Chassis relay closed
Description:
The chassis relay (K18) status indicates that the relay is

closed when the truck has been switched off.
Measure:

Code:
2:504
Error type:
Chassis relay does not respond
Description:
The chassis relay (K18) status indicates that the relay

does not close when the truck is started.
Measure:

Check the fuse F60.
Service Manual
BT Europe AB

Order number
227761-040
BT Europe AB
Date
2005-11-28

919699-
T-code
712, 713
Code:
2:505
Error type:
Battery voltage error.
Description:
The battery voltage to the MCU is less than 35.5 V during start-up.
Measure:
Inspect the battery's charge status.

Inspect the battery connector.
Inspect the battery cables.
Inspect the fuse F61.
Inspect the cabling on input X131:1.
Code:
2:506
Error type:
ICP CAN PDO error
Description:
The ICP has not acknowledged the PDO message during the past 70 ms.
Measure:
Check that the ICP connector X101 is OK.

Inspect the mast CAN cabling.
Code:
2:507
Error type:
ACTR CAN PDO error
Description:
The ACTR has not acknowledged the PDO message

during the past 70 ms.
Measure:
Check to make sure that the ACTR connection is OK.

Code:
2:508
Error type:
ACTL CAN PDO error
Description:
The ACTL has not acknowledged the PDO message during the past 70 ms.
Measure:
Check to make sure that the ACTL connection is OK.

Service Manual
20- 271

T-code
712, 713
20- 272

919699-
Date
2005-11-28
Order number
227761-040
Code:
2:509
Error type:
DCHI CAN PDO error
Description:
The DCHI has not acknowledged the PDO message during the past 70 ms.
Measure:
Check to make sure that the DCHI connection is OK.

Code:
2:510
Error type:
DCHI start-up error
Description:
The DCHI does not respond during start-up.
Measure:
Check the LED status on the DCHI.

Code:
2:511
Error type:
ACH start-up error
Description:
The ACH does not respond during start-up.
Measure:
Check for a green LED indication on the ACH.

Code:
2:512
Error type:
ACH time-out error
Description:
The ACH reports a communication error (time-out).
Measure:

Service Manual
BT Europe AB

Order number
227761-040
BT Europe AB
Date
2005-11-28

919699-
T-code
712, 713
Code:
2:513
Error type:
ACTx start-up error
Description:
Neither the ACTR nor ACTL respond during start-up.
Measure:
Check for a green LED indication on the ACTR and

ACTL.
Check to make sure that the ACTR and ACTL connection is OK.
Code:
2:514
Error type:
ACTx time-out error
Description:
The ACTR or ACTL reports a communication error (timeout).
Measure:
Check for a green LED indication on the ACTR and

ACTL.
Check to make sure that the ACTR and ACTL connection is OK.
Code:
2:516
Error type:
ACTR start-up error
Description:
The ACTR does not respond during start-up
Measure:
Check for a green LED indication on the ACTR.

Code:
2:518
Error type:
ACTL start-up error
Description:
The ACTL does not respond during start-up
Measure:
Check for a green LED indication on the ACTL.

Service Manual
20- 273

T-code
712, 713
20- 274

919699-
Date
2005-11-28
Order number
227761-040
Code:
2:519
Error type:
Controller, voltage error
Description:
The capacitors in the ACH/ACTR/ACTL are below 30 V

when the MCU needs to activate the main contactor K10.
Measure:
Check the fuse F62.

Inspect the X131:15 connection.
Code:
2:520
Error type:
Controller, start-up error
Description:
The ACH/ACTR/ACTL or DCHI start-up sequence failed.
Measure:
Inspect the cabling to all controllers.

Inspect the connector plugs on all controllers.
Code:
2:521
Error type:
CAN 1 bus off, error
Description:

Measure:

Code:
2:522
Error type:
CAN 2 bus off, error
Description:

Measure:

Service Manual
BT Europe AB

Order number
227761-040
BT Europe AB
Date
2005-11-28

919699-
T-code
712, 713
Code:
2:523
Error type:
Description:
Measure:

Check the MCU voltage feed value.
Code:
2:524
Error type:
+5 V logic voltage outside tolerance limits
Description:
5 V voltage feed for the MCU's internal logical circuits is

outside the allowed limit.
Measure:

Code:
2:525
Error type:
+15 V internal voltage outside tolerance limits
Description:
15 V voltage feed for the MCU's internal circuits is outside the allowed limit.
Measure:

Code:
2:526
Error type:
Description:
Measure:

Code:
2:527
Error type:
+12 V internal voltage outside tolerance limits
Description:
12 V voltage feed for the MCU's internal circuits is outside the allowed limit.
Service Manual
20- 275

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Code:
2:527
Measure:

Code:
2:528
Error type:
+UgV internal voltage outside tolerance limits
Description:
UgV voltage feed for the MCU's internal A/D converters

is outside the allowed limit.
Measure:

Code:
2:529
Error type:
The MCU and ICP emergency drive modes differ.
Description:
The MCU and ICP are not in accord regarding the emergency drive mode.
Measure:
Try to restart the truck.
20.23.3 Drive system, code group 3

Drive system - warning codes
Note:
20- 276
Code:
3:001
Error type:
Right drive motor, temperature warning
Description:
The temperature in the right drive motor is too high or the

temperature sensor in the motor is defective.
Measure:
Check the drive motor temperature.

Inspect the temperature sensor B2 in the drive motor M2.
Inspect the temperature sensor connection plug.
Inspect the cabling between M2 and the ACTR.
Code:
3:002
Error type:
ACTR, temperature warning
Description:
The temperature in the ACTR is too high, the temperature in the capacitors of the ACTR is too high or the temperature sensor in the ACTR is defective.
Service Manual
BT Europe AB

Order number
227761-040
BT Europe AB
Date
2005-11-28

919699-
T-code
712, 713
Code:
3:002
Measure:
Check the ACTR temperature.

Inspect the ACTR connection plug.
Inspect the cabling connecting the ACTR.
Code:
3:003
Error type:
ACTR offset warning
Description:
ACTR current calibration error.
Measure:
Check the ACTR LED.

Code:
3:005
Error type:
Left drive motor, temperature warning
Description:
The temperature in the left drive motor is too high or the

Measure:

Inspect the cabling between M1 and the ACTL.
Code:
3:006
Error type:
ACTL, temperature warning
Description:
The temperature in the ACTL is too high, the temperature in the capacitors of the ACTL is too high or the temperature sensor in the ACTL is defective.
Measure:
Check the ACTL temperature.

Inspect the ACTL connection plug.
Inspect the cabling connecting the ACTL.
Service Manual
20- 277

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Code:
3:007
Error type:
ACTL offset warning
Description:
ACTL current calibration error.
Measure:
Check the ACTL LED.

Note:
Code 100-499 is stored in the error code log and the following measures are taken: The travel speed is reduced.
20- 278
Code:
3:100
Error type:
Signal error, narrow aisle sensors
Description:
The narrow aisle sensor 1 does not have the same signal
level as the narrow aisle sensor 2 (they must have the
same signal level).
Measure:

Use a magnet to verify that the sensors are triggered.
Inspect the sensor cabling and check for short-circuits
and interruptions.
Inspect the connection plugs of the cabling.
Set the signal level to the same level as that of the magnet.
Code:
3:101
Error type:
Signal error, narrow aisle centre zone sensors
Description:
The end-of-aisle braking sensor triggers, but the narrow

aisle sensors 1 and 2 do not come on (outside narrow
aisle).
Measure:

and interruptions.
Service Manual
BT Europe AB

Order number
227761-040
BT Europe AB
Date
2005-11-28

919699-
T-code
712, 713
Code:
3:102
Error type:
PPS, time-out error
Description:
Information not available.
Measure:
Information not available.
Code:
3:103
Error type:
Signal error, end-of-aisle braking sensor
Description:
The end-of-aisle braking sensor 1 does not have the

same signal level as sensor 2 (they must have the same
signal level).
Measure:

and interruptions.
Code:
3:104
Error type:
Signal error, end-of-aisle stopping sensor
Description:
The end-of-aisle stopping sensor 1 does not have the

same signal level as sensor 2 (they must have the same
signal level).
Measure:

and interruptions.
Service Manual
20- 279

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Drive system - error codes

Measures:
All truck movements will be stopped as a result of the main contactor
K10 opening.
20- 280
Code:
3:500
Error type:
ACTR CPU or memory error
Description:
Internal ACTR error.
Measure:
Verify the voltage feed to the ACTR.
Code:
3:501
Error type:
Right drive motor, overheating
Description:
The temperature in the right drive motor is too high or the

Measure:

Inspect the cabling between M2 and the ACTR.
Code:
3:502
Error type:
ACTR, capacitor temperature
Description:
The temperature in the ACTR capacitors is too high.
Measure:

Code:
3:503
Error type:
ACTR, cooling unit temperature
Description:
The temperature in the ACTR cooling unit is too high.
Measure:

Code:
3:504
Error type:
ACTR, current limit
Description:
The ACTR is constantly above the current limit.
Service Manual
BT Europe AB

Order number
227761-040
BT Europe AB
Date
2005-11-28

919699-
T-code
712, 713
Code:
3:504
Measure:
Verify that the parking brake Y2 is not applied.

Inspect the power cables ACTR/M2.
Inspect the M2 windings.
Check for mechanical seizure in M2.
Check for mechanical seizure in the right driving gear.
Code:
3:505
Error type:
ACTR, over-voltage
Description:
DC voltage has been detected as too high by the hardware.
Measure:
This may happen when regenerating to an overcharged

battery.
Check the battery voltage.
Code:
3:506
Error type:
ACTR, over-voltage
Description:
DC voltage has been detected as too high by the

firmware.
Measure:

battery.
Code:
3:507
Error type:
ACTR, under-voltage
Description:
DC voltage has been detected as too low by the

firmware.
Measure:

Inspect the K10 contactor tips.
Service Manual
20- 281

T-code
712, 713
20- 282

919699-
Date
2005-11-28
Order number
227761-040
Code:
3:508
Error type:
ACTR, under-voltage at start-up
Description:
DC voltage has been detected as too low during start-up.
Measure:

Code:
3:509
Error type:
ACTR, too many CAN errors
Description:
The ACTR has detected too many communication errors

in CAN 2.
Measure:

Code:
3:510
Error type:
ACTR time-out error
Description:
The ACTR reports a communication error (time-out).
Measure:
Check for a green LED indication on the ACTR.

Code:
3:511
Error type:
ACTL CPU or memory error
Description:
Internal ACTL error.
Measure:
Inspect the voltage feed to the ACTL.
Code:
3:512
Error type:
Left drive motor, overheating
Description:
The temperature in the left drive motor is too high or the

Measure:

Inspect the cabling between M1 and the ACTL.
Service Manual
BT Europe AB

Order number
227761-040
BT Europe AB
Date
2005-11-28

919699-
T-code
712, 713
Code:
3:513
Error type:
ACTL, capacitor temperature
Description:
The temperature in the ACTL capacitors is too high.
Measure:

Code:
3:514
Error type:
ACTL, cooling unit temperature
Description:
The temperature in the ACTL cooling unit is too high.
Measure:

Code:
3:515
Error type:
ACTL, current limit
Description:
The ACTL is constantly above the current limit.
Measure:
Verify that the parking brake Y1 is not applied.

Inspect the power cables ACTL/M1.
Check for mechanical seizure in the left driving gear.
Code:
3:516
Error type:
ACTL, over-voltage
Description:
Measure:

battery.
Service Manual
20- 283

T-code
712, 713
20- 284

919699-
Date
2005-11-28
Order number
227761-040
Code:
3:517
Error type:
ACTL, over-voltage
Description:

firmware.
Measure:

battery.
Code:
3:518
Error type:
ACTL, under-voltage
Description:

firmware.
Measure:

Code:
3:519
Error type:
ACTL, under-voltage at start-up
Description:
Measure:

Code:
3:520
Error type:
ACTL, too many CAN errors
Description:
The ACTL has detected too many communication errors

in CAN 2.
Measure:

Service Manual
BT Europe AB

Order number
227761-040
BT Europe AB
Date
2005-11-28

919699-
T-code
712, 713
Code:
3:521
Error type:
ACTL time-out error
Description:
The ACTL reports a communication error (time-out).
Measure:
Check for a green LED indication on the ACTL.

Code:
3:522
Error type:
Motor braking error
Description:
Slowdown during motor braking does not follow the

specified retardation curve.
Measure:
Check the LED status on the ACTx.

Inspect the power cabling ACTx-M1/M2.
Inspect M1/M2.
Code:
3:523
Error type:
Description:
Short-circuit in the left parking brake Y1 circuit.
Measure:
Inspect the parking brake (Y1) coil.

Code:
3:524
Error type:
Description:
Interruption in the left parking brake Y1 circuit.
Measure:

Service Manual
20- 285

T-code
712, 713
20- 286

919699-
Date
2005-11-28
Order number
227761-040
Code:
3:525
Error type:
Description:
Short-circuit in the right parking brake Y2 circuit.
Measure:

Code:
3:526
Error type:
Description:
Interruption in the right parking brake Y2 circuit.
Measure:

Code:
3:527
Error type:
PWM output 3 interrupted
Description:
The circuit of the support arm brakes Y5 and Y6 has

short-circuited.
Measure:
Inspect the support arm brake (Y5/Y6) coils.

Code:
3:528
Error type:
Description:
Interruption in the circuit of the support arm brakes Y5

and Y6.
Measure:
Inspect the support arm brake (Y5/Y6) coils.

Service Manual
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
20.23.4 Cabin lift system, code group 4

Cabin lift system - warning codes
Note:
BT Europe AB
Code:
4:001
Error type:
Pump motor, temperature warning
Description:
The temperature in the AC pump motor is too high or the

Measure:
Check the pump motor temperature.

Inspect the cabling between M3 and the ACH.
Code:
4:002
Error type:
ACH, temperature warning
Description:
The temperature in the ACH is too high, the temperature

in the capacitors of the ACH is too high or the temperature sensor in the ACH is defective.
Measure:
Check the ACH temperature.

Inspect the ACH connection plug.
Inspect the cabling connecting the ACH.
Code:
4:003
Error type:
ACH offset warning
Description:
ACH current calibration error.
Measure:
Check the ACH LED.

