227761-040 Vce150a

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

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

Issued: 2008-04-25ITS
© BT Europe AB
Document revisions:
Publishing Order Changes

date number
2003-10-03 Completely new issue
2005-03-01 Updated/new chapters: P4, 5000, 6000, 7100, 7200, 8700,
9390
2005-10-28 New part number documentation/new name
Updated/new chapters: M2 , P1, P2, P3, P4, 0000, 0400,
2550, 3100, 3530, 3550, 5000, 6000, 7100, 7800
2008-04-25 Updated/new chapters: P2, P3, P4, 0000, 0320,0350, 2550,
3100.1 3100.2, 3180, 3550, 5000, 6000, 6280, 6610, 7160,
7200, 7800
This manual contains information on the following trucks:
T code Model Machine number

712 C15 564221-919698
712 VCE150A/ 919699-
VCE150AC
713 VCE125ASF/ 919699-
VCE125ACSF
© BT Europe AB Service manual VCE150A, 150AC, 125ASF, 125ACSF Approved by:K Hallman
Contents
Order no. Date Applies from machine no. T code
227761-040 2008-04-25 919699- 712, 713
1- Contents
2- Preventive maintenance – P2 (T code 712) ........................................ 2-1
3- Preventive maintenance – P2 (T code 713) ........................................ 3-1
4- Oil and grease specifications – P3 (T code 712) ............................... 4-1
5- Oil and grease specification – P3 (T code 713) ................................ 5-1
6- Tools – P4 ............................................................................................. 6-1

6.1 Super Seal contact ......................................................................... 6-1
6.1.1 AMP connector ................................................................. 6-2
6.1.2 Miscellaneous tools .......................................................... 6-3
7- Chassis – 0000 Truck installation ..................................................... 7-1

7.1 General........................................................................................... 7-1
7.2 Tool list ........................................................................................... 7-1
7.3 Unloading the truck......................................................................... 7-2
7.3.1 Unloading a standing truck ............................................... 7-3
7.3.2 Unloading a truck lying down ........................................... 7-5
7.3.3 Unloading the truck using cranes ..................................... 7-7
7.3.4 Erecting the truck ........................................................... 7-10
7.3.5 Final assembly ............................................................... 7-14
7.3.6 Assembly of the initial mast ............................................ 7-14
7.4 Preparations for commissioning ................................................... 7-15
7.5 Installation in narrow aisle ............................................................ 7-17
7.5.1 General .......................................................................... 7-17
7.5.2 Rail-guided truck ............................................................ 7-17
7.5.3 Wire-guided truck ........................................................... 7-17
7.5.4 Support arm collision guards .......................................... 7-18
7.6 Removal/reassembly of rear chassis, including bearings ............. 7-19
7.6.1 Special tools ................................................................... 7-19
7.6.2 Standard hand tools ....................................................... 7-19
7.6.3 Disassembly ................................................................... 7-20
7.6.4 Disassembly of components .......................................... 7-25
7.6.5 Dismantle the rear chassis ............................................. 7-30
7.7 Replace the pivot bearings ........................................................... 7-32
7.7.1 Remove the old bearings ............................................... 7-32
7.7.2 Install new bearings ....................................................... 7-33
7.7.3 Reassemble the pivot ..................................................... 7-35
7.7.4 Reassemble the truck .................................................... 7-37
7.7.5 Lower the truck to the ground ........................................ 7-38
7.7.6 Final assembly ............................................................... 7-38
7.8 Battery locking device................................................................... 7-39
8- Frame pivot – 0320 ............................................................................... 8-1

8.1 Greasable axle ............................................................................... 8-1
9- General tightening torque – 0400 ....................................................... 9-1

9.0.1 Galvanised, non-oiled bolts .............................................. 9-1
9.0.2 Untreated, oiled bolts ....................................................... 9-1
9.1 Tightening torque ........................................................................... 9-2
© BT Europe AB Service manual VCE150A, 150AC, 125ASF, 125ACSF 1- 1

Contents
T code Applies from machine no. Date Order no.
712, 713 919699- 2008-04-25 227761-040
10- Electric pump motor – 1710.1 ......................................................... 10-1

10.1 General ........................................................................................ 10-1
10.2 Disassembled pump motor .......................................................... 10-1
10.3 Disassembly and assembly of the pump motor............................ 10-2
10.3.1 Dismantling .................................................................... 10-3
10.3.2 Assembly ....................................................................... 10-4
10.4 Replacing the ball bearing............................................................ 10-5
10.4.1 Dismantling .................................................................... 10-5
10.4.2 Assembly ....................................................................... 10-6
10.5 Assembly instruction for the external temperature sensor ........... 10-7
11- Electric pump motor – 1710.2 ......................................................... 11-1

11.1 General ........................................................................................ 11-1
11.2 Disassembled pump motor .......................................................... 11-1
11.2.1 Connection .................................................................... 11-1
11.3 Disassembly and assembly of the pump motor............................ 11-2
11.3.1 Dismantling .................................................................... 11-3
11.3.2 Assembly ....................................................................... 11-4
11.4.1 Disassembly (D side) ..................................................... 11-5
11.4.2 Assembly ....................................................................... 11-5
11.4.3 Disassembly (N side) ..................................................... 11-5
11.4.4 Assembly (N side) ......................................................... 11-6
11.4.5 Carbon brushes and carbon brush-rocker .................... 11-6
12- Electric drive motor – 1760 ............................................................. 12-1

12.1 General ........................................................................................ 12-1
12.2 Disassembled drive motor ........................................................... 12-2
12.3 Disassembly and assembly of the drive motor ............................. 12-3
12.3.1 Disassembly of the drive motor ..................................... 12-3
12.3.2 Assembly of the drive motor .......................................... 12-4
12.4.1 Assembly ....................................................................... 12-6
12.5 Assembly instructions for the external temperature sensor ......... 12-7
13- Drive unit/gear – 2550 ..................................................................... 13-1