Service Manual
20- 287

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Code:
4:005
Error type:
Narrow aisle identification, sensor warning
Description:
One of the narrow aisle sensors is defective.
Measure:
Check the inputs X130:41, X131:2 and X131:16.
Note:
Code 100-499 is stored in the error code log and the following measures are taken: Cabin lifting is blocked, the travel speed is reduced.
Cabin lowering is blocked for codes 100-111 and 116-117.
20- 288
Code:
4:100
Error type:
Regeneration error, lowering
Description:
The lowering speed is too high.
Measure:
Inspect the speed sensor U12 in M3.

Check the LED status on the ACH.
Inspect the power cabling ACH-M3.
Inspect M3.
Code:
4:101
Error type:
ACH CPU or memory error
Description:
Internal ACH error.
Measure:
Verify the voltage feed to the ACH.
Code:
4:102
Error type:
Pump motor, overheating
Description:
The temperature in the AC pump motor is too high or the

Measure:
Check the pump motor temperature.

Inspect the cabling between M3 and the ACH.
Service Manual
BT Europe AB

Order number
227761-040
BT Europe AB
Date
2005-11-28

919699-
T-code
712, 713
Code:
4:103
Error type:
ACH, capacitor temperature
Description:
The temperature in the ACH capacitors is too high.
Measure:

Code:
4:104
Error type:
ACH, cooling unit temperature
Description:
The temperature in the ACH cooling unit is too high.
Measure:

Code:
4:105
Error type:
ACH, current limit
Description:
The ACH is constantly above the current limit.
Measure:
Inspect the power cables ACH/M3.

Check for mechanical seizure in the hydraulic pump.
Code:
4:106
Error type:
ACH, over-voltage
Description:
Measure:

battery.
Service Manual
20- 289

T-code
712, 713
20- 290

919699-
Date
2005-11-28
Order number
227761-040
Code:
4:107
Error type:
ACH, over-voltage
Description:

firmware.
Measure:

battery.
Code:
4:108
Error type:
ACH, under-voltage
Description:

firmware.
Measure:

Code:
4:109
Error type:
ACH, under-voltage at start-up
Description:
Measure:

Code:
4:110
Error type:
ACH, too many CAN errors
Description:
The ACH has detected too many communication errors

in CAN 2.
Measure:

Service Manual
BT Europe AB

Order number
227761-040
BT Europe AB
Date
2005-11-28

919699-
T-code
712, 713
Code:
4:111
Error type:
ACH time-out error
Description:
The ACH reports a communication error (time-out).
Measure:

Code:
4:112
Error type:
Hydraulic pressure during lifts, error
Description:
The sensor signal for the hydraulic pressure during cabin

lifting is outside the allowed limits.
Measure:
Inspect input X130:3.

Inspect sensor B5.
Code:
4:113
Error type:
B cylinder pressure, error
Description:
The sensor signal for the hydraulic pressure in the B cylinder is outside the allowed limits.
Measure:

Inspect sensor B6.
Code:
4:114
Error type:
Height sensor error
Description:
No signals received from the height measuring sensor

during cabin lifting.
Measure:
Verify the voltage feed to U10.

Verify the U10 pulses.
Service Manual
20- 291

T-code
712, 713
20- 292

919699-
Date
2005-11-28
Order number
227761-040
Code:
4:115
Error type:
Incorrect measuring of the height sensor
Description:
The current height value does not correspond with the

height reference signal.
Measure:
Check to make sure that the reference sensor S71 is

operating.
Verify the voltage feed to S71.
Also check parameter 176, i.e. the predefined cabin floor
height at which the reference sensor should switch operating status.
Code:
4:116
Error type:
Description:
The circuit for the cabin lowering valves Y21/Y29 has

short-circuited.
Measure:
Inspect the valve (Y21/Y29) coils.

Inspect output X131:8.
Code:
4:117
Error type:
Description:
Interruption of the circuit for the cabin lowering valves

Y21/Y29.
Measure:
Inspect the valve (Y21/Y29) coils.

Inspect output X131:8.
Service Manual
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
20.23.5 Steering system, code group 5

Steering system - warning codes
Note:
Code:
5:001
Error type:
Articulated centre potentiometer warning
Description:
The potentiometer value for straight centre has not been

learned.
Measure:
Calibrate the straight centre posture.
Code:
5:002
Error type:
Wire guidance has not been learned
Description:
The wire guidance parameters are outside the allowed

limits.
Measure:
Calibrate the offset or the frequency.
Code:
5:003
Error type:
DCHI, temperature warning
Description:
The temperature in the DCHI cooling unit is too high.
Measure:
Check the DCHI temperature.

Inspect the DCHI connection plug.
Inspect the cabling connecting the DCHI.
Code:
5:004
Error type:
DCHI, under-voltage
Description:
DC voltage has been detected as too low.
Measure:

Note:
Code 100-499 is stored in the error code log and the following measures are taken: The truck will be braked and stop through reversing of
the motor, steering will be disengaged and initial lifting unit operation
will be blocked.
BT Europe AB
Service Manual
20- 293

T-code
712, 713
20- 294

919699-
Date
2005-11-28
Order number
227761-040
Code:
5:100
Error type:
Right coil of load direction antenna, error
Description:
The wire guidance logic system does not receive any

signal from the right coil in the load direction antenna.
Measure:
Verify the voltage feed to W1.

Inspect the cabling and the connection plugs.
Check the W1 signal level.
Try to restart the truck and search for the wire anew.
Code:
5:101
Error type:
Left coil of load direction antenna, error
Description:

signal from the left coil in the load direction antenna.
Measure:

Code:
5:102
Error type:
Reference coils of the load direction antenna, error
Description:

signal from the reference coils in the load direction
antenna.
Measure:

Code:
5:103
Error type:
Right coil of drive unit direction antenna, error
Description:

signal from the right coil in the drive unit direction
antenna.
Measure:

Service Manual
BT Europe AB

Order number
227761-040
BT Europe AB
Date
2005-11-28

919699-
T-code
712, 713
Code:
5:104
Error type:
Left coil of drive unit direction antenna, error
Description:

signal from the left coil in the drive unit direction antenna.
Measure:

Code:
5:105
Error type:
Reference coils of drive unit load direction antenna, error
Description:

signal from the reference coils in the drive unit direction
antenna.
Measure:

Code:
5:106
Error type:
The search limits of the wire guidance system have been

exceeded.
Description:
The truck has drifted outside the configured angle and

lateral signal values.
The truck has driven off the wire.
Measure:
Check how the trucks travels on the wire.
Calibrate OFFSET.
Check/adjust the angle and lateral parameter values.
Reduce the speed on the wire.
Service Manual
20- 295

T-code
712, 713
20- 296

919699-
Date
2005-11-28
Order number
227761-040
Code:
5:107
Error type:
The angle search limit of the wire guidance system has

been exceeded.
Description:
The truck has drifted outside the configured angle signal

values.
Measure:
Calibrate OFFSET.
Check/adjust the angle parameter value.
Code:
5:108
Error type:
The distance-to-wire search limit of the wire guidance

system has been exceeded.
Description:
The truck has drifted outside the configured lateral signal

values.
Measure:
Calibrate OFFSET.
Check/adjust the distance-to-wire parameter value.
Code:
5:109
Error type:
Too large a steering response in wire-guided aisle
Description:
Steering angle > 10o when driving on the wire.
Measure:
Calibrate STEERING for both PIVOT and VALVES
Calibrate OFFSET.
Service Manual
BT Europe AB

Order number
227761-040
BT Europe AB
Date
2005-11-28

919699-
T-code
712, 713
Code:
5:110
Error type:
Wire was lost
Description:
Truck was locked on wire, but none of the antennas

sense the wire.
Measure:
Calibrate OFFSET.
Code:
5:111
Error type:
No signal from the drive unit direction antenna
Description:
The drive unit direction antenna does not sense the wire
when the truck is locked on the wire or the truck has lost
the wire.
Measure:
Check the voltage feed to W2.
Calibrate OFFSET.
Code:
5:112
Error type:
No signal from the load direction antenna
Description:
The load direction antenna does not sense the wire

when the truck is locked on the wire or the truck has lost
the wire.
Measure:
Calibrate OFFSET.
Service Manual
20- 297

T-code
712, 713
20- 298

919699-
Date
2005-11-28
Order number
227761-040
Code:
5:113
Error type:
Field strength of wire is too high for the coil pair in the
antennas
Description:
The wire generator could be incorrectly adjusted.
Measure:
Inspect the wire generator.

Check the antenna mounting height.
Calibrate FREQUENCY.
Select parameter 165 and set another frequency.
Code:
5:114
Error type:
Signal level from load direction antenna too high
Description:
The "Tracking wire" signal from the load direction

antenna exceeds 4.75 volts
Measure:
Check the antenna mounting height, W1.

Calibrate OFFSET.
Code:
5:115
Error type:
Signal level from drive unit direction antenna too high
Description:
The "Tracking wire" signal from the drive unit direction

antenna exceeds 4.75 volts
Measure:
Check the antenna mounting height, W2.

Calibrate OFFSET.
Code:
5:116
Error type:
Wire guidance not installed
Description:
No filter card in the MCU; internal communication error
Measure:
Service Manual
BT Europe AB

Order number
227761-040
BT Europe AB
Date
2005-11-28

919699-
T-code
712, 713
Code:
5:117
Error type:
No variation of the antenna signal
Description:
The truck moves but the signal from the drive unit direction antenna does not vary.
Measure:

Code:
5:118
Error type:
Wire guidance was not requested in wire-guided aisle
Description:
Wire guidance was not requested when the truck passes

the aisle sensor
Measure:
Operator error. S120 not active.

Defective S120 switch
Defective cabling to S120
Code:
5:119
Error type:
Wire not detected in wire-guided aisle
Description:
The wire guidance system has not received the Tracking wire signal
Measure:
Incorrect parameter values

Calibrate WIRE.
Code:
5:120
Error type:
The wire was lost
Description:
The wire was lost in the wire guidance mode
Measure:
Incorrect parameter values

Calibrate WIRE.
Service Manual
20- 299

T-code
712, 713
20- 300

919699-
Date
2005-11-28
Order number
227761-040
Code:
5:121
Error type:
Articulated centre plunger
Description:
The articulated centre plunger is locked when it should

be free, or vice versa.
Measure:
Currently this error code is not in use.
Code:
5:122
Error type:
Steering accumulator pressure
Description:
The steering accumulator pressure has fallen below 70

bar or the sensor is outside the allowed limits.
Measure:
Check the voltage feed to valve Y7.

Inspect the Y7 coil.
Check for correct operation of Y7.
Inspect the cabling and connection plugs between the
MCU and the B4 sensor.
Inspect the sensor B4.
Verify the value on input X130:31
Code:
5:123
Error type:
Articulated centre potentiometer
Description:
The articulated centre potentiometer R7 is outside the

allowed calibration limits or the potentiometer value is
outside the allowed range (<0.5 or >4.5V).
Measure:
Verify the value on input X130:4

Check the voltage feed to R7, output X130:1.
Check output X131:15, potentiometer minus.
MCU and the R7 sensor.
Preset R7 mechanically to approx. 2.5 V with the centre
set straight.
Calibrate the articulated centre potentiometer.
Service Manual
BT Europe AB

Order number
227761-040
BT Europe AB
Date
2005-11-28

919699-
T-code
712, 713
Code:
5:124
Error type:
DCHI M minus
Description:
The DCHI generates an alarm of an error in the M- circuit

of the pump motor.
Measure:
Check the DCHI voltage feed

Inspect the DCHI power cabling
Code:
5:125
Error type:
DCHI power amplifier
Description:
The DCHI generates an alarm of an error in the power

amplifier circuit.
Measure:
Verify the DCHI error indication
Code:
5:126
Error type:
DCHI time-out error
Description:
The DCHI reports a communication error (time-out).
Measure:
Check the indication on the DCHI.

Code:
5:127
Error type:
Description:
The circuit of the steering pressure valve Y7 has shortcircuited.
Measure:
Inspect the valve (Y7) coil.

Service Manual
20- 301

T-code
712, 713
20- 302

919699-
Date
2005-11-28
Order number
227761-040
Code:
5:128
Error type:
Description:
Interruption in the circuit of the steering pressure valve

Y7.
Measure:

Code:
5:129
Error type:
Description:
The circuit of the steering lock valve Y31 has shortcircuited.
Measure:

Code:
5:130
Error type:
Description:
Interruption in the circuit of the steering lock valve Y31.
Measure:

Code:
5:131
Error type:
Description:
The proportional valve Y4 circuit has short-circuited.
Measure:

Service Manual
BT Europe AB

Order number
227761-040
BT Europe AB
Date
2005-11-28

919699-
T-code
712, 713
Code:
5:132
Error type:
Description:
The proportional valve Y4 circuit has been interrupted.
Measure:

Code:
5:133
Error type:
PWM output 2 short-circuited
Description:
The proportional valve Y3 circuit has short-circuited.
Measure:

Code:
5:134
Error type:
Description:
The proportional valve Y3 circuit has been interrupted.
Measure:

Code:
5:135
Error type:
Description:
The plunger valve circuit Y55 has short-circuited.
Measure:

Service Manual
20- 303

T-code
712, 713
20- 304

919699-
Date
2005-11-28
Order number
227761-040
Code:
5:136
Error type:
Description:
The plunger valve circuit Y55 has been interrupted.
Measure:

Code:
5:137
Error type:
Excessive steering angle in rail-guided narrow aisle
Description:
The steering angle is >8o in the narrow aisle or when

entering the aisle.
Measure:
Verify the value of the articulated centre potentiometer

R7 when the centre is set straight.
Code:
5:138
Error type:
No steering in the free travel mode
Description:
The MCU cannot detect any change in the steering angle

despite the steering command received from the ICP.
Measure:
Verify the signal from the articulate centre potentiometer

R7.
Inspect operation of hydraulic valves Y3, Y4, Y7 and Y31
in the steering system.
Code:
5:139
Error type:
To large steering angle when locked on wire
Description:
Steering angle drifted beyond stop value when locked on

wire
Measure:
Try to restart the truck and acquire the wire again. Check
the pivot angle sensor (R7).
Service Manual
BT Europe AB

Order number
227761-040
BT Europe AB
Date
2005-11-28

919699-
T-code
712, 713
Code:
5:140
Error type:
Exceeded virtual displacement point error
Description:
The truck has drifted beyond the virtual displacement

point stop value or the truck has been driven off the guide
wire
Measure:
Try to restart the truck and acquire the wire again.
Service Manual
20- 305

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
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
Note:
Code 001-099 is stored in the error code log and the following measures are taken: The initial lift unit speed for the affected function is reduced.
20- 306
Code:
6:001
Error type:
Traversing pulse transducer, warning
Description:
No pulses received from the traversing pulse transducer

during traversing.
Measure:
Check for correct operation of the hydraulic components.

Inspect the pulse transducer U13.
Inspect the connection cabling and the connection plugs
of the pulse transducer.
Check inputs FCU:008 and FCU:009.
Check the voltage feed to the pulse transducer, outputs
FCU:028 and FCU:015.
Also check the home position sensor (S50) input,
FCU:010.
Code:
6:002
Error type:
Rotation potentiometer
Description:
The rotation potentiometer R8 does not provide feedback during rotational movement or the potentiometer
value is outside the allowed limits (<0.5 or >4.5 V).
Measure:
Verify the value on input FCU:007.

Check the voltage feed to R8, output FCU:002.
Check output FCU:15, potentiometer minus.
FCU and the R8 sensor.
Preset R8 mechanically to approx. 2.5 V with the forks
set straight ahead.
Calibrate ROTATE CCW and ROTATE CW.
Service Manual
BT Europe AB

Order number
227761-040
BT Europe AB
Date
2005-11-28

919699-
T-code
712, 713
Code:
6:003
Error type:
Initial lift height pulse transducer, warning
Description:
No pulses received from the height pulse transducer during initial lifting.
Measure:
Inspect the pulse transducer U9.

of the pulse transducer.
Check inputs FCU:011 and FCU:012.
Check the voltage feed to the pulse transducer, outputs
FCU:028 and FCU:015.
Code:
6:004
Error type:
Initial lift hydraulic pressure
Description:
The sensor signal for the initial lift system's hydraulic

pressure is outside the allowed limits (<0.5 V or >4.5 V).
Measure:
Check the FCU:014 input.

Inspect sensor B7.
of the sensor.
Check the voltage feed to the sensor, FCU:002 and
FCU:015.
Code:
6:005
Error type:
Description:
Default parameters have been downloaded to the FCU.
Measure:
Code:
6:006
Error type:
Incorrect measurement in initial lift height sensor
Description:

Measure:
Check to make sure that the reference sensor S93 is

operating.
Verify the voltage feed to S93.
Check the FCU:013 input.
Service Manual
20- 307

T-code
712, 713
20- 308

919699-
Date
2005-11-28
Order number
227761-040
Code:
6:007
Error type:
Initial lift, lowering speed warning
Description:
The lowering speed of the initial lift system does not correspond with the calibrated value.
Measure:
Calibrate LOWER
Code:
6:008
Error type:
Auto rotation, outside range warning
Description:
The auto rotation movement is outside the calculated

geometric course.
Measure:
Calibrate ROTATE CCW, ROTATE CW and TRAV/

LIFT.
Code:
6:009
Error type:
Clockwise rotation, proportional valve error
Description:
FCU output 021 has short-circuited or the circuit has

been interrupted.
Measure:
Check the FCU:021 output.

Inspect the valve coil Y28.
of the valve.
Inspect minus feedback from Y28.
Code:
6:010
Error type:
Counter-clockwise rotation, proportional valve error
Description:

been interrupted.
Measure:

of the valve.
Service Manual
BT Europe AB

Order number
227761-040
BT Europe AB
Date
2005-11-28

919699-
T-code
712, 713
Code:
6:011
Error type:
Initial lowering, proportional valve error
Description:

been interrupted.
Measure:

of the valve.
Code:
6:012
Error type:
Traversing right, valve error
Description:

been interrupted.
Measure:

of the valve.
Code:
6:013
Error type:
Traversing left, valve error
Description:

been interrupted.
Measure:

of the valve.
Code:
6:014
Error type:
Initial lift, valve error
Description:

been interrupted.
Measure:

of the valve.
Service Manual
20- 309

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Code:
6:015
Error type:
Fork rotation, relay error
Description:

been interrupted.
Measure:

Inspect the coil and the switches of relay K19.
Inspect the resistor R9.
of the relay.
Inspect minus feedback from K19.
Code:
6:016
Error type:
Option 1A, valve error
Description:

been interrupted.
Measure:

of the valve.
Code:
6:017
Error type:
Option 1B, valve error
Description:

been interrupted.
Measure:

of the valve.
Code:
6:018
Error type:
Option 2A, valve error
Description:
Measure:
20- 310
Service Manual
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
Code:
6:019
Error type:
Option 2B, valve error
T-code
712, 713
Description:
Measure:
Code:
6:022
Error type:
Traversing and initial lift, proportional valve error
Description:

been interrupted.
Measure:

of the valve.
Code:
6:023
Error type:
Slight version deviation, compatibility warning
Description:
Slight deviation in compatibility between the MCU and

FCU firmware versions. The FCU does not support certain functions used by the MCU, and vice versa.
Measure:

used.
Note:
Code 100-499 is stored in the error code log and the following measures are taken: The initial lift system functions are blocked.
BT Europe AB
Service Manual
20- 311

T-code
712, 713
20- 312

919699-
Date
2005-11-28
Order number
227761-040
Code:
6:101
Error type:
Memory checksum error, warning.
Description:
The checksum of the FCU memory is wrong.
Measure:

rectify the error.
The FCU could be defective.
Code:
6:102
Error type:
Outputs of the FCU slave processor, communication

error
Description:
Communication between the CPU and the slave processor does not work.
Measure:

rectify the error.
The FCU could be defective.
Code:
6:103
Error type:
FCU CAN communication error
Description:
The FCU has detected that the MCU has stopped PDO
communication with the FCU.
Measure:

rectify the error.
Code:
6:104
Error type:
Considerable version deviation, compatibility warning
Description:
Large deviation in compatibility between the MCU and

FCU firmware versions. Communication cannot be considered safe.
Measure:

used.
Service Manual
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
20.23.7 Shuttle Fork system (including FCU

cautions) - code group 6 (t-code 713)
Note:
Code 001-099 is stored in the error code log and cause fork speed reductions for corresponding function.
Code:
6:001
Error type:
Traverse position sensor warning
Description:
No pulses received from traverse position sensor when

traversing.
Measure:
Inspect sensor U13, wires and connectors.

Check inputs A4:008 and A4:009 and supply voltage
A4:028 and A4:015.
Also check the end position sensor (S50) input, A4:010.
Code:
6:002
Error type:
Description:
Not used
Measure:
BT Europe AB
Code:
6:003
Error type:
Initial lift height sensor, warning
Description:
No action of initial height sensor when lifting.
Measure:
Check sensor U9, wires and connectors. Check input

A4:011 and A4:012 and supply voltage A4:028 and
A4:015
Code:
6:004
Error type:
Lift pressure sensor warning
Description:
Lift pressure sensor signal out of range (<0.5 V or >4.5

V).
Measure:
Check sensor B7, wires and connectors. Check input

A4:014, and supply voltage A4:002 and A4:015
Service Manual
20- 313

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Code:
6:005
Error type:
Default parameters FCU
Description:
Factory default parameters have been loaded to the

FCU.
Measure:
Make sure to set up truck to desired application.
Code:
6:006
Error type:
Incorrect measurement in initial lift height sensor
Description:

Measure:
Check height reference sensor S93, power supply and

wires. Check reference signal input A4:013.
Code:
6:007
Error type:
Lowering speed warning. Not used
Description:
Measure:
Code:
6:008
Error type:
Not used
Description:
Measure:
Code:
6:009
Error type:
Not used
Description:
Measure:
20- 314
Service Manual
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
Code:
6:010
Error type:
Not used
T-code
712, 713
Description:
Measure:
Code:
6:011
Error type:
Fork lower proportional valve error
Description:
A4 output short-circuit or open.
Measure:
Check wires, connectors and solenoid Y10. Could be

electronics card error.
Check output A4:031.
Code:
6:012
Error type:
Traverse right on/off-valve error
Description:
A4 output short-circuit or open
Measure:

electronics card error.
Check output A4:004.
Code:
6:013
Error type:
Traverse left on/off -valve error
Description:
A4 output short-circucit or open.
Measure:

electronics card error. Check output A4:017
Code:
6:014
Error type:
Lift on/off-valve error
Description:
Measure:

electronics card error. Check output A4:005.
Code:
6:015
Error type:
Not used
Description:
Measure:
BT Europe AB
Service Manual
20- 315

T-code
712, 713

919699-
Date
2005-11-28
Code:
6:016
Error type:
Spare 1A on/off-valve error
Description:
Check valve Y16 and output A4:018
Order number
227761-040
Measure:
Code:
6:017
Error type:
Spare1B on/off-valve error.
Description:
Check valve Y17 and output A4:019.
Measure:
Code:
6:018
Error type:
Spare2A on/off-valve error. Not used
Description:
Measure:
Code:
6:019
Error type:
Spare2B on/off-valve error. Not used
Description:
Measure:
Code:
6:022
Error type:
Traverse and lift proportional valve error
Description:
Measure:

electronics card error. Check output A4:016.
Code:
6:023
Error type:
FCU minor version compability warning
Description:
The minor version in the MCU and FCU does not match.
FCU may not support some functions used by the MCU
or vice versa.
Measure:
Make sure correct software versions are used.
Note:
Code 100-499 is stored in the error code log and the following measures are taken: The initial lift system functions are blocked.
20- 316
Service Manual
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
Code:
6:100
Error type:
Not used
T-code
712, 713
Description:
Measure:
BT Europe AB
Code:
6:101
Error type:
FCU memory Checksum error
Description:
FCU memory corrupt
Measure:
The FCU card could be defective.
Code:
6:102
Error type:
FCU output slave circuit communication error
Description:
Communication between the CPU and the slave processor does not work.
Measure:

rectify the error.
The FCU card could be defective.
Code:
6:103
Error type:
FCU CAN communication error
Description:
The FCU has detected that the MCU has stopped PDO
communication with the FCU.
Measure:
Check if CAN1 is ok. Wires, terminal resistors and other

CAN1-nodes.
Code:
6:104
Error type:
FCU major version compability error
Description:
The major version in the MCU and FCU does not match.
Communication may not be possible in a safe way.
Measure:
Make sure correct software versions are used.
Service Manual
20- 317

T-code
712, 713
20- 318

919699-
Service Manual
Date
2005-11-28
Order number
227761-040
BT Europe AB
Hydraulic system 6000

General
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
21- Hydraulic system 6000

21.1 General
The truck contains two separate hydraulic systems: one for cabin lifting
that uses an AC pump motor, and another for initial lifting, turret head
fork unit operation and steering that relies on a DC pump motor.
The hydraulic circuits contain a pressure accumulator for steering
pressure and, depending on the lifting height, one or two accumulators
for the B (Balance) cylinder built into the mast. The B cylinder is tasked
with supporting part (approx. 1/3) of the mast and cabin weight.
WARNING!
Pressurised system.
bar.
2
BT Europe AB
Service Manual
21- 1

General
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
21.1.1 Symbols
The table explains the various symbols that are use in the hydraulic
flow diagram.
Symbol
21- 2
Description
Symbol
Description
Single-acting hydraulic cylinder
Single-acting hydraulic cylinder with purging
Double-acting hydraulic cylinder with damper

(reducer)
Reservoir
Filter
Air drier
Accumulator
Pressure sensor, analogue
Non-return valve, springloaded (hose rupture valve)
Non-return valve
Hydraulic lock
Shuttle valve
Cut-off valve
(emergency lowering)
Routing valve 2/2,

two ports,
two distinct positions,
electromagnetic operation
Service Manual
BT Europe AB

General
Order number
227761-040
Symbol
Date
2005-11-28

919699-
Description
Symbol
T-code
712, 713
Description
Routing valve 2/2,

two ports, drain,
Routing valve 4/2,

spring back function,
Routing valve 4/3,

four ports,
three distinct positions,
Proportional valve, controlled

by electromagnet

by electromagnet

by electromagnet
Priority valve,
self-adjusting proportional
valve type
Back-pressure valve, with

integrated non-return valve
Pressure-limiting valve
Pressure compensating
valve, closing action
Throttling
Electric motor and one pump

with fixed displacement, two
flow directions
Hydraulic motor with fixed

displacement, two flow directions
Framing of two or more functions concentrated in one single unit
Pilot conduit (control)
Operational conduit
Operational conduit, crossoperation
Operational conduit, connection
BT Europe AB
Service Manual
21- 3

Cabin lifting
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
21.2 Cabin lifting

21.2.1 General
The hydraulic system includes the following functions:
Lifting/lowering of the operator's cabin using 2 lift cylinders
B cylinder system with accumulator
The truck has a hydraulic unit located in the motor compartment. The
unit includes a pump motor, a pump and a main valve plate mounted
directly on the pump discharge gate.
The main valve plate contains a pressure sensor for monitoring the
hydraulic pressure, a pressure limiting valve, two routing valves for
cabin lowering and a manual valve for emergency lowering of the cabin.
21.2.2 Cabin lifting - S44 closed

The flow in the pump runs via the non-return valves in the routing
valves Y21 and Y29 to the lift cylinders. The pressure in the hydraulic
system is governed by the load and is monitored by the pressure sensor B6. In case of too high a pressure, the pressure limiting valve (3)
opens, i.e. hydraulic oil flows towards the reservoir.
S44
When the cabin is lifted, the accumulated hydraulic pressure in the B

cylinder system is utilised as an auxiliary lifting aid.
The B cylinder provides a lifting power of between 9.5 and 2 kW
depending on the actual cabin height. The power decreases as the
height of the cabin increases.
21.2.3 Cabin lowering - S70 closed