13.1 General ........................................................................................ 13-1
13.2 Components/data of the drive unit and gear ................................ 13-1
13.2.1 Component identification ............................................... 13-2
13.2.2 Technical data ............................................................... 13-4
13.2.3 Dismantled gear ............................................................ 13-4
13.3 Replacing the drive motor/drive gear ........................................... 13-5
13.3.1 Dismantling of drive unit from truck ............................... 13-5
13.3.2 Fitting the drive unit in truck ........................................... 13-5
13.3.3 Dismantling the drive motor and the gear ...................... 13-6
13.3.4 Fitting the drive motor and the gear ............................... 13-6
13.4 Oil level check/replacement ......................................................... 13-7
13.4.1 Oil inspection/replenishment ......................................... 13-7
13.4.2 Oil replacement ............................................................. 13-7
13.5 Repairs ........................................................................................ 13-8
13.5.1 Replacing the drive shaft sealing ring ............................ 13-9
13.5.2 Leakage from the top cover ......................................... 13-10
13.5.3 Leakage from the lower cover ..................................... 13-10
13.5.4 Replacing the wheel bolt ............................................. 13-11
1- 2 Service manual VCE150A, 150AC, 125ASF, 125ACSF © BT Europe AB
Contents
227761-040 2008-04-25 919699- 712, 713
14- Service brake system – 3100.1 ....................................................... 14-1

14.1 General......................................................................................... 14-1
14.2 Functional description................................................................... 14-1
14.2.1 Releasing the accelerator pedal ..................................... 14-2
14.2.2 Travel direction selector ................................................. 14-2
14.2.3 Depressing the brake button .......................................... 14-2
14.2.4 Parking brake ................................................................. 14-2
14.2.5 Emergency braking ........................................................ 14-2
14.3 Electromechanical disc brake, drive motor ................................... 14-4
14.3.1 Assembly ........................................................................ 14-4
14.3.2 Dismantling .................................................................... 14-5
14.3.3 Inspection ....................................................................... 14-5
14.3.4 Assembly ........................................................................ 14-5
14.4 Maintenance................................................................................. 14-5
14.4.1 Adjustment of play .......................................................... 14-6
14.4.2 Wear ............................................................................... 14-6
14.4.3 Inspect the braking force ................................................ 14-7
14.5 Disc brake with multiple discs, support arms ................................ 14-7
14.5.1 Assembly ........................................................................ 14-8
14.5.2 Dismantling .................................................................... 14-9
14.5.3 Inspection ....................................................................... 14-9
14.5.4 Assembly ...................................................................... 14-10
14.6 Maintenance............................................................................... 14-11
14.6.1 Adjustment of play ........................................................ 14-11
15- Service brake system – 3100.2 ....................................................... 15-1

15.0.1 General .......................................................................... 15-1
15.0.2 Functional description .................................................... 15-1
15.0.3 Releasing the accelerator pedal ..................................... 15-1
15.0.4 Travel direction selector ................................................. 15-1
15.0.5 Depressing the brake button .......................................... 15-2
15.0.6 Parking brake ................................................................. 15-2
15.0.7 Emergency braking ........................................................ 15-3
15.0.8 Electromechanical disc brake, drive motor .................... 15-3
15.0.9 Dismantling .................................................................... 15-3
15.0.10 Inspection ....................................................................... 15-5
15.0.11 Assembly ........................................................................ 15-5
15.0.12 Maintenance ................................................................... 15-6
15.0.13 Adjustment of play .......................................................... 15-6
15.0.14 Wear ............................................................................... 15-6
15.0.15 Inspect the braking force ................................................ 15-7
15.0.16 Disc brake with multiple discs, support arms ................. 15-9
15.0.17 Assembly ........................................................................ 15-9
15.0.18 Dismantling .................................................................. 15-10
15.0.19 Inspection ..................................................................... 15-11
15.0.20 Assembly ...................................................................... 15-11
15.0.21 Maintenance ................................................................. 15-11
15.0.22 Adjustment of play ........................................................ 15-12
16- Support arm brake – 3180 ............................................................... 16-1

16.1 Location of support arm brake ...................................................... 16-1

Contents
712, 713 919699- 2008-04-25 227761-040
17- Drive wheel – 3530 .......................................................................... 17-1

17.1 General ........................................................................................ 17-1
17.2 Dismantling the drive wheel ......................................................... 17-1
17.3 Assembling the drive wheel ......................................................... 17-1
18- Fork/support arm wheel – 3550 ...................................................... 18-1

18.1 Dismantling the wheel .................................................................. 18-1
18.2 Assembling the wheel .................................................................. 18-3
18.3 Dismantling/assembling the wheel bearings ................................ 18-4
18.3.1 300 mm wheel with brake and 350 mm wheel .............. 18-4
18.4 Support arm wheel axle ............................................................... 18-6
19- Electrical system – 5000 ................................................................. 19-1

19.1 General ........................................................................................ 19-1
19.1.1 Terminology ................................................................... 19-3
19.1.2 Truck firmware ............................................................... 19-3
19.1.3 Communication .............................................................. 19-3
19.2 Main Computer Unit, MCU (A5) ................................................... 19-4
19.2.1 General .......................................................................... 19-5
19.2.2 Voltage feed .................................................................. 19-7
19.2.3 Battery negative ............................................................. 19-7
19.2.4 Electric connectors ........................................................ 19-7
19.2.5 Internal status monitoring .............................................. 19-8
19.2.6 Resetting the battery indicator ....................................... 19-8
19.2.7 External inputs and outputs ........................................... 19-9
19.2.8 Installing a new card in the truck ................................. 19-14
19.2.9 Programming the MCU ................................................ 19-14
19.3 Fork computer unit, FCU (A4) .................................................... 19-15
19.3.1 General ........................................................................ 19-15
19.3.2 Voltage feed ................................................................ 19-16
19.3.3 Battery negative ........................................................... 19-16
19.3.4 Electric connectors ...................................................... 19-16
19.3.5 Safety measure ........................................................... 19-16
19.3.6 External inputs and outputs ......................................... 19-17
19.3.7 Installing a new card in the truck ................................. 19-20
19.3.8 Programming ............................................................... 19-20
19.4 Integrated Control Panel, ICP (A16) .......................................... 19-21
19.4.1 General ........................................................................ 19-21
19.4.2 ICP modules ................................................................ 19-23
19.4.3 Voltage feed ................................................................ 19-24
19.4.4 Battery negative ........................................................... 19-25
19.4.5 External inputs and outputs ......................................... 19-25
19.4.6 Installing a new ICP in the truck .................................. 19-29
19.4.7 Programming ............................................................... 19-29
19.5 AC regulators, ACTL (A1), ACTR (A31) and ACH (A2).............. 19-30
19.5.1 General ........................................................................ 19-30
19.5.2 Connection terminal and terminal pillars ..................... 19-31
19.5.3 Technical data ............................................................. 19-32
19.5.4 Installing a new frequency converter in the truck ........ 19-32
19.5.5 Programming ............................................................... 19-32
19.5.6 Maintenance ................................................................ 19-33
19.5.7 Safety .......................................................................... 19-33
19.5.8 Cleaning ...................................................................... 19-33

Contents
227761-040 2008-04-25 919699- 712, 713
19.6 DC regulator, DCHI (A32)........................................................... 19-34

19.6.1 General ........................................................................ 19-34
19.6.2 Connection terminal and terminal pillars ...................... 19-35
19.6.3 Technical data .............................................................. 19-36
19.6.4 Installing a new transistor panel ................................... 19-36
19.7 Parameters................................................................................. 19-37
19.7.1 Diagnostics and troubleshooting .................................. 19-37
19.7.2 Maintenance ................................................................. 19-39
19.7.3 Safety ........................................................................... 19-39
19.7.4 Cleaning ....................................................................... 19-39
19.7.5 Hand-held terminal 1307 .............................................. 19-40
19.7.6 Using the hand-held terminal ....................................... 19-42
19.7.7 Viewing and adjusting parameters ............................... 19-43
19.7.8 SPECIAL PROGRAM MODE ....................................... 19-44
19.7.9 Using the TEST mode .................................................. 19-44
19.7.10 Using the DIAGNOSTICS MODE ................................ 19-45
19.7.11 SPECIAL DIAGNOSTICS MODE ................................ 19-45
19.8 Electrical system, overview ........................................................ 19-46
19.9 List of symbols and electric circuit diagrams............................... 19-51
19.9.1 List of symbols ............................................................. 19-51
19.9.2 Electrical wiring diagrams (T code 712) ....................... 19-53
19.9.3 Electrical wiring diagrams (T code 713) ....................... 19-83
19.10 Component List ........................................................................ 19-112
19.10.1 Placement of components .......................................... 19-119
19.10.2 Cabling contacts ......................................................... 19-128
19.11 Functional description, General................................................ 19-131
19.12 Functional description, starting, driving, steering and braking .. 19-131
19.12.1 Battery connected, truck switched off ........................ 19-131
19.12.2 Log-in / Start-up ......................................................... 19-132
19.12.3 Log-out / Switch-off .................................................... 19-137
19.12.4 Presence verification .................................................. 19-138
19.12.5 Selecting the drive direction / Driving ......................... 19-138
19.12.6 Emergency driving mode ........................................... 19-140
19.12.7 Travel speeds ............................................................. 19-141
19.12.8 Steering ...................................................................... 19-149
19.12.9 Braking ....................................................................... 19-154
19.13 Electrical description of the hydraulic functions ........................ 19-159
19.13.1 Allowed combined functions ....................................... 19-160
19.13.2 Monitoring and functional limitations .......................... 19-161
19.13.3 Slack chain guard ....................................................... 19-164
19.13.4 Height measurement .................................................. 19-164
19.13.5 Cabin lifting ................................................................ 19-166
19.13.6 Special height (lift limiter function) ............................. 19-168
19.13.7 Cabin lowering ........................................................... 19-169
19.13.8 Special function with cab lifting/lowering
and forks set straight ahead ....................................... 19-171
19.14 Turret head unit (T code 712) ................................................... 19-172
19.14.1 Auto rotation ............................................................... 19-182
19.14.2 Miscellaneous electrical functions .............................. 19-184
19.14.3 Narrow aisle ID system .............................................. 19-185
19.14.4 Alternative “narrow aisle system” ............................... 19-186
19.15 Shuttle fork unit (T code 713).................................................... 19-188
19.15.1 Traversing of the forks ............................................... 19-188
19.15.2 Fork lifting/lowering .................................................... 19-191

Contents
712, 713 919699- 2008-04-25 227761-040
19.16 Wire guidance .......................................................................... 19-194

19.16.1 General ...................................................................... 19-194
19.16.2 Wire guidance components ....................................... 19-194
19.16.3 Modified monitoring during wire guidance ................. 19-199
19.16.4 Functional description ................................................ 19-201
19.17 Display ..................................................................................... 19-204
19.17.1 Normal mode ............................................................. 19-204
19.17.2 Information mode ....................................................... 19-207
19.18 Calibration Turret Head (T code 712) ...................................... 19-209
19.18.1 Calibration mode ....................................................... 19-209
19.19 Calibration Shuttle fork (T code 713)........................................ 19-217
19.19.1 Calibration of Shuttle fork .......................................... 19-217
19.20 Parameters .............................................................................. 19-220
19.20.1 Accessing parameters ............................................... 19-221
19.20.2 Operator parameters (operators 1-10) ...................... 19-222
19.20.3 Truck parameters ...................................................... 19-224
19.20.4 MCU parameters ....................................................... 19-226
19.20.5 Wire guidance parameters: ....................................... 19-243
19.20.6 FCU parameters (T code 712) ................................... 19-251
19.21 Parameters Shuttle fork (T code 713) ..................................... 19-260
19.21.1 Service Parameters (T code 713) .............................. 19-260
19.21.2 Learned data (T code 713) ........................................ 19-262
19.21.3 ICP parameters ......................................................... 19-263
19.22 Warning and error codes.......................................................... 19-266
19.22.1 Error handling ............................................................ 19-266
19.22.2 Safety logics .............................................................. 19-268
19.23 Warning and error codes.......................................................... 19-271
19.23.1 ICP, code group 1 ...................................................... 19-271
19.23.2 MCU, code group 2 ................................................... 19-281
19.23.3 Drive system, code group 3 ....................................... 19-291
19.23.4 Cabin lift system, code group 4 ................................. 19-302
19.23.5 Steering system, code group 5 .................................. 19-308
19.23.6 Initial lift and turret head fork unit systems,
code group 6 (T code 712) ........................................ 19-321
19.23.7 Shuttle fork system (including FCU warnings) -
code group 6 (T code 713) 19-328