When lowering the cabin, the routing valves Y21 and Y29 open, and
the oil returns from the lift cylinders through the lowering valves and the
pump back to the reservoir. The pump motor is now forced to rotate in
reverse. It is braked by the electronics, similar to the operation principle
of a generator. The generated electric power is returned to the truck
battery, i.e. regenerative lowering.
S70
When the cabin is lowered, the pressure increases in the B cylinder

system accumulator as a result of the compression of the B cylinder.
The valve plate features a manually operated emergency lowering
valve (4).
Each lifting cylinder also has a hose rupture valve at the base insert.
21- 4
Service Manual
BT Europe AB

Cabin lifting
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
21.2.4 AC hydraulic unit, components
B5
Y21
Y29
BT Europe AB
R
C1
C2
Service Manual
21- 5

Cabin lifting
T-code
712, 713
21- 6

919699-
Date
2005-11-28
Order number
227761-040
Pos.
Designation
Pump motor
Hydraulic pump
Main valve plate
Emergency lowering valve
B5
Analogue pressure sensor
Y21
Routing valve, cabin lowering
Y29
C1
Cabin lifting cylinder connection
C2
Cabin lifting cylinder connection
Measurement connection
For analogue pressure

sensor B6
Reservoir port
Return oil flow to the reservoir
Service Manual
Remarks
250 bar
BT Europe AB

Cabin lifting
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
21.2.5 Hydraulic flow diagram, cabin lifting
Huvudlyft/
Main lift
Vnster/
Left
Hger/
Right
B5
C1
C2
Y21
Y29
P
P1
BT Europe AB
Service Manual
21- 7

Cabin lifting
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Symbol list, chassis

Pos.
Designation
Function
B5
Pressure sensor
Measures the hydraulic pressure in the

cabin lifting system
P1
Pump
Hydraulic pump
Y21
Magnetic valve
Y29
Magnetic valve
Filter
Air filter
Filter
Air drying filter
Only cold store specifications
Opens in case of overloading
250 bar
Valve
Emergency lowering valve
Non-return valve
21- 8
Service Manual
Remarks
BT Europe AB

Cabin lifting
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
21.2.6 B cylinder system

During normal operation, the B cylinder (1) with its valve plate (2) and
accumulator(s) (3) is a closed system, completely separated from the
truck's ordinary hydraulic functions.
When calibrating the hydraulic system pressure, the DC pump is used

to charge the accumulators on the hydraulic side. The calibration procedure is presented in the C code 5000 document, under the heading
"Calibration".
Maintenance and charging of the gas side of the accumulators are
described in the C code 6280 document.
BT Europe AB
Service Manual
21- 9

Cabin lifting
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Hydraulic flow diagram, B cylinder system
Balanscylinder/
Counter balance cylinder
C
4
B5
B5
2
R1
P1
R2
P2
Symbol list, B cylinder system

Pos.
Designation
Function
B6
Pressure sensor
Measures the hydraulic pressure in

the B cylinder system
Valve
Manually operated valve for closing

the pressure side
Open when calibrating the

hydraulic system pressure
Valve

the return side
Open when draining the

hydraulic system
Non-return valve
Pressure-limiting
valve
250 bar
Accumulator
Hydraulic pressure storage
One accumulator is used

for cabin lifts up to 8,600
mm.
Two accumulators are
used for lifting heights
above 8,600 mm.
Cylinder
Balance cylinder
21- 10
Service Manual
Remarks
BT Europe AB

Fork units and steering
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
21.3 Fork units and steering

21.3.1 General
The turret head fork unit and truck steering depend on a hydraulic system, completely separated from the cabin lifting system. It uses an electric DC motor, valves, etc. The oil flow is controlled by a routing valve
and proportional valves to achieve fork lifting, traversing and rotation of
the fork unit thanks to a valve plate mounted under the operator's chair
in the cabin. Exact control is achieved by regulating the oil flow via the
proportional valves located in the valve plate mounted in the rear chassis of the truck. To assure uninterrupted availability of hydraulic steering, an accumulator has been introduced in the steering circuit.
In the hydraulic DC system, charging of the steering accumulator
always has the highest priority.
When using fork lifting/lowering, cabin lifting/lowering and while driving,
the fork rotation and fork traversing operations are blocked.
The return oil flow from the fork unit and steering is a straight path
through the return filter on the reservoir, back into the reservoir.
The difference between the VCE150A and VCE125ASF hydraulic system is in the manifold for traversing, initial lift and lower functions and in
the shuttle fork unit that differs from the standard fork unit. The manifold
for traversing and initial lift and lower functions utilises many of the
same component as the manifold for traversing, initial lift and lower and
fork rotation and is mounted in the same location. The biggest difference is in the inlet block that in the VCE125ASF manifold is just an nlet
block while the VCE150A has valves for fork rotation in that block. A
double load hoding valve is unique for VCE125ASF.
BT Europe AB
Service Manual
21- 11

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
21.3.2 Hydraulic flow diagram, DC system

(t-code 712)
Gaffelvridning/
Fork turning
Initiallyft/
Initial lift
Traversering/
Horizontal move
A
Vnster/
Left
Hger/
Right
A1
B1
240 bar
A2
B2
100 bar
100 bar
90 bar
90 bar
30 bar
30 bar
Styrning/
Steering
R
Vnster/
Left
B
Hger/
Right
C
M
R1
R2
P1
P2
A2
B2
250 bar
A1
B1
30 bar
250 bar
P1
R1
M1
S
2.0
250 bar
250 bar
M2
21- 12
Service Manual
BT Europe AB
BT Europe AB
Service Manual
P1
R1
Not1/
Note 1
B
P2
R2
B6
Balanscylinder/
Counter balance cylinder
Y31
A1
B1
P1
M1
R1
Vnster/
Left
A2
10
Y4
Y3
Styrning/
Steering
10
B2
Y7
11
Hger/
Right
11
M2
B4
12
12

919699-
Hydraulic lines through the mast
Hydraulledningar genom stativet/
Y8
Denna ackumulator ansluts fr

korghjder > 8600/
This accumulator is connected for
cabin heights > 8600
Y9
Y10
Traversering
Horizontal move
Not1/
Note 1
Y11
B7
Initial lyft/
Initial lift
Y25
Date
2005-11-28
Order number
227761-040

T-code
712, 713
21.3.3 Hydraulic diagram (t-code 713)
21- 13

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Symbol list, fork unit and steering

Pos.
Designation
Function
Remarks
B4
Pressure sensor

the steering system
90 - 250 bar
Shut-off limit = 70 bar
B7
Pressure sensor

the initial lift system
Used for weight indication
Y3
Proportional valve
Steering right
Y4
Proportional valve
Steering left
Y7
Routing valve
Opens the steering accumulator circuit
Y8
Routing valve
Traversing to the right
Y9
Routing valve
Traversing to the left
Y10
Proportional valve
Initial lowering
Y11
Routing valve
Initial lifting
Y25
Proportional valve
Initial lift and traversing movement
Y27
Proportional valve
Fork rotation, counterclockwise

(Tcode 712)
Y28
Proportional valve
Fork rotation, clockwise (Tcode 712)
Y31
Routing valve
Steering lock, negative side of steering cylinders
Pressure-limiting
valve
250 bar
Valve

the return side
Open when draining the

hydraulic system
Accumulator
Hydraulic pressure storage
Steering pressure accumulator
Non-return valve
Pressure compensating valve
Provides constant pressure reduction

(flow) via proportional valve Y3/Y4
Back-pressure valve
Oil flow damper (cylinder movement)
Opening pressure: 30 bar
Cylinder
Steering cylinder
Single-acting
Pressure-limiting
valve
90 bar
Hydraulic motor
Traversing movement
10
Cylinder
Initial lifting
11
Priority valve
Distributes the oil flow between the

rotational operations and other turret
head operations
12
Shuttle valve
Provides a balancing counter pressure for the priority valve (11)
21- 14
Service Manual
Self-adjusting proportional
valve type
Priority is always 4 l/m for
fork rotation.
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
Pos.
Designation
Function
Remarks
13
Hydraulic lock
Locks the hydraulic pressure on the

cylinder side when rotational movement has stopped
14
Back-pressure valve
Oil flow damper (cylinder movement)
Opening pressure: 100 bar
15
Pressure-limiting
valve
240 bar
16
Cylinder
Turret head cylinder for fork rotation
17
Non-return valve
Turret head fork unit valve (t-code 712)
BT Europe AB
Service Manual
21- 15
21- 16
Service Manual
4
11
11
12
12
Date
2005-11-28
10
/2AL..BL-AS..BS..
Y11
Y9
HAWE
... ...
Ventilblock fr shuttle forks aggregat/

Valve block fr shuttle forks unit
10
EMP21V20
EM21V
Y25
Y8
Ventilblock fr midjestyrning/
Valve block for the articulated steering
Ventilblock fr balanscylinder/
Valve block for counter balance cylinder
Y10

919699-
T-code
712, 713

Order number
227761-040
21.3.4 Shuttle fork valve blocks (Tcode 713)
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
21.3.5 Fork rotation (t-code 712)

The turret head cylinders and the chain rotate the fork unit mast, mounted in bearings at the top and bottom.
The hydraulic pump provides hydraulic pressure at the inlet port P, and
the oil flows through the priority valve (11) to the proportional valves.
The pressure difference between the front and rear sides in the proportional valve affects the position of the priority valve via the pilot conduits, thus balancing the required oil flow for fork rotation to 4 litres/
minute. Excess oil is drained through the bypass channel Y25 back to
the oil reservoir.
The rotational fork movement is adjusted using the proportional valves
Y27 and Y28, which determine the direction of rotation as well as the
speed of rotation. When rotating, the oil flows through the non-return
valve in the counter-pressure valve (14) back to the turret head cylinder, which powers the other cylinder via the turret head chain.
The counter-pressure valve on the opposite side requires a hydraulic
pressure of 100 bar to open and allows return oil to flow back into the
reservoir, thus effectively dampening jerking motions during fork movement.
When the forks are not rotating, the hydraulic lock (13) operates as a
load booster valve. Because the hydraulic lock captures the hydraulic
pressure on the cylinder side, this prevents the forks from moving out of
position when braking.
The pressure limiting valves (15) operate as choke valves in case of
pressure peaks.
21.3.6 Traversing movement

Traversing movement is controlled by a hydraulic motor. Traversing
movement is achieved through use of the routing valves Y8 and Y9,
which determine the traversing direction, as well as the proportional
valve Y25, which determines the traversing speed.
the oil flows through the priority valve (11) to the proportional valves
used for fork rotation.The pressure difference between the front side of
the proportional valve and the priority valve affects the position of the
priority valve via the pilot conduit, allowing the valve to change position
and open the channel to Y25. The pilot pressure in the priority valve is
slowly drained inside the valve during actual operation, which is the
very reason the valve alternates between open and closed positions on
the pilot side. This explains the self-adjusting function of the priority
valve. Depending on the position of Y25, excess oil is drained via the
bypass channel back to the oil reservoir.
BT Europe AB
Service Manual
21- 17

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
When traversing, the oil passes though the priority valve (11), Y25, Y8/
Y9 and the non-return valve in the counter-pressure valve (6) to the
hydraulic motor.
pressure of 30 bar to open and allows return oil to flow back into the
reservoir, thus effectively dampening jerking motions during traversing
movement.
The non-return valve (6) in the counter-pressure valves in combination
with the routing valves Y8/Y9 keeps the load in place during truck travel
in curves.
The pressure limiting valves (8) operate as choke valves in case of
pressure peaks.
21.3.7 Fork lifting

The initial lift cylinder is a single-acting cylinder.
Lifting movement is achieved through use of the routing valve Y11 and
proportional valve Y25, which determine the lifting speed.
the oil flows through the priority valve (11) to the proportional valves
used for fork rotation. The pressure difference between the front side of
the proportional valve and the priority valve affects the position of the
priority valve via the pilot conduit, allowing the valve to change position
and open the channel to Y25. The pilot pressure in the priority valve is
slowly drained inside the valve during actual operation, which is the
very reason the valve alternates between open and closed positions on
the pilot side. This explains the self-adjusting function of the priority
valve. Depending on the position of Y25, excess oil is drained via the
bypass channel back to the oil reservoir.
Hydraulic pressure in the initial lift circuit is measured by the pressure
sensor B7 in order to calculate the current load weight and is used for
weight indication.
When the lift is completed, the non-return valve (17) and non-return
valve in Y10 keep the load in position.
21.3.8 Fork lowering

Lowering movement is achieved through use of proportional valve Y10,
which determines the lowering speed.
When lowering is completed, the non-return valve (17) and non-return
valve in Y10 keep the load in position.
21- 18
Service Manual
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
21.3.9 Steering
When the truck is switched on, the routing valve Y7 opens to build up
pressure in the steering accumulator circuit. If the steering pressure is
insufficient, the pump motor starts operating to build up steering pressure. The pressure sensor B4 ensures that the steering pressure is
within the specified limits. The normal operation pressure limits are
250-90 bar. For safety reasons, the truck is switched off if the accumulator pressure falls to 70 bar.
When steering pressure has been achieved and the steering wheel is
turned, the proportional valve Y3 or Y4 (depending on in which direction the steering wheel is turned) is actuated. Y3 and Y4 determine in
which direction the truck steers. One of the steering cylinders is then
extended, while the other is mechanically compressed by the chassis.
When steering, the oil flows through the non-return valve in the counter-pressure valve (6) to the steering cylinder, which compresses the
other cylinder via the chassis movement.
pressure of 30 bar to open and allow return oil to flow back into the reservoir, thus effectively dampening jerking motions during steering.
A pressure-compensating valve (5) provides constant fall of pressure,
and thus a constant hydraulic oil flow, across Y3/Y4. This ensures that
the steering speed remains independent of the pressure in the steering
accumulator.
The pressure reducing valve (1) limits the maximum pressure in the
steering system to 250 bar.
The steering cylinders (7) are single-acting and use the negative side of
the cylinders as dampers/stabilisers during steering when this side is
not operating. The negative side of the cylinders sucks in oil, via valve
Y31, from the return conduit (vacuum effect). When steering is not in
use, e.g. during steering straight ahead, Y31 closes and captures the
oil on the negative side, thus achieving a stabilising steering effect.
BT Europe AB
Service Manual
21- 19

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Steering valve
21- 20
Service Manual
BT Europe AB

Extra hydraulic function (T-code 712)
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
21.4 Extra hydraulic function (T-code

712)
21.4.1 Valves used for the extra hydraulic
functions
The routing valves Y16 and Y17 have been introduced on the valve
plate in the operator's cabin to control the turret head fork unit.
The routing valves Y18 and Y19 have been introduced for connection
of the hydraulic components installed on the turret head fork unit.
Electrical connection
Electrical connection of the valves is depicted in the electrical wiring
diagram.
BT Europe AB
Service Manual
21- 21

Extra hydraulic function (T-code 712)
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
21.4.2 Hydraulic diagram, extra hydraulic

function (t-code 712)
21- 22
Service Manual
BT Europe AB
Hydraulic pump 6140

General
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
22- Hydraulic pump 6140

22.1 General
There is one pump size in the truck that has a max flow of 60 litres per
minute.
These service instructions contain a description on how to replace the
hydraulic pump.
BT Europe AB
Service Manual
22- 1
Hydraulic pump 6140

Replacing the hydraulic pump
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
22.2 Replacing the hydraulic pump
6
7
12
4
22.2.1 Dismantling
Disconnect the battery plug.
Drop the forks to the lowest position to reduce pressure in the hoses
and pump.
Pump the oil out of the hydraulic tank 3 with filter pump V10-15191.
Remove the bumper (4) so that the bolt joint (5) to the pump motor
mounting is accessible.
Remove the temperature/speed measuring contacts (6) and power
cables (7) from the pump motor (8).
Loosen the hose clips (10) on the suction hose (9) on the tank and
remove the hydraulic hoses.
Loosen the quick couplings and remove the return hose from the
fork unit (11) and the return hose to the tank (12) from the valve
block.
Loosen the quick couplings and remove the pressure hoses to the
mast (13) and the fork unit (14) from the underside of the valve
block.
Fasten a lifting eye in the motor axle.
Remove the bolts (5) holding the pump mounting (15) to chassis.
Lift out the hydraulic pump and place it on a clean surface.
22- 2
Service Manual
BT Europe AB
Hydraulic pump 6140

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
Remove both mountings (15) from the pump motor (8).

Remove the hose coupling (16) from the pump unit (19).
Remove the valve block (17) from the pump unit.
Remove the bolts (18) and dismount the pump (19).
Remove the carrier.
BT Europe AB
Service Manual
22- 3
Hydraulic pump 6140

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
22.2.2 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 underside and the return hoses (11 and 12) as well as the temperature
gauge/speedometer connectors (6) and the power cables (7).
Fill the hydraulic tank (3) with 38 litres of new oil.
Test the hydraulic functions up to the overflow pressure, and check
that all connections do not leak.
22- 4
Service Manual
BT Europe AB
Main mast and mast 7100

Setting the cab and mast stoppers
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
23- Main mast and mast 7100

23.1 Setting the cab and mast stoppers
23.1.1 Cab stoppers
When service work of the cab involves working under the cab, it must
first be secured by two cab stoppers. The cab stoppers are situated on
both sides of the cab and rest against the catches welded onto the
mast.
To enable placement of the cab stoppers, remote control of the cab is
required. A control unit (remote controller) is required for cab lifting
(Order number 214303). Use the production mode to switch the truck's
electronic systems to remote controlled operation of cab lifting/lowering.
Connect the control unit to the X10 terminals (the terminal on the electric panel on the chassis) and the X27 terminal (spare connector in the
cabling between the electric panel and the MCU).
Connect the Truck Com SE (TCSE) to the CAN connector in the motor
compartment.
To electronically connect the control unit, call up the TCSE Tools menu
and select the Production mode (ctrl + p). The truck then enters the
production mode.
Lift/lower the cabin/mast using the control unit.
BT Europe AB
Service Manual
23- 1

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
23.1.2 Setting the cab stoppers
Warning!
Do not stand under the cab. Stand to the side of the truck and fit the
cab stopper.
Catches that connect with the cab stoppers have been welded onto
both sides of the inner guides of the mast.
The picture shows where the cab stoppers should be set on the cab.
23- 2
Service Manual
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
The tool set V10-16169 contains the various tools used when working
under the cab. Use part A as the cab stopper.
BT Europe AB
Service Manual
23- 3

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Set the cab stoppers on both sides of the cab.
Use the control unit to lower the cabin to the catches.
When the cab rests against the catches, use the TCSE to switch off the
truck with the ctrl +O command.
Connect the battery and use the TCSE to switch on the truck with the
ctrl + I command.
23- 4
Service Manual
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
23.1.3 Mast stoppers
Warning!
Fit the mast stopper from behind. Do not stand on the truck. Do not
stand under the cab.
The mast stoppers are used to secure the mast when it is necessary to
perform repair work under the truck. Set one stopper on each side of
the mast carefully aligning each one with the mast bolts on the chassis.
1. Lift the mast to allow the mast stopper be set.

2. Loosen the upper nut of the mast bolt.
3. Set the mast stopper with the cut-out touching the mast bolt.
The mast stopper has a pin that must be aligned with the
groove in the rear of the chassis.
BT Europe AB
Service Manual
23- 5

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
4. Tighten the upper nut to lock the mast stopper between the
upper and lower nuts.
5. Repeat steps 2-4 on the opposite side of the mast.
6. Lower the mast until the mast assembly connects with the two
mast stoppers.
7. Remove the mast stoppers once service work has been completed. Then tighten the nuts to a torque of 80-100 Nm.
23- 6
Service Manual
BT Europe AB
Main lift chain system 7120

General
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
24- Main lift chain system 7120

24.1 General
Applies to all machines with a mast.
NOTE!
On machines with T-code 407 RR B7-B8/15, 408 RR B7C-B8C/15, 413
RR E7-E8/15 and 414 RR E7C-E8C the chains should be replaced every 2.5 years.
24.2 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.
24.3 Chain inspection

The chains are exposed to two types of wear, outline wear and stretching. Wear to the bolts and disc holes is caused by stretching. The
chains are also affected by the environment they are used in.
24.3.1 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.
24.3.2 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
24.3.3 Rusty links

Fretting corrosion results in a reddish brown powder being visible by
the outer discs. It can also appear as if the chain is bleeding when lubricated.
BT Europe AB
Service Manual
24- 1

Chain inspection
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
24.3.4 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.
24.3.5 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
.
24.3.6 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.
24- 2
Service Manual
BT Europe AB

Chain inspection
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
24.3.7 Outline wear

P
H2
H3
P = Pitch
H2 = Nominal disc height.
H3 = Minimum disc height.
A new lift chain has a specific nominal disc height, defined as H2 in the
figure. As the truck is used the lift chain wears radically, on the side that
runs over the chain sprocket. The minimum disc height is define as H3
in the figure and denotes the minimum permitted value of the disc
height.
Maximal permitted outline wear is 5% of the height H2. If a lift chain
reaches the maximum level of wear, the chain should be replaced.
The nominal and minimum disc heights for respective lift chains are
stated in the table in the chapter Stretching.
BT Europe AB
Service Manual
24- 3

Chain inspection
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
24.3.8 Stretching
The amount of stretch on a lift chain is measured on the part of the
chain that runs over the chain sprocket. The amount of stretch may, at
the most, be 2% on the most worn section of the chain. Measurement is
suitably made over 300-1000 mm of the chain.
The nominal and maximum permitted chain lengths for lift chains are
stated in the table below.
Type of
chain
Nominal
disc height
H2 ( mm)
Minimum
disc height
H3 (mm)
Pitch P
(mm)
Nominal chain
length for 20/30/
50 discs (mm)
Maximum permitted
chain length for 20/
30/50 discs (mm)
3/4, 2x3
17.8
16.9
19.05
381/572/953
389/583/972
3/4, 3x4
17.8
16.9
19.05
381/572/953
389/583/972
3/4, 4x6
17.8
16.9
19.05
381/572/953
389/583/972
1, 4x4
23,6
22,4
25,4
508/762/1270
518/777/1295
1, 6x6
23,6
22,4
25,4
508/762/1270
518/777/1295
Wear to the bolts and around the holes on the discs are a reason why
the chain stretches. The chain should be replaced if stretching is
more than 2%.
24.3.9 Damage
The chain should be replaced if damaged in any way.
24- 4
Service Manual
BT Europe AB

Cleaning
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
24.3.10 Damaged discs

If a disc has broken on the chain, this can be due to overloading or corrosion.
24.3.11 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.
24.3.12 Dirty chain

If a chain is very dirty it is first and foremost recommended that it is
replaced. It can also be dismantled and cleaned as set out in the chapter Cleaning.
24.4 Cleaning
If a chain is very dirty it is recommended that it is replaced.
Dirty chains should be cleaned before they are lubricated, e.g. by
washing with solvent such as diesel or petrol.
The chain should be blown dry using compressed air and lubricated
directly after cleaning
NOTE!
Exercise care with degreasing agent as these can contain abrasives.
BT Europe AB
Service Manual
24- 5

Lubrication
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
24.5 Lubrication
Mineral and synthetic oils can be used to relubricate Rexnord chains.
NOTE!
Lubricant must not contain substances such as molybdenum disulphide, PTFE or the like.
A lift chain should be offloaded from the weight of the fork carriage
(hanging free) when lubricated.
Lubrication intervals:
- 500 hours with normal operations
- 100 hours when driving in rugged environments such as cold
stores and corrosive environments.
The chains are sprayed with lubricant. Note the entire chain must be
lubricated, even the fastening bolts. It is especially important that the
part of the chain which runs over the chain sprocket is well lubricated.
The lubricate must comply with the viscosity demands at respective
temperatures as set out in the table below. The following lubricants are
recommended:
Ambient
temperature
Viscosity
class
Recommended Products*
> - 40C
< - 30C
VG 15
Klberoil 4UH 1-15, Klber Lubrication
> - 30C
< + 5C
VG 68
Klberoil 4UH 1-68N, Klber Lubrication

Anticorit LBO 160 TT, Fuchs DEA
> + 5C
< + 45C
VG 150
Klberoil 4UH 1-150N, Klber

Lubrication
Anticorit LBO 160, Fuchs DEA
>+ 45C
<+ 80C
VG 220
Klberoil 4UH 1-220N, Klber

Lubrication
* 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.
24- 6
Service Manual
BT Europe AB
Initial mast/Turret head fork unit 7200 (t-code 712)

General
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
25- Initial mast/Turret head fork unit

7200 (t-code 712)
25.1 General
The initial mast/turret head fork unit share the same hydraulic system
with the truck's steering system. The DC pump motor, pump and reservoir are located in the rear chassis of the truck. Oil is supplied via hoses
in the mast to the valve core in the cab and is used for initial lifting, traversing (side shifting) and turning the forks. Please also see C codes
5000 and 6000.
BT Europe AB
Service Manual
25- 1

Assembly/disassembly of the initial mast
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
25.2 Assembly/disassembly of the

initial mast
25.2.1 Mast assembly
Remove the end plates on the aluminium members and the retaining
screws at the end of the wearing rails of the horizontal rollers.
Lift the initial mast by using another forklift or a cable lift.

Align the initial mast and push it onto the aluminium members.
Pay attention to the belts. Keep them out of the way to prevent
pinching and bending.
NOTE:
A belt with two bends must be replaced since it is very likely that the
belt cord has been damaged.
25- 2
Service Manual
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
Set the friction plates A in the upper and lower part of the mast holder.
Insert the adjusting screws into the mast holder.
2
Set the friction plate in the mast holder.
NOTE:
Friction plate lock washer.
The convex side of the washer should face the adjusting screw.
Use cup grease as adhesive to ensure the washer remains in place
in the friction plate recess during assembly.
Tighten the adjusting screws of the lower friction plates securely.
BT Europe AB
Service Manual
25- 3

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Verify that the upper horizontal rollers press against the beam.
If necessary, make adjustment to ensure both excenter rollers are in
contact with the beam.
The punch mark indicates the highest point for the excenter rollers.
See the picture.
Tighten the nuts at the excenter shafts to a torque of 220 Nm. (22
kpm)
Tighten the adjusting screws of the upper friction plates securely.
At the same time, loosen the friction plate adjusting screws 60o from
the tightened position.
Insert and tighten the locking screws used to lock the adjusting
screws.
7
25- 4
Service Manual
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
Install the belts and adjust belt tensioning according to the separate
installation instructions in this guide.
Cut off and remove the straps holding the belts in position on the
transmission shaft.
Install the end retaining screws of the wearing rails.

Install the traversing stoppers and end plates.
Install all electric cabling and the hydraulic hoses according to the
separate installation instructions in this guide.
Verify initial mast lift, rotation and traversing operation.
Install the forks on the fork yoke.
Traverse the forks to full travel length a couple of time and then
reverify that belt tensioning is correct.
BT Europe AB
Service Manual
25- 5

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
25.2.2 Installation of belts on a new truck
Install the upper and lower belt on one side of the truck.
Insert the end piece of the belt with the wing facing inwards. Install
the shaft with the locking screw groove facing upwards and the
threaded hole facing down.
Tighten the locking screw.
Push the initial mast to the other side to enable installation of the other end pieces of the belts.
Install the adjusting screws used for the belt tensioning device.
Labels on the truck next to each adjusting screw indicate the screw
position for correct belt tensioning when the initial mast was disassembled at the factory prior to delivery.
25- 6
Service Manual
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
Adjust each adjusting screw to the value indicated on the label.

Measure the adjusting screw projection, without the locking nut, as
shown in the picture.
NOTE:
The value indicated on the label only applies to reassembly of a newly
delivered truck.
Following initial installation, be sure to remove the labels.
Check the belt tension as explained in the section Checking belt

tensioning".
BT Europe AB
Service Manual
25- 7

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
25.2.3 Installing the hydraulic hose and

electric cabling
1
2
3
Install the coupling chain (1) in the initial mast bracket (2).
Connect the hydraulic hoses (3) as shown below.
11
12
13
14
15
11
14
15
12
13
25- 8
Pos.
Connection for+
11
Initial lift cylinder
12
Traversing to the left
13
Traversing to the right
II
14
Left rotation cylinder
15
Right rotation cylinder
Service Manual
Marking
(with a silver marker
pen)
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
Connect the electric cable connectors (4) as shown below.