Contents
227761-040 2008-04-25 919699- 712, 713
20- Hydraulic system – 6000 ................................................................. 20-1

20.1 General......................................................................................... 20-1
20.1.1 Symbols ......................................................................... 20-2
20.2 Cabin lifting................................................................................... 20-4
20.2.1 General .......................................................................... 20-4
20.2.2 Cabin lifting - S44 closed ............................................... 20-4
20.2.3 Cabin lowering - S70 closed .......................................... 20-4
20.2.4 AC hydraulic unit, components ...................................... 20-5
20.2.5 Hydraulic flow diagram, cabin lifting ............................... 20-7
20.2.6 B cylinder system ........................................................... 20-9
20.3 Fork units and steering ............................................................... 20-11
20.3.1 General ........................................................................ 20-11
20.3.2 Hydraulic flow diagram, DC system (T code 712) ....... 20-12
20.3.3 Hydraulic diagram (T code 713) ................................... 20-13
20.3.4 Shuttle fork valve blocks (T code 713) ......................... 20-16
20.3.5 Fork rotation (T code 712) ............................................ 20-17
20.3.6 Traversing movement .................................................. 20-17
20.3.7 Fork lifting ..................................................................... 20-18
20.3.8 Fork lowering ................................................................ 20-18
20.3.9 Steering ........................................................................ 20-19
20.4 Extra hydraulic function (T code 712) ......................................... 20-21
20.4.1 Valves used for the extra hydraulic functions ............... 20-21
20.4.2 Hydraulic diagram, extra hydraulic
function (T code 712) 20-22
21- Hydraulic pump – 6140 .................................................................... 21-1

21.1 General......................................................................................... 21-1
21.2 Replacing the hydraulic pump ...................................................... 21-2
21.2.1 Dismantling .................................................................... 21-2
21.2.2 Assembly ........................................................................ 21-4
22- Accumulators – 6280 ....................................................................... 22-1

22.1 Charging of the lifting and steering accumulators......................... 22-1
22.1.1 Preparations ................................................................... 22-2
22.1.2 Measuring the pressure in the lifting accumulator .......... 22-3
22.1.3 Charging the lifting accumulator ..................................... 22-6
22.1.4 Order numbers for country-specific adapter kits. ........... 22-7
22.2 Measuring the pressure in the steering accumulator .................... 22-8
22.2.1 Charging the steering accumulator .............................. 22-10
23- Main lift cylinder – 6610 ................................................................... 23-1

23.1 Replacing the seal in the B cylinder.............................................. 23-1
24- Main mast and mast – 7100 ............................................................. 24-1

24.1 Setting the cab and mast stoppers ............................................... 24-1
24.1.1 Cab stoppers .................................................................. 24-1
24.1.2 Setting the cab stoppers ................................................ 24-2
24.1.3 Mast stoppers ................................................................. 24-5

Contents
712, 713 919699- 2008-04-25 227761-040
25- Main lift chain system – 7120 ......................................................... 25-1

25.1 General ........................................................................................ 25-1
25.2 Checking the chain setting ........................................................... 25-1
25.3 Chain inspection .......................................................................... 25-1
25.3.1 Noise ............................................................................. 25-1
25.3.2 Surface rust ................................................................... 25-1
25.3.3 Rusty links ..................................................................... 25-1
25.3.4 Stiff links ........................................................................ 25-2
25.3.5 Bolt rotation ................................................................... 25-2
25.3.6 Loose bolts .................................................................... 25-2
25.3.7 Outline wear .................................................................. 25-3
25.3.8 Stretching ...................................................................... 25-4
25.3.9 Damage ......................................................................... 25-4
25.3.10 Damaged discs .............................................................. 25-5
25.3.11 Damaged bolts .............................................................. 25-5
25.3.12 Dirty chain ...................................................................... 25-5
25.4 Cleaning....................................................................................... 25-5
25.5 Lubrication ................................................................................... 25-6
25.5.1 Chain adjustment ........................................................... 25-7
25.6 Tool list .......................................................................... 25-7
25.7 Main lift chain adjustment .............................................. 25-7
25.8 Cabin chain adjustment ................................................. 25-9
25.9 Initial mast chain adjustment ......................................... 25-9
25.10 Initial mast – 7160 ........................................................................ 26-1
26- Initial mast/Turret head fork unit – 7200 (T code 712) .................. 27-1
26.1 General ........................................................................................ 27-1
26.2 Assembly/disassembly of the initial mast ..................................... 27-2
26.2.1 Mast assembly ............................................................... 27-2
26.2.2 Installation of belts on a new truck ................................ 27-6
26.2.3 Installing the hydraulic hoses and electric cabling ......... 27-8
26.2.4 Mast disassembly .......................................................... 27-9
26.3 Inspection and replacement of belts used for fork traversing ..... 27-10
26.3.1 Inspection .................................................................... 27-10
26.3.2 Replacing the belt ........................................................ 27-11
26.3.3 Checking belt tensioning ............................................. 27-14
26.4 Friction plate adjustment ............................................................ 27-17
26.5 Parallel adjustment of forks........................................................ 27-18
26.5.1 Measuring fork parallelism ........................................... 27-19
27- Shuttle fork – 7800 (T code 713) .................................................... 28-1

27.1 Assembly of the shuttle fork ......................................................... 28-1
27.2 Maintenance ................................................................................ 28-3
27.2.1 Maintenance chart ......................................................... 28-4
27.2.2 Lubrication ..................................................................... 28-6
27.2.3 Chain adjustment ........................................................... 28-7
27.3 Replacing the shuttle forks......................................................... 28-10
27.4 Shuttle fork unit – 7800 .............................................................. 28-13
27.4.1 Shuttle forks coming loose from the fork carriage holders 28-13
28- Wire guidance equipment – 8200 ................................................... 29-1

28.1 General ........................................................................................ 29-1
28.2 Generator..................................................................................... 29-2
28.2.1 Technical data ............................................................... 29-2
Contents
227761-040 2008-04-25 919699- 712, 713
29- Height preselection – 9390 .............................................................. 30-1

29.1 General......................................................................................... 30-1
29.2 Parameters................................................................................... 30-1
29.2.1 MCU parameters ............................................................ 30-1
29.3 Programming................................................................................ 30-2
29.3.1 Programming a level ...................................................... 30-3
29.3.2 Operation/Automatic operations ..................................... 30-5

Contents
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Preventive maintenance – P2 (T code 712)
227761-040 2008-04-25 919699- 712, 713
2- Preventive maintenance – P2 (T
code 712)
Maintenance chart
I: Inspect, adjust and replace if necessary. T: Tighten. C: Clean L: Lubricate.
M: Measure and adjust if necessary.
Pos. Work to carry out
no. Intervals in hours Initial- 500 1000 2000 3000
ly 250
Intervals in Days/Weeks/Months 3M 6M 12M 24M 36M
0000 Chassis
0000.1 Inspect the battery locking device I I
0000.2 Inspect for cracking and other damage I
0000.3 Inspect the overhead guard mounting I
0320 Greasable axle
0320.1 Lubricate the articulated centre axle L
0800 Protective equipment
0800.1 Inspect the life line I
0640 Operator controls
0640.1 Inspect the mounting I
0640.2 Inspect the strength of the gas struts and the I
locking performance
1700 Electric motors
1700.1 Inspect all cable connections I I
1700.2 Tighten all mounting bolts T T
1700.3 Inspect all cooling fan functions I I
1800 Hydraulic motors
1800.1 Inspect mounting, and retighten the mounting I/T
bolts
1800.2 Check for leakage I I

712, 713 919699- 2008-04-25 227761-040

ly 250
2550 Drive assembly
2550.1 Inspect for leakage/inspect the oil level I
2550.2 Replace the drive gear oil IC1) I
2550.3 Inspect any noise I
3180 Electrically controlled service brake
3180.1 Clean C
3180.2 Inspect wear on the brake disc/ohm measure the M
brake coil
3180.3 Inspect play in the neutral position M
3370 Electric parking brake
3370.1 Clean C
3370.2 Inspect the braking torque T
3500 Wheels
3500.1 Remove strings and other dirt I
3500.2 Inspect the drive wheel for wear and the tighten- I/T
ing torque of the bolts

Order No.. Date Applies from machine No. T Code
227761-020 2008-04-25 919699- 712, 713
I: Inspect, correct and replace if necessary. T: Tighten. C: Clean L: Lubricate.

M: Check measure, correct if necessary
Pos. Work to be performed
No Interval in hours - may vary depending on Initially 500 1000 2000 3000
application 250h
Interval in days/weeks/months - 3m 6m 12m 24m 36m
can vary depending on application
5000 Electrical functions
5000.1 Retighten all cable connectors T
5000.2 Check the contactor tips and their function I
5000.3 Check the function of the emergency switch (ICP, I
chassis)
5000.4 Check the function of the safety gates I
5000.5 Check the warning light (flasher) function I
5000.6 Check the slack chain guards I
5000.7 Check the error code log and operating hours I
5110 Battery
5110.1 Check the electrolyte level: 10-15 mm above the M
cell plates
5110.2 Check all connections to battery, truck and I
charger
5110.3 Check that the cell and pole protectors are not I
damaged
5110.4 Check the fluid density and temperature M
5110.5 Suck up any excess fluid from the battery tray C
6100 Hydraulic unit
6100.1 Check for leakage from hoses, connections, I
filters and cylinder seals.
6100.2 Check the oil level/leakage I
6100.3 Check the gas pressure in the accumulators I I
6100.4 Check the steering cylinders for internal leakage IB
6100.5 Change the hydraulic oil IB
6100.6 Change the oil and air filters I I
6100.7 Check carbon brush wear in the M
initial pump motor and clean.
© BT Europe AB Service manual VCE150A, 150AC, 125ASF, 125ACSF 2-3

T Code Valid from machine No. Date Order No.
712, 713 919699- 2008-04-25 227761-020
I: Inspect, correct and replace if necessary. T: Tighten. C: Clean L: Lubricate.

M: Check measure, correct if necessary
No Interval in hours - may vary depending on Initially 500 1000 2000 3000
application 250h
Interval in days/weeks/months - 3m 6m 12m 24m 36m
can vary depending on application
7100 Main mast
7100.1 Check emergency lowering I
7100.2 Check the lifting cylinders’ mountings I
7100.3 Check the wear on the lifting chains and the I
chain wheel
7100.4 Lubricate the lifting chains LA
7100.5 Lubricate the mast rails at the guide runners and LF LF
side guide runners
7100.6 Check the adjustment of the lifting chains. Check I
the chain bolts and the chain mounting.
Check tighten the locking nuts and inspect the
safety cotter pin.
7200 Initial mast
7200.2 Check the adjustment of the lifting chains. Check I
the chain bolts and the chain mounting.
Check tighten the locking nuts and inspect the
safety cotter pin.
7200.3 Lubricate the turret head chain LA
7200.4 Check the pre-tension of the belts I I
7200.5 Lubricate the guide roller contact surface in the U LD
member. NOTE!
7200.6 Lubricate the mast rails at the guide runners LF
7200.7 Lubricate the breaker runner bearings (4 pcs LE
breaker runners for the belts)
7200.8 Lubricate the mast rails at the sliding block LG LG
7200.9 Lubricate the support roller (4 pcs) contact LF
surfaces
(2 pcs steel strips in stainless material).
7200.10 Lubricate the initial mast’s turret bearings (2 pcs) LE
7200.11 Check hoses, couplings and cylinders for I
leakage.
7200.12 Check line components, cylinders and the I
hydraulic motor for leakage
2-4 Service manual VCE150A, 150AC, 125ASF, 125ACSF © BT Europe AB

227761-040 2008-04-25 919699- 712, 713

ly 250
7200.13 Inspect the rotation cylinders for internal leakage. I
(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 = The oil should be changed for the first time after 250 hours/3 month
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.