X61 X59
X62
X61
X59
X60
X62
X58
X70
X60
X58
X70
Terminal
Connection for
X58
Reference switch S93, initial lifting
X59
Pulse transducer for height measurement U9,

initial lifting
X60
Pulse transducer U13, traversing
X61
Home position sensor S50, traversing
X62
Potentiometer R8, rotation
X70
Valves for extra hydraulic functions, Y18/Y19
25.2.4 Mast disassembly

Disassemble the initial mast by following the assembly instructions in
reverse.
NOTE:
Make sure the markings on the hydraulic hoses are legible.
If the markings are illegible, then be sure to mark the hoses to prevent
mix-ups during subsequent reassembly of the initial mast.
NOTE:
Do not forget to plug up the hoses following disconnection. This will
prevent contamination of the hydraulic system.
BT Europe AB
Service Manual
25- 9

Inspection and replacement of belts used for fork traversing
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
25.3 Inspection and replacement of

belts used for fork traversing
25.3.1 Inspection
Inspect belt condition and tensioning at the intervals specified in the
truck's maintenance diagram, i.e. every 500 work hours (B time).
Inspecting the belt condition

Perform a visual inspection of the belts.
The belt must have no cracks or wear damage on the edges.
Be sure to immediately replace a cracked or worn belt since there is
a risk of belt breakage.
Check the belt tension as explained in the section Checking belt
tensioning".
25- 10
Service Manual
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
25.3.2 Replacing the belt

Disassembly of the belt
If possible, traverse the initial mast to the centre.
2
3
6
1
Disassemble the traversing stoppers and the end plates (1).

Disassemble the adjusting screws on the belt tensioning device (2).
Remove one break roller holding the belt in the initial mast.
Press the roller (3) up as far as possible to enable removal of the
locking washer (4) from the shaft (5).
Pull out the shaft.
Release the axle locking screw on the belt end piece and pull out the
shafts (6).
NOTE:
The shaft hole has an M8 thread.
Use an M8 bolt and a pair of tongs to pull out the shaft.
Separate the belt end pieces in order to disassemble them from the
belt (7).
Pull out the belt from the initial mast.
Measure the total belt length, or count the number of teeth, in order
to be sure the new belt is of correct length.
BT Europe AB
Service Manual
25- 11

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Installing the belt

Verify that the new belt is of the same length, or that is has the same
number of teeth, as the old one.
Mark the centre point on the belt using a light marker pen.
Insert the belt through the initial mast.
Install the belt break roller.
Install the belt end pieces.
Tighten the screws of the clamp to 28 Nm.
Install the belt on one side of the truck.

Insert the end piece of the belt with the wing facing inwards. Install
the shaft with the locking screw groove facing upwards and the
threaded hole facing down.
Tighten the locking screw.
Push the initial mast to the other side to enable installation of the other end pieces of the belt.
Install the clamping screws on the belt tensioning device.
Adjust the clamping screws to the same length (24 mm) on both
sides as shown in the picture below.
Verify the vertical posture of the initial mast. Use the centre beam of
the cab as line of sight.
If vertical mast posture is incorrect, perform alignment of the initial
mast.
25- 12
Service Manual
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
If the deviation is estimated to less than 8 mm, adjustment using the

clamping screws is possible.
- Adjust (release) the adjusting screw on the side to which the initial mast is leaning.
- Then adjust the adjusting screw on the other side until mast posture is completely vertical.
If the deviation is estimated to more than 8 mm, move the belt one
tooth (or more in case of larger deviation) on the transmission shaft
in the initial mast.
- Use a light marker pen and put a mark on the belt and the cog
wheel on the transmission shaft as a reference point.
- Completely loosen both clamping screws.
- Move the belt by one tooth on the transmission shaft in the direction to which the mast was leaning.
- Adjust the clamping screws to the same length (24 mm) on both
sides as shown in the picture below.
- Verify the vertical posture of the initial mast.
Adjust both adjusting screws equally, in intervals, until correct belt
tension has been achieved as explained in the section Checking
belt tensioning.
NOTE:
Verify belt tensioning regularly during the adjustment using the belt
tensioning meter, order no. 213973.
BT Europe AB
Service Manual
25- 13

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
25.3.3 Checking belt tensioning

NOTE:
Check the belt tension at normal room temperature, 20-25oC.
Belt tension meter 213973

Set the belt tension meter 213973 according to the table below:
Unit
Traversing
belt, 220210
standard
Traversing belt,
217388-001/-002
cold stores
Drive belt,
200190 standard
Drive belt,
217885 cold
stores
Weight, g/m
005,4
004,7
005,4
004,7
Width, mm
085,0
085,0 (217388-001)
080,0 (217388-002)
050,0
036,0
Span, mm
As measured
As measured
147
139
Belt tension, N
5900 - 6100
7650 - 7850
1800 - 2000
1800 - 2000
Span measurement of the traversing arm

Measure the free length of the belt when measurement is to be
made. See the picture.
Perform measurement between the first contact point between the

belt/end piece and the centre of the initial mast break roller.
Enter the measured length in millimetres in the belt tensioning meter.
25- 14
Service Manual
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
Tension measurement of the traversing belt

Press the Measure key.
Lightly tap the belt with a tool while holding the belt tensioning meter against the belt at the same point.
The indicated value, in Newton (N), should be 4500 - 5000 N.

Warning
Belt tensioning must not exceed 5000 N.
There is a risk that the belt will become overtensioned with premature
belt breakage as a result.
Install the locking nuts on the clamping screws and tighten the nuts
to 50 Nm.
Warning
Risk of belt breakage.
Once a belt has been tensioned to 4500-5000 N during installation,
never retension the belt again.
The belt may become overtensioned resulting in premature belt
breakage.
If belt tensioning is below 2250 N, the belt is worn and must be replaced.
Tension measurement of the drive belt

Press the Measure key.
Lightly tap the belt with a tool while holding the belt tensioning meter against the belt at the same point.
The indicated value, in Newton (N), should be 1800 - 2000 N.
Warning
Belt tensioning must not exceed 2000 N.
There is a risk that the belt will become overtensioned with premature
belt breakage as a result.
BT Europe AB
Service Manual
25- 15

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Install the locking nuts on the clamping screws and tighten the nuts
to 50 Nm.
Warning
Risk of belt breakage.
Once a belt has been tensioned to 1800-2000 N during installation,
never retension the belt again.
The belt may become overtensioned resulting in premature belt
breakage.
If belt tensioning is below 1200 N, the belt is worn and must be replaced.
25- 16
Service Manual
BT Europe AB

Friction plate adjustment
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
25.4 Friction plate adjustment

1. Unscrew the locking screws securing the adjusting screws
2. Tighten the adjusting screws of the lower friction plates securely.
3. Tighten the adjusting screws of the upper friction plates securely.
4. At the same time, loosen the adjustment screws for the sliding
plates 60o from the tightened position.
5. Insert and tighten the locking screws (A) used to lock the adjusting screws.
BT Europe AB
Service Manual
25- 17

Friction plate adjustment
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
25- 18
Service Manual
BT Europe AB
Shuttle fork unit 7800 (t-code 713)

Assembling shuttle forks
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
26- Shuttle fork unit 7800 (t-code

713)
26.1 Assembling shuttle forks
Insert the shuttle fork unit using a reach truck. See arrows.
Warning
When working beneath the cab, a cab stopper must be fitted. See C
code 7100.
Fit shaft journals and locking strips.

Tighten the bolts to a torque of 181 Nm.
BT Europe AB
Service Manual
26- 1

Assembling shuttle forks
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Tighten the stop screws to a torque of 78 Nm (19 Nm).
Fit the hoses.
Connect the cabling.
26- 2
Service Manual
BT Europe AB

Maintenance
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
Test-drive and adjust speed and ramps.
26.2 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.
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 persons which results from this action.
BT Europe AB
Service Manual
26- 3

Maintenance
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
26.2.1 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.

Pos.
no.
on application
Initially
250 h
500
1000
2000
3000

3m
6m
12 m
24 m
36 m
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
7800.6
Check the adjustment of the shuttle fork

chain
7800.7
Check the reach carriage play +/- 2mm
7800.8
Check the mounting and wear on the chain

wheel
7800.9
Inspect line components and the hydraulic

motor for leakage
The letters A-F indicate the lubricant type to be used. See the separate
table.
26- 4
Service Manual
BT Europe AB

Maintenance
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
7800.1
7800.1
7800.2
7800.2
7800.3
BT Europe AB
Service Manual
7800.2
7800.4
26- 5

Maintenance
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
26.2.2 Lubrication
Oil and grease specification
Pos.
Lubricant
Ambient
temperature
Viscosity
class
Use
Recommended
products*
Chain Lubrication
> - 40C
< - 30C
VG 150
Chains
Klberoil 4UH 1-15,

Klber Lubrication
> - 30C
< + 5C
VG 68
Chains
Klberoil 4UH 1-68N,

Klber Lubrication
Fuchs DEA
> + 5C
< +45C
VG 150
Chains

Klber Lubrication
Anticorit LBO 160,
Fuchs DEA
>+ 45C
<+ 80C
VG 220
Chains

Klber Lubrication
> - 40C
< - 15C
EP2
Mast girders
Q8 Rubens LT
> -15C
< +45C
EP2
Mast girders
Q8 Rembrandt EP2
26- 6
Grease
Service Manual
BT Europe AB

Maintenance
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
26.2.3 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 excessive 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 applying 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.
BT Europe AB
Service Manual
26- 7

Maintenance
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
BF K468170-353
3
2
Fig. 1 Adjustment of chains
26- 8
Service Manual
BT Europe AB

Maintenance
Order number
227761-040
BT Europe AB
Date
2005-11-28

919699-
Service Manual
T-code
712, 713
26- 9

Replacement of shuttle fork unit
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
26.3 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
26- 10
Service Manual
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
B B
T-code
712, 713
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 surfaces 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)
BT Europe AB
Service Manual
26- 11

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
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)
26- 12
Service Manual
BT Europe AB
Wire guidance equipment 8200

General
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
27- Wire guidance equipment 8200

27.1 General
Wire guidance is used for automatic steering in narrow aisles. A generator generates alternating current in a cable that is set into the floor and
which the truck follows. The cable follows the narrow aisles in a closed
loop from the generator in aisle 1, on to aisle 2, etc. From the last aisle
it then returns to the generator. The maximum length that a generator
can supply is approx. 750-1000 m. A further generator must be installed
with a separate loop if more is required.
The current flowing in the laid cable gives rise to a magnetic field
around the cable. This field is used to guide the truck. The magnetic
field is sensed by means of antennae mounted under the truck. The
antennae are connected to the regulator unit that controls the steering.
The system is monitored by the ordinary truck computer, which stops
the truck if an error should occur.
BT Europe AB
Service Manual
27- 1
Wire guidance equipment 8200

Generator
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
27.2 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.
27- 2
Power supply
Model LDU-22
220 V 50Hz
Output current
75 m A +/- 5%
Frequency
6.25 kHz +/- 3.5%
Output current
7.5 Voutput unloaded
Battery
2 x 12 V 3 Ah
Battery backup
> 6 hours
Max cable length
approx. 750 m
Cable cross section
> 0.75 mm2
Fuse
0.4 A (slow burn) on the voltage card
Service Manual
Model LDU-21
110 V 50/60Hz
BT Europe AB
Control/computer equipment 8700

General
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
28- Control/computer equipment

8700
User Guide for TruckCom SE - for trucks with t-code 712,713,714.
The manual applies to TruckCom SE, version number 214705-003.
28.1 General
TruckCom is a communication application that communicates with
trucks equipped with a CAN (Controller Area Network) interface.
The application supports the following functions:
Firmware downloading.
Viewing and adjusting operator and truck parameters as well as
measuring data. It is also possible to save the parameter values (including measuring data) for later download.
Viewing of data for the digital inputs/outputs and analogue data, including voltage, amperage and specific temperature levels.
Truck diagnostic functions.
This is a Windows application that runs under
Windows XP/2000 and Windows NT.
28.2 Connection
To be able to connect to the truck, a CPC-PP type CAN interface with
cable is required. The interface must be connected to the printer port on
the PC, and the cable is connected between this interface and the
Truck's CAN connector.
The CAN interface is powered by the truck electronics and is protected
against voltage surges in case of an error.
28.2.1 Specifications
CAN interface
BT Europe AB
Description
Value
Unit
Current consumption
40-120
mA
Supply voltage
11-28
Transfer rate
125
Kbit/s
Storage temperature
-20-80
0C
Operating temperature
0-60
Service Manual
28- 1

Truck software management on the PC
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
28.3 Truck software management on the

PC
The software applications for the trucks are supplied as software packages for all logic cards in the truck.
The software application file consists of a configuration file, with the .ini
format, which describes the various applications for each logic card.
The software package has order no.: 213017-XXX.
The software package is usually distributed as WinZip files via the
BT Europe Intranet or BT On-Line network.
28.3.1 Downloading the software package via

the network
Log on to www.intranet.bt-europe.com (BT companies) or
www.bt-ind.net (distributors).
Go to the SOFTWARE page and click on the CT tab.
Double-click Download program
28- 2
Service Manual
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
The following dialogue box appears.
Click Open.
A new dialogue box with the path to TruckCom SE\Packages will be
displayed.
NOTE!
BT recommends use of the suggested path for saving the truck software package since this will ensure optimum operation of the TruckCom SE.
If another path is chosen to store the files, the full path including
\Packages must be entered. Additionally, the same path must also be
entered in the TruckCom SE program settings.
Click Unzip to extract and save the application files on the PC hard
disk.
BT Europe AB
Service Manual
28- 3

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
If file extraction is successful, the following dialogue box is displayed.
Click OK. Downloading of the software package is now complete.