712, 713 919699- 2008-04-25 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
7200.6 1700
7200.8 3370
5000
0640
0800
3500
7200.5

227761-040 2008-04-25 919699- 712, 713
7100.5
6100
2550

712, 713 919699- 2008-04-25 227761-040

227761-040 2008-04-25 919699- 712, 713
3- Preventive maintenance – P2
(T code 713)
I: Inspect, adjust and replace if necessary. T: Tighten. C: Clean. L: Lubricate.

no. Interval in hours - can vary depending Ini- 500 1000 2000 3000
on application tially
250 h
Interval in months – can vary 3m 6m 12 m 24 m 36 m
depending on application
0000 Chassis
0000.1 Inspect the battery locking device I I
0000.2 Inspect for cracking and other damage I
0000.3 Inspect the overhead guard mounting I
0320 Greasable axle
0320.1 Lubricate the articulated centre axle L
0800 Protective equipment
0800.1 Inspect the life line I
0640 Operator controls
0640.1 Inspect the mounting I
0640.2 Inspect the strength of the gas struts and the I
locking performance
1700 Electric motors
1700.1 Inspect all cable connections I I
1700.2 Tighten all mounting bolts T T
1700.3 Inspect all cooling fan functions I I
1800 Hydraulic motors
1800.1 Inspect mounting, and retighten the mount- I/T
ing bolts
1800.2 Check for leakage I I
2550 Drive assembly
2550.1 Inspect for leakage/inspect the oil level I
2550.2 Replace the drive gear oil IC1 I
2550.3 Inspect any noise I

712, 713 919699- 2008-04-25 227761-040

no. Interval in hours - can vary depending Ini- 500 1000 2000 3000
on application tially
250 h
3180 Electrically controlled service brake
3180.1 Clean C
3180.2 Inspect wear on the brake disc/ohm measure M
the brake coil
3370 Electric parking brake
3370.1 Clean C
3370.2 Inspect the braking torque T
3500 Wheels
3500.1 Remove strings and other dirt I
3500.2 Inspect the drive wheel for wear and the I/T
tightening torque of the bolts
5000 Electric functions
5000.1 Tighten all cable connectors T
5000.2 Inspect the contactor tips and their function I
5000.3 Inspect the emergency stop switch function I
(ICP, chassis)
5000.4 Inspect the operation of the safety gates I
5000.5 Inspect the warning light (blinker) function I
5000.6 Inspect the slack chain guards I
5000.7 Inspect the error code log & operating hours I
5000.8 Check the horn I

Order No.. Date Applies from machine No. T Code
227761-020 2008-04-25 919699- 712, 713
I: Check, adjust and replace if necessary. T: Tighten. C: Clean. L: Lubricate.

Pos. Work to be carried out
No. Interval in hours - may vary due to Initially 500 1000 2000 3000
application 250 h
Interval in months - may vary 3m 6m 12 m 24 m 36 m
due to application
5110 Battery
5110.1 Check the electrolyte level: the level should M
be 10-15 mm above the cell plates
5110.2 Check all connections on the battery, truck I
and charger
5110.3 Check that the cell and terminal guards are I
undamaged
5110.4 Check the fluid density and temperature M
5110.5 Suck up any fluid that has run out into the C
battery tray
6100 Hydraulic unit
6100.1 Check hoses, connections, filters and I
cylinder head gaskets for leakage
6100.2 Check the oil level and if there is oil leakage I
6100.3 Check the gas pressure in the accumulators I I
6100.4 Check the steering cylinders for internal IB
leakage
6100.5 Change the hydraulic oil IB
6100.6 Change the air and oil filters I I
6100.7 Check carbon brush wear in the M
initial pump motor and clean
7100 Main mast
7100.1 Check the emergency lowering function I
7100.2 Check the lift cylinder mountings I
7100.3 Check the wear on the lifting chains and I
chain wheel
7100.5 Lubricate the mast members at the runner LF LF
wheels and the vertical runner wheels
7100.6 Check the adjustment of the lifting chains. I
Check the chain bolts and the chain
mountings.
Retighten all locking nuts to the correct
torque and inspect the safety cotter pin.
© BT Europe AB Service manual VCE150A, 150AC, 125ASF, 125ACSF 3-3

T Code Valid from machine No. Date Order No.
712, 713 919699- 2008-04-25 227761-020
I: Check, adjust and replace if necessary. T: Tighten. C: Clean. L: Lubricate.

Pos. Work to be carried out
No. Interval in hours - may vary due to Initially 500 1000 2000 3000
application 250 h
Interval in months - may vary 3m 6m 12 m 24 m 36 m
due to application
7200 Initial mast
7200.2 Check the adjustment of the lifting chains. I
Check the chain bolts and the chain
mountings.
Retighten all locking nuts to the correct
torque and inspect the safety cotter pin.
7200.3 Lubricate the guide roller contact surfaces at LD
the U member (NOTE)
7200.4 Lubricate the mast members at the guide LF
rollers
7200.5 Check all hoses, connections and cylinders I
for leakage.
7200.6 Check all hoses for wear I
7800 Reach carriage
7800.1 Lubricate the drive chain LA LA
7800.2 Lubricate the shuttle fork chain LA LA
7800.3 Lubricate the gear rods on the guide LF LF
7800.4 Lubricate the contact surfaces on the guide LF LF
rollers
7800.5 Check the adjustment of the guide chain I I
7800.6 Check the adjustment of the shuttle fork I I
chain
7800.7 Check the reach carriage clearance +/- 2 mm I I
7800.8 Check the mounting and wear of the chain I I
wheel
7800.9 Check line components and the hydraulic I
motor for leakage
Note! 500 h is based on average loads of 700-800 kg. For heavier

average loads, the interval should be changed to 250 h.
a) After 250 h, further replacement is no longer necessary.
b) Oil change every 2000 hours or every other year.
The letters A-G indicate the lubricant type to be used. See separate
table.
3-4 Service manual VCE150A, 150AC, 125ASF, 125ACSF © BT Europe AB

Oil and grease specifications – P3 (T code 712)
227761-040 2008-04-25 919699- 712, 713
4- Oil and grease specifications – P3 (T

code 712)
Pos. Lubricant Ambient Viscosity Application Recommended
temperature class products*
A Chain Lubri- > - 40°C VG 150 Chains Klüberoil 4UH 1-15,
cation Klüber Lubrication
< - 30°C
< - 30°C VG 68 Chains Klüberoil 4UH 1-68
N, Klüber Lubrication
< + 5° C
Anticorit LBO 160 TT,
Fuchs DEA
< + 5° C VG 150 Chains Klüberoil 4UH 1-150N,
Klüber Lubrication
< +45°C
Anticorit LBO 160,
Fuchs DEA
Rexoil, Rexnord Kette
>+ 45°C VG 220 Chains Klüberoil 4UH 1-220N,
Klüber Lubrication
<+ 80°C
B Hydraulic oil > - 40°C ISO-VG 15 Hydraulic system
< - 15°C
> -15 °C ISO-HM 32 Hydraulic system
< +45°C
C Transmission > - 40°C Hypoid oil Gears
oil SAE 75W
< - 15°C
> -15 °C Hypoid oil Gears
SAE 80W/90
< +45°C
D Grease > - 40°C --------- Support roller con- Klüberpasta 46 MR 401
tact surfaces (Klüber)
< - 15°C
> -15 °C --------- Support roller con- Grafloscon C-SG 2000
tact surfaces Ultra (Klüber)
< +45°C
E Grease > - 40°C --------- Rotation bearings Polylube GLY
and interruption 801 (Klüber)
< - 15°C
rollers
> -15 °C --------- Rotation bearings Microlube GL 261
and interruption (Klüber)
< +45°C
rollers
F Grease > - 40°C EP2 Mast girders Gleitmo 805
Q8 Rubens LT
< - 15°C
> -15 °C EP2 Mast girders Gleitmo 805
Q8 Rembrandt EP2
< +45°C

Oil and grease specifications – P3 (T code 712)
712, 713 919699- 2008-04-25 227761-040

temperature class products*
G Articulated centre Klüber Polylub Gly801
axle, rotating bear- (BT-number 243531)
ing and bushings
for the pulley roll-
ers

Oil and grease specification – P3 (T code 713)
227761-040 2008-04-25 919699- 712, 713
5- Oil and grease specification – P3 (T

code 713)
tempera- class products*
ture
A Chain Lubri- > - 40°C VG 150 Chains Klüberoil 4UH 1-15,
cation Klüber Lubrication
< - 30°C
< - 30°C VG 68 Chains Klüberoil 4UH 1-68
N, Klüber Lubrication
< + 5°C
Anticorit LBO 160 TT,
Fuchs DEA
< + 5°C VG 150 Chains Klüberoil 4UH 1-150N,
Klüber Lubrication
< +45°C
Anticorit LBO 160,
Fuchs DEA
>+ 45°C VG 220 Chains Klüberoil 4UH 1-220N,
Klüber Lubrication
<+ 80°C
B Hydraulic oil > - 40°C ISO-VG 15 Hydraulic sys-
tem
< - 15°C
> -15 °C ISO-HM 32 Hydraulic sys-
tem
< +45°C
C Transmission > - 40°C Hypoid oil Gears
oil SAE 75W
< - 15°C
> -15 °C Hypoid oil Gears
SAE 80W/90
< +45°C
D Grease > - 40°C --------- Support roller Aeroshell Grease 17
contact surfaces (Shell)
< - 15°C
> -15 °C --------- Support roller Grafloscon C-SG
contact surfaces 2000 Ultra (Klüber)
< +45°C
E Grease > - 40°C --------- Rotation bear- Polylube GLY
ings and inter- 801 (Klüber)
< - 15°C
ruption rollers
> -15 °C --------- Rotation bear- Microlube GL 261
ings and inter- (Klüber)
< +45°C
ruption rollers
F Grease > - 40°C EP2 Mast girders Q8 Rubens LT
< - 15°C
> -15 °C EP2 Mast girders Q8 Rembrandt EP2
< +45°C
G Grease --------- Gleitmo 805
Oil and grease specification – P3 (T code 713)
712, 713 919699- 2008-04-25 227761-040

tempera- class products*
ture
H Articulated cen- Klüber Polylub Gly801
tre axle, rotat- (BT-number 243531)
ing bearing and
bushings for the
pulley rollers

Tools – P4
Super Seal contact
227761-040 2008-04-25 919699- 712, 713
6- Tools – P4
6.1 Super Seal contact
3
3
Tools Number Application

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)

Tools – P4
Super Seal contact
712, 713 919699- 2008-04-25 227761-040
6.1.1 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)

151080 (PT) Tools for removing pins/sleeves
213296 (JPT) Tools for removing pins/sleeves
213298 (MPT) Tools for removing pins/sleeves
1=163787 (JPT) Tools for fitting sleeves

2=163788 (JPT)
1=213336 (MPT)
1 2=213337 (MPT)
2
1=213336 (JPT) Tools for fitting pins
2=213549 (JPT) For 0,5-2,5 mm2
1
2