Select the Packages folder in Windows Explorer and check that the
downloaded software package is in the correct folder. It should be in the
TruckCom SE subdirectory.
28- 4
Service Manual
BT Europe AB

Connecting to the truck
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
28.4 Connecting to the truck

First connect to the network by starting TruckCom SE on the computer.
Start the application when the truck is switched on, but is not logged
onto the network.
When the application starts, the main window with the menu window
(1), workspace (2) and status row (3) appear.
3
The menu window and workspace are empty since communication with
the truck has not yet been established.
BT Europe AB
Service Manual
28- 5

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
28.4.1 Connecting to the truck

To establish communication with the truck, depress the F8 function key
on the PC keyboard or select View/Read Configuration.
The application will verify the CAN interface settings. It also starts a
diagnosis to verify which units are connected in the system and which
firmware package has been installed in the truck.
NOTE!
In order to establish successful communication between the truck
and PC, the truck's current firmware software package must have
been saved on the PC hard disk.
The firmware package must have been saved in the directory specified in the TruckCom SE settings.
Following completed diagnosis, the number of connected units (nodes)

will be displayed in the Menu window, the status of each unit is displayed in the Workspace, while the current truck firmware package is
displayed on the Status bar.
28- 6
Service Manual
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
28.4.2 Menu window tree
Click on a unit to open it and see the substructure, which can be used to
verify input and output signals as well as for diagnosis during troubleshooting.
NOTE!
The appearance of the menu window depends on the configuration
file that has been read and can vary between different firmware packages.
To check and change parameters and performs diagnostics, see section 8, Using the menu tree.
28.4.3 Disconnection
To interrupt communication with the truck, select "Abort communication" from the View menu or press Esc on the PC keyboard.
BT Europe AB
Service Manual
28- 7

Menus
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
28.5 Menus
28.5.1 File menu
The File menu contains the following options.
28- 8
Service Manual
BT Europe AB

Menus
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
Open package
Use Open Package to open a firmware package in order to change or
alter the appearance/display in TruckCom SE.
Open package can be used when a Generic file has been created
during start-up of TruckCom SE, e.g. if the truck's current firmware
package has not been saved on the PC.
Open the .ini file in the firmware package, e.g. 213017-008.

This function uses the configuration file inside the package to update
display menus, etc. inside TruckCom SE.
NOTE!
If another package than that in the truck is opened, the configuration
of this package will be shown and used.
This could mean that the displayed information does not correspond
100% with the actual configuration of the truck.
Different firmware packages may contain differences.
BT Europe AB
Service Manual
28- 9

Menus
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Save truck report

Use this option to create a truck report that contains all information that
has been stored in the truck.
NOTE!
Use Save truck report when the truck has been logged off.
This option creates a text file (.txt) which contains information about the
truck's current firmware, the hour meter settings, parameter settings
and the error code log.
Create a directory on the PC where the truck reports should be saved.
Save the report under a name that contains the serial number of the
truck.
28- 10
Service Manual
BT Europe AB

Menus
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
Save output window to file

Use this option to create a computer file from the information displayed
in the workspace. These files are useful to make diagnoses during troubleshooting, at which time it can be handy to look up input and output
signals for several units.
BT Europe AB
Service Manual
28- 11

Menus
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Save parameter setup to file

This options enables saving of all truck parameter settings to one computer file.
truck.
NOTE!
Use the option Save parameter setup to file when the truck has
been logged out.
NOTE!
This option does not save learned settings for height preselection.
28- 12
Service Manual
BT Europe AB

Menus
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
Update parameter setup in truck

This option is useful for downloading a saved parameter set if the electronic module has been replaced or when several trucks must be programmed with an identical parameter set. Select the parameter file
from a truck you know corresponds to the one being updated.
NOTE!
Use the option Update parameter setup to file when the truck has
been logged out.
NOTE!
The height pre-selection settings will not be updated.
Warning
Incorrect truck operation.
Downloading a parameter file to a truck may cause the truck's parameter settings to become incorrect.
Before putting a truck back into service, always verify the truck's parameter settings when a file has been downloaded.
BT Europe AB
Service Manual
28- 13

Menus
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Save height pre-selection setup to file

Use this option to save the truck's learned height pre-selection values
in a computer file.
truck.
NOTE!
Use the option Save height pre-selection setup to file when the
truck has been logged out.
Update height pre-selection from file

This option is useful for downloading saved settings for height preselection if the electronic module has been replaced or when several
trucks must be programmed with identical height pre-selection values.
Select the settings file from a truck you know corresponds to the one
being updated.
NOTE!
Use the option Update height pre-selection from file when the truck
has been logged out.
Warning
Downloading a settings file with height pre-selection data to a truck
may cause height pre-selection on the truck to be incorrect.
Before putting a truck back into service, always verify the height preselection settings when a file has been downloaded.
28- 14
Service Manual
BT Europe AB

Menus
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
28.5.2 View menu
Read configuration
By depressing the F8 function key or selecting View/Read Configuration, the truck's configuration file and the configuration file in the corresponding firmware package in the PC are read by TruckCom SE.
If F8 is depressed when communication between the truck and PC is
in progress, communication will restart. See section 5.1.
Update
Depress the F5 function key or select View/Update to update the
information displayed in the workspace.
The workspace information is updated instantaneously with truck data
each time F5 is depressed.
BT Europe AB
Service Manual
28- 15

Menus
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Run
If the F9 function key is depressed or by selecting View/Run, the current information in the workspace is continuously updated.
The information colour in the worksapce simultaneously switches from
black to green.
NOTE!
The Run mode does not support all display functions.
Only the functions used for diagnostics are supported.
The update speed can be adjusted using the Program settings on the
Option menu.
This is a very useful function when making diagnoses during troubleshooting.
Abort communication
Communication between the truck and the PC can be aborted by
depressing the Esc key.
28- 16
Service Manual
BT Europe AB

Menus
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
28.5.3 Tools menu
Log In
The truck can be started from the application by pressing the Ctrl + I
keys on the PC keyboard.
Log In Production mode

The truck can be started in the production mode from the computer by
pressing the Ctrl + P keys on the PC keyboard.
The production mode is used to switch the electronic systems in the
truck to operate cab lifting/lowering by remote control 214303.
Log Out
The truck can be switched off from the application by pressing the Ctrl
+ O keys on the PC keyboard.
BT Europe AB
Service Manual
28- 17

Menus
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Read error log

Use this option to show all error codes stored in the truck in the workspace.
28- 18
Service Manual
BT Europe AB

Menus
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
The table below describes the meaning of the various headers in the
error code log.
Header
Meaning
Header
Meaning
No
Position in log
Tactr
Temperature in AC regulator, right

drive motor, oC
Code
Error code
Tactl
Temperature in AC regulator, left

drive motor, oC
Time
Date and time
Total logged in time
Height
Cab height, mm
Total operation time, travel/AC

pump/DC pump
SPEED
Travel speed, km/h
Number of travelled hours
Pcab
Hydraulic pressure in cab lift system

(AC pump), bar
Number of operating hours for the

AC pump motor
Pini
Hydraulic pressure in the initial lift

system (DC pump), bar
Number of operating hours for the

DC pump motor
Batt
Battery charge level, %
Opt1
Extra log 1. Selection of what to

record is made using parameter
152. Displayed as raw data.
Tach
Temperature in the pump motor AC

regulator, oC
Opt2
Extra log 2. Selection of what to

record is made using parameter
153. Displayed as unformatted data
BT Europe AB
Service Manual
28- 19

Menus
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Erase error log

Use this option to erase the error code log in the MCU.
To prevent accidental erasing of the error log, a confirmation dialogue is

presented prior to the log being erased.
NOTE!
Before erasing the error code log, create a truck report for possible
future error analysis.
28- 20
Service Manual
BT Europe AB

Menus
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
Set hour meters

Use this option to set/change all hour meters and the date and time in
the truck.
Use this option if the MCU has been replaced.
BT Europe AB
Service Manual
28- 21

Menus
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
Set all parameters to default

Use this option to reset all truck parameters to the default values, which
are listed in the parameter list, C code 5000.
NOTE!
Keep in mind that not all default parameter values are suitable for all
trucks. As an example, wire guidance will be reset to rail guidance,
learned height limitations will be removed, etc.
To prevent accidental change of the parameter settings, a confirmation

dialogue is presented prior to the settings being reset.
WARNING!
If the parameter list is reset to the default settings, the truck characteristics may change resulting in certain truck functions not operating as expected.
If reset, all truck parameters must be reviewed without fail and adjustments made whenever required.
NOTE!
The height pre-selection settings are not affected.
Download package
This option is used to update the truck's firmware.
See the separate description in section 7.
28- 22
Service Manual
BT Europe AB

Menus
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
28.5.4 Option menu

Program settings
If another directory than C:\Program Files\TruckCom SE\Packages
(TruckCom SE standard) has been selected, then use Program settings to specify the directory path..
Program settings also enable customisation of the monitor refresh rate
in the Run display mode (F9).
BT Europe AB
Service Manual
28- 23

Download package, Function for firmware downloading
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
28.6 Download package, Function for

firmware downloading
NOTE!
The truck must have been logged off prior to downloading firmware
packages.
To download new firmware to one or more nodes, select the "Download

package" option from the Tools menu.
A new window is opened.

TruckCom SE automatically verifies the firmware package version
stored on the PC hard disk (under Package) with the current
firmware (Actual) in each truck node.
NOTE!
If a firmware package has been opened with Open Package, it is the
opened package's firmware that is displayed under Package.
This firmware package may be of a version older than the one already
installed on the truck.
If the current firmware version of a node corresponds to the firmware

version included in the package, the message UPDATED is displayed for the node. In this case, updating the firmware is not necessary.
If the current version and the version included in the software package differ, UPDATE NEEDED is displayed and the check box for
the node will be marked.
To ensure that all nodes are updated simultaneously, it is possible to
manually mark the check box for a node.
28- 24
Service Manual
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
28.6.1 Normal firmware download

Click the Package button.
A new window opens showing the directory where applications will
be downloaded as selected in the TruckCom SE settings.
Mark the software package file to be downloaded. This is usually the

file with the highest version number (e.g. 213017-008) and select
Open. The file name, file type and version number are displayed in
the File information dialogue box.
TruckCom SE then verifies which nodes need to be updated.
Click Update.
BT Europe AB
Service Manual
28- 25

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
The old firmware is erased in the node, after which the new firmware
is downloaded.
When download is complete, use Cancel to close the download

window.
When download is complete, the current status of the node is displayed.
To verify the new firmware, re-establish communication with the

truck by pressing F8.
NOTE!
Once programmed, the logic cards for certain trucks can only be updated with the same basic firmware. In other words, it is not possible
to change the basic firmware (i.e. to another machine type).
28- 26
Service Manual
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
Errors encountered during downloading

If for any reason an error is encountered while downloading
firmware, an error message with the reason for the error is displayed
for that node.
The following error codes and reasons exist:
Code
Reason
Code
Reason
-1
Download interrupted by user
-5
Incorrect data in the download file
-2
Checksum error during communication
-6
Unallowed truck file
-3
Cannot open (find) file
-7
Incorrect marking of the download file
-4
Checksum error in file

If the truck firmware has been damaged and does not respond to
commands from the TruckCom SE application, Emergency download can be used to manually download new firmware.
BT Europe AB
Service Manual
28- 27

T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
28.6.2 Emergency download

For emergency download, mark the Emergency download check
box.
NOTE!
Only one node can be selected at a time for emergency download.
A message prompting the user to disconnect the battery connector

appears.
Disconnect the battery connector and confirm it has been disconnected by clicking OK.
28- 28
Service Manual
BT Europe AB

Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
TruckCom SE then displays a new message prompting the user to

connect the battery.
Connect the battery.

Emergency download starts automatically.
When download is complete, the current status of the node is displayed.
When download is complete, close the download window.

To verify the new firmware, re-establish communication with the
truck by pressing F8.
NOTE!
Once emergency download is complete, it is recommended to download the complete firmware package in order to load the correct
firmware version in the truck.
BT Europe AB
Service Manual
28- 29

Using the menu tree to verify/change parameters and perform diagnostics
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
28.7 Using the menu tree to verify/

change parameters and perform
diagnostics
Click on a node to open its menu functions. To view information about a
specific function in the workspace, click on the desired function.
28.7.1 Software
To verify the firmware version in a node, select Software".
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Date
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919699-
T-code
712, 713
28.7.2 Parameters
To verify or change truck parameters, select "Parameter".
The workspace displays all parameters for the current firmware including parameter number, a description of the parameter's function and
the current parameter value together with the minimum, maximum and
default values.
The parameter numbers correspond to the descriptions in the Service

Manual for the truck.
BT Europe AB
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28- 31

T-code
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919699-
Date
2005-11-28
Order number
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To change one or more node parameters, double-click on the selected

parameter row in the workspace.
A window with information about the selected parameter then opens.

Change the parameter by entering a new value in the Value dialogue box and click Save.
The parameter can be reset to the default value by clicking Set to
default and then clicking Save.
If more parameters need to be changed, then use he left and right
arrow buttons to scroll up or down in the parameter list.
NOTE!
Each parameter that is changed must be saved before a new one is
selected.
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Date
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919699-
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28.7.3 Diagnostics/troubleshooting
To use TruckCom SE to troubleshoot of a problem, set the display
method of the workspace to Run by depressing the F9 function key
once the desired function has been selected.
The workspace is updated continuously with the refresh speed selected in the program settings.
NOTE!
When switching between different display/diagnostics functions, to
continue to use the Run display mode be sure to press F9 each time
a change has been made.
The description of what is displayed in the window is retrieved from the

configuration file on the hard disk and the corresponding data is read
from the truck.
Digital IO
Displays the digital input and output status of the node, including terminal number, function and signal direction.
BT Europe AB
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919699-
Date
2005-11-28
Order number
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Analog IO
Displays the signal value of the node's analogue input and outputs,
including terminal number, function and signal direction.
Example: Diagnostics procedure for the Initial lift

function
To perform complete diagnostics, it may be necessary to view several
nodes and different functions in each node.
The usual way is to start the diagnostics process by verifying the status
of the command signals (controls) and to end it by verifying the drive
signals (signals output to connected components).
The example below describes the diagnostics process on the Initial lift
function on a truck. It can be used as an example of how to perform
diagnostics.
Select ICP Digital IO.
Set the workspace display mode to Run mode by depressing F9.
Operate the initial lift function while at the same time reading the status and values in the different displays.
The electric wiring diagram shows where in the system the values and
commands used in the various steps in the diagnostics process can be
verified.
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BT Europe AB

Order number
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BT Europe AB
Date
2005-11-28

919699-
Service Manual
T-code
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28- 35

T-code
712, 713
28- 36

919699-
Service Manual
Date
2005-11-28
Order number
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BT Europe AB

Order number
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Date
2005-11-28

919699-
T-code
712, 713
1. Verify the S72 shift button status using the ICP digital IO function.
2. Verify the analogue signal from the left rocker switch R2 using
the ICP analogue IO function.
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T-code
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919699-
Date
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Order number
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3. Verify that no messages about lift limits or stops are displayed

using the MCU initial lift diagnostics function.
4. Verify the command values, CMD IN/CMD OUT, using the MCU
initial lift diagnostics function.
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Date
2005-11-28

919699-
T-code
712, 713
5. Verify the command values, CMD IN/CMD OUT, using the FCU
initial lift diagnostics function.
6. Verify the status of the output signal sent to the lifting valve
Y11 using the FCU digital IO function.
BT Europe AB
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T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
7. Verify the analogue signal and current level of the proportional valve Y25 using the FCU analogue IO function.
8. Verify the status of the input signal received from the height
measurement sensor U9 and the height reference sensor S93
using the FCU digital IO function.
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Installation
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2005-11-28

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9. Verify the analogue signal and voltage level from the pressure
sensor B7 using the FCU analogue IO function.
28.8 Installation
NOTE!
Install the software application from a hard disk.
NOTE!
The software application may become damaged in the PC and, as a
precaution, the application should be installed on the PC by a person
with the required knowledge.
BT does not accept any responsibility for any errors that may occur
during the installation.
NOTE!
All references to the PC operating system functions, menus and commands are based on the English Windows version.
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Installation
T-code
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Date
2005-11-28
Order number
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28.8.1 Installation of TruckCom SE on a PC

The TruckCom SE application is usually distributed as WinZip files via
the BT Europe Intranet or BT On-Line network.
Downloading TruckCom SE via the Internet

Log on to www.intranet.bt-europe.com (BT companies) or
www.bt-ind.net (distributors).
Go to the SOFTWARE page and click the CT tab.
Double-click Download program
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Installation
Order number
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Date
2005-11-28

919699-
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712, 713
A link to the window in the database opens.
Double-click the application icon. WinZip opens.

Click Extract. The window for saving the application opens.
Save the entire TruckCom SE folder on the PC's desktop.
BT Europe AB
Service Manual
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Installation
T-code
712, 713

919699-
Date
2005-11-28
Order number
227761-040
A folder icon is created on the desktop and in the PC's temporary

library.
Installing/updating TruckCom SE on the PC

Open Installation TruckCom SE from the desktop.
A window with all TruckCom SE files opens.
Double-click the TruckCom SE icon.
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Installation
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Date
2005-11-28

919699-
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712, 713
A window with a suggested destination folder is appears.
NOTE!
BT recommends use of the suggested path for saving the truck
firmware package since this will ensure optimum operation of the
TruckCom SE applications.
If another path is chosen to store the applications, then the entire
path, including \Packages, must be entered when the truck firmware
application is saved on the PC hard disk. Additionally, the same path
must also be entered in the TruckCom SE program settings.
Click Next.
A confirmation dialogue box appears before the actual installation process begins.
Click Install.
When installation is complete, look up the C:\Program Files\TruckCom
SE path using the Explorer and open the folder.
BT Europe AB
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Installation
T-code
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919699-
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Order number
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The TruckCom SE installation application has now created the Packages subfolder where truck firmware can later be saved.
28.8.2 Necessary changes in Windows XP

and Windows 2000 for TruckCom SE
To enable operation of the application, a new value must be created in
the Windows registry and a few changes are required in the Windows
Control Panel.
These changes must be made manually because of the built-in safety
features in Windows.
The following is a step-by-step guide explaining how to make these
changes in order that the interface can operate correctly under Windows XP and Windows 2000.
The changes can be made either before or after TruckCom is installed.
Open the Registry Editor by selecting Start - Run, type regedit in the
box and click OK.
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Installation
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2005-11-28

919699-
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Mark the Enum folder, which can be found under

HKEY_LOCAL_MACHINE\SYSTEM\CurrentControlSet inside the
Registry Editor.
Open Find under Edit and enter the PortName to search for the correct
folder.
NOTE!
The place of the folder can vary between different computers (in the
example it is .. \Enum\Root\.., but it could also be ...\Enum\ACPI\...),
thus, be sure to search for the PortName.
BT Europe AB
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Installation
T-code
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919699-
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2005-11-28
Order number
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When the folder is found, verify that LPTx (x=1, 2, 3, 4) is shown in the
PortName data field and that the name of the folder is Device Parameters.
Right-click in the right space to create a new value of the type DWORD
with the name
EnableConnectInterruptIoctl.
Change the value in data field to 1 by right-clicking on the name and

selecting Modify.
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EnableConnectInterruptIoctl
The Device Parameters folder should now look as shown in the picture.
The Registry change is now complete. Close the Registry Editor.
BT Europe AB
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Installation
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Date
2005-11-28
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Changes in Windows Control Panel

Choose Start - Settings and double-click on System, then select Hardware.
Click on Device Manager and open Ports (Com & LPT).
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Double-click the LPT port that should be changed and select the Port
Settings tab. Mark the "Use any Interrupt assigned to the port" check
box and click OK.
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Installation
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28.8.3 In case of communication errors with

the CAN
Verify that the printer port settings in the setup (BIOS) are as follows:
Port address:0378
IRQ:7
Mode:Output only
For information on how to change these settings, refer to the user guide
supplied with the computer.
28.8.4 To uninstall
To uninstall TruckCom, from the Windows Start menu select < Settings | Control Panel |Add or Remove Programs > . Mark the TruckCom
application and then select <Add/Remove Program>.
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Height pre-selection 9390

General
Order number
227761-040
Date
2005-11-28

919699-
T-code
712, 713
29- Height pre-selection 9390

29.1 General
In firmware version 213017-008, the optional height pre-selection function has been introduced. Height pre-selection is activated using a new
parameter. For more details, refer to the section on parameters.
Using the height pre-selector, it is possible to lift and lower the forks and
to lift the operator's cabin to a suitable picking height from among a
maximum of 199 different programmable heights.
The lifting and lowering movements are adjusted to stop at a desired
level based on the information received from the height level meter.
Picking and setting down cargo is performed using manual traversing
and by lifting or lowering the forks.
Programming of the correct level for loading and unloading is very easy
using the ICP keyboard and the teach-in function of the height preselector. Simply move the forks/operator's cabin to the desired height
and confirm the level and height.
29.2 Parameters
29.2.1 MCU parameters
Nr
Parameter type Unit
Min
Max Std. value Note
159
Height pre selection
BT Europe AB
Service Manual
0: Height pre-selection not active

1: Height pre-selection is programmable
2: Height pre-selection is not programmable
29- 1

Programming
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Order number
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Parameter 159
Using this parameter, the optional height pre-selection function can be
activated
Height pre-selection is active and is open for programming via the
information menu on the display.
Height pre-selection is active, but programming via the information menu is blocked.
29.3 Programming
NOTE!
It is not necessary to use the CAN key for programming if parameter
159 has been set to parameter value 1.
Lift the forks to the desired level using the control panel
Lift the operator's cabin to the desired height in the racking
Select the information menu by depressing button [ i ].
Depress the option button next to the driver's symbol
To enter the programming mode, depress the option button next to
the height pre-selection symbol.
Indicate the height pre-selection level.
29- 2
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Programming
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Confirm the selected height pre-selection level by depressing the

confirmation button (start button).
NOTE:!
It is possible to program a height pre-selection level without this level
being programmed for pallet handling.
In this case, simply enter the programming mode for the order picking
level.
It is possible to program new lifting heights, change and remove programmed values.
29.3.1 Programming a level

Collection level
Adjust the fork height with the initial mast until the forks enter the pallet.
Depress the up arrow to save the setting.
The current height is displayed in the pick-up window.

NOTE:
Once the pick-up height has been stored, another height, 10 cm higher, is simultaneously saved as a set-down height for the selected preselection level.
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Programming
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919699-
Date
2005-11-28
Order number
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Leaving level
If the set-down height that was saved when programming the pickup height is not suitable, then the set-down height can be manually
changed/adjusted.
Use the initial mast to lift a pallet with a cargo to an appropriate clearance height.
Depress the down arrow to save the setting.
The current height is displayed in the set-down window.
Order picking level

Make sure the forks are not inserted in the racking.
Adjust the operator's cabin height to a height allowing comfortable
picking.
Depress the plus button to save the setting.
The current operator's cabin height is displayed in the order picking
window.
Erasing programmed levels

Enter the programming mode and select the pre-selection level.
Depress the option button next to the waste basket symbol.
The entire level, including all programmed heights, is erased.
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Programming
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Changing the programmed level

To change the lifting heights of a previously programmed level, repeat the programming procedure for the pick-up level, set-down level and/or order picking level.
29.3.2 Operation/Automatic operations

There are three different automatic travel modes. lifting or lowering the
forks to the desired level without any load when an order needs to
picked up and with load when cargo needs to be set down. The third
mode involves order picking where the operator's cabin is lifted to the
desired level for retrieving the order.
General
It is possible to cancel the selection of a level whenever desired by
depressing the Cancel [C] button,
If a height level that has not been programmed is selected, the ICP
buzzer will sound a long signal. Select another, already programmed
level.
Collecting a load
Select the pick-up pallet function using the arrow up button.
The height level meter display is replaced by the height pre-selection level and the height pre-selection symbol is displayed in the upper, left corner of the display.
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Programming
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919699-
Date
2005-11-28
Order number
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State the required height level using buttons 09, (e.g. 5 = level 5.
The display will show LE05).
NOTE:
The height pre-selection symbol starts blinking and the ICP buzzer
sounds to remind the operator that a level was not selected within 5
seconds.

NOTE:
The height pre-selection starts blinking and the ICP buzzer sounds to
remind the operator that the selected level was not confirmed within 5
seconds.
Warning!
Confirmation not received
If the operator forgets to confirm the pre-selection height with the
confirmation (start) button, the operator's cabin will not stop at the
selected height.
In this case, lift/lower the operator's cabin until it is automatically

stopped by the electronic controller.
If the wrong direction is selected with the lifting buttons, lifting/lowering movement will be cancelled. In this case, the controller expects
selection of the correct direction.
NOTE:
Pre-programmed lift height limits.
When the operator's cabin is lifted, the lifting motion stops at the
heights that have been programmed as lift height limits.
The lift height limits can be bypassed by following the explanations in
the section DRIVING.
When the operator's cabin stops, insert the forks under the cargo.
Lift the forks until they are stopped automatically by the electronic
controller.
Move the cargo out of the racking. When the cycle has been completed, the height level meter display will be replaced by the current
lifting height.
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Programming
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Depositing a load
Select the set-down pallet function using the arrow down button.
NOTE:
seconds.

NOTE:
seconds.
Warning!
selected height.

NOTE:
When the operator's cabin stops, insert the forks with the suspended
cargo in the racking.
Lower the forks until they are stopped automatically by the electronic
controller.
BT Europe AB
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Programming
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919699-
Date
2005-11-28
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Pull out the forks from the racking. When the cycle has been completed, the height level meter display will be replaced by the current
lifting height.
Order picking
Select the order picking mode using the plus button.
NOTE:
seconds.

NOTE:
seconds.
Warning!
selected height.
29- 8
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Programming
Order number
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2005-11-28

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NOTE:
When the operator's cabin stops, the height level meter display will
be replaced by the current lifting height.
BT Europe AB
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Programming
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919699-
Date
2005-11-28
Order number
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29- 10
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Programming
Order number
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Date
2005-11-28

919699-
T-code
712, 713
BT Europe AB
Service Manual
29- 11
BT Europe AB
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Service Manual

VCE150A, 150AC, 125ASF, 125ACSF

Order number: 227761-040

Completely new issue

Updated/new chapters: P4, 5000, 6000, 7100, 7200, 8700, 9390

New partnumber documentation/new name

This manual covers following truck models:

VCE150A, 150AC, 125ASF, 125ACSF

Approved by: K Hallman

Valid from serial number

4- Introduction, maintenance P1 (t-code 712) .................................... 4-1

VCE150A, 150AC, 125ASF, 125ACSF

Valid from serial number

Maintenance work that is to be carried out by the

6- Preventive maintenance P2 (t-code 712) ........................................ 6-1

11- Chassis 0000

VCE150A, 150AC, 125ASF, 125ACSF

Valid from serial number

12.0.2 Untreated, oiled bolts ..................................................... 12-1

13- Electric pump motor 1710.1 .........................................................

14- Electric pump motor 1710.2 .........................................................

15- Electric drive motor 1760 .............................................................

16- Drive unit/gear 2550 .....................................................................

VCE150A, 150AC, 125ASF, 125ACSF

Valid from serial number

Replacing the drive motor/drive gear ........................................... 16-5

17- Travel brake system 3100 ............................................................ 17-1

18- Drive wheel 3530 ..........................................................................

19- Fork/support arm wheel 3550 ......................................................

VCE150A, 150AC, 125ASF, 125ACSF

Valid from serial number

20- Electrical system 5000 ................................................................. 20-1

VCE150A, 150AC, 125ASF, 125ACSF

Valid from serial number

20.5.6 Maintenance ................................................................ 20-30

VCE150A, 150AC, 125ASF, 125ACSF

Valid from serial number

Closed cabin gates .................................................... 20-134

VCE150A, 150AC, 125ASF, 125ACSF

Valid from serial number

20.14.3 Narrow aisle ID system ..............................................

VCE150A, 150AC, 125ASF, 125ACSF

Valid from serial number

Parameter 103 ...........................................................

VCE150A, 150AC, 125ASF, 125ACSF

Valid from serial number

Parameter 167 ...........................................................

VCE150A, 150AC, 125ASF, 125ACSF

Valid from serial number

Parameter 458 ...........................................................

VCE150A, 150AC, 125ASF, 125ACSF

Valid from serial number

20.23.7 Shuttle Fork system (including FCU cautions) - code group 6

22- Hydraulic pump 6140 ...................................................................

23- Main mast and mast 7100 ............................................................

24- Main lift chain system 7120 .........................................................

VCE150A, 150AC, 125ASF, 125ACSF

Valid from serial number

24.3.5 Bolt rotation ...................................................................

27- Wire guidance equipment 8200 ...................................................

28- Control/computer equipment 8700 .............................................

VCE150A, 150AC, 125ASF, 125ACSF

Valid from serial number