Tools – P4
Super Seal contact
227761-040 2008-04-25 919699- 712, 713
6.1.2 Miscellaneous tools

156263 Service instrument (CAN)
1=163793 Service instrument for program

2=163792 changes
The TruckCom TruckCom program

service manual is
a separate manual
that can be down-
loaded from the
web site where the
TruckCom
firmware is availa-
ble.
08-15444 Drive motor/Pump motor

Tools – P4
Super Seal contact
712, 713 919699- 2008-04-25 227761-040

10-15639 Socket for transmission nuts
08-13022 Puller, transmission
08-13585 Pressing tool for the support

arm wheels
08-13585-2 Tools for wheel axle
Tools for wheel axle

08-13585-1/5.1 A=30
08-13585-1/5.2 A=40
A

Tools – P4
Super Seal contact
227761-040 2008-04-25 919699- 712, 713

08-13585-1/4 Tools for wheel axle
808-410 Socket for support arm wheel

808-4XX
V08-14044 Pressing tool for the support

arm wheels
V08-14044/1 Pressing tool for the support

arm wheel bearings
V08-14044/2 Socket for support arm wheel
Compl=V1015191 Oil cleaning

1=V10-15191-1 1=Filter for cleaning
2=V10-15191-2 2=Filter for removing water
3=V10-15191-3 3=Pipe
-1
-2 4=V10-15191-4 4=Pipe
-3
-4

Tools – P4
Super Seal contact
712, 713 919699- 2008-04-25 227761-040

219730 Hydraulic pressure gauge
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. Capac-
ity 8000 kg.

Tools – P4
Super Seal contact
227761-040 2008-04-25 919699- 712, 713

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.

Tools – P4
Super Seal contact
712, 713 919699- 2008-04-25 227761-040

Chassis – 0000 Truck installation
General
227761-040 2008-04-25 919699- 712, 713
7- Chassis – 0000 Truck installation
7.1 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.
7.2 Tool list

• 2 counterweight trucks with a capacity of min.5000 kg to unload the
new 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
Or, as an alternative, 2 counterweight trucks each with a capacity of
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 tension meter, order no. 213973
• Rags
• Absorption agent
• Bundling ribbon

Unloading the truck
712, 713 919699- 2008-04-25 227761-040
7.3 Unloading the truck

Trucks with low lifting height, i.e. under 4,700 mm, are supplied fully
assembled standing on their wheels.
Trucks with lifting heights exceeding 4,700 mm are supplied lying on
the side on pallets. See picture. In some cases, trucks supplied in hori-
zontal position may be delivered with a disassembled initial mast/turret
head fork unit.
The recommended unloading procedure uses two fork lifts with the indi-
cated 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.

Unloading the truck
227761-040 2008-04-25 919699- 712, 713
7.3.1 Unloading a standing truck

Driving 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 supplied 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 turnj 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.

Unloading the truck
712, 713 919699- 2008-04-25 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. En-
sure 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 clear the bed of the trailer.
• Reverse slowly and once the truck is clear of the lorry bed, lower it to
the ground.
NOTE:
Prior to first use, do not forget to remove the mechanical locking pin.

Unloading the truck
227761-040 2008-04-25 919699- 712, 713
7.3.2 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 articu-
lated centre on pallets. See 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.

Unloading the truck
712, 713 919699- 2008-04-25 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 fit-
ted with forged forks with a length of approx. 1500 mm. The lifting
points are located under the mast and operator's cabin. See 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.

Unloading the truck
227761-040 2008-04-25 919699- 712, 713
7.3.3 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.

Unloading the truck
712, 713 919699- 2008-04-25 227761-040

Unloading the truck
227761-040 2008-04-25 919699- 712, 713

Unloading the truck
712, 713 919699- 2008-04-25 227761-040
7.3.4 Erecting the truck

WARNING!
Stand at a safe distance when lifting/elevating the truck.
Fit lifting yoke V11-1053/4.

Unloading the truck
227761-040 2008-04-25 919699- 712, 713

Unloading the truck
712, 713 919699- 2008-04-25 227761-040

Unloading the truck
227761-040 2008-04-25 919699- 712, 713

Unloading the truck
712, 713 919699- 2008-04-25 227761-040
7.3.5 Final assembly

• Pull out the aisle transmitter cabling and also the wire guidance ca-
bling (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 pre-
pared for wire guidance, also the rear wire guidance antenna.
• Lift the battery into place using lifting bridle no. 11-1310
.
B 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.
7.3.6 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.

Preparations for commissioning
227761-040 2008-04-25 919699- 712, 713
7.4 Preparations for commissioning

• Fill the hydraulic fluid reservoir with oil according to the specifica-
tions.
Prior to using the truck, be sure to bleed both pumps. Follow the proce-
dure below:
a) Open the emergency lowering valve (A) and the drain valve (B).
b] Restart the truck. (The DC pump starts automatically.)

c) Close drain valve for steering operation.
d) Raise the cabin for approx. 3 seconds, stop lifting and then allow the
cabin to sink to the bottom.
e) Close the emergency lowering valve again.

Preparations for commissioning
712, 713 919699- 2008-04-25 227761-040
• 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 func-
tions and all fork unit movements.
• Inspect to make sure there is no oil leakage from the hydraulic hos-
es.
• Dry off and clean the truck oil from any waste oil.
• Calibrate the hydraulic pressure in the lifting accumulator(s) accord-
ing 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.
NOTE:
On trucks with two accumulators, to prevent wear on the hydraulic
pumps top up the reservoir with oil until it reaches the max. level.

Installation in narrow aisle
227761-040 2008-04-25 919699- 712, 713
7.5 Installation in narrow aisle
7.5.1 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.
7.5.2 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.
7.5.3 Wire-guided truck

• Inspect the frequency and current data of the wire.
• Verify the wire-guidance settings of the truck. See the instructions
under 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.

Installation in narrow aisle
712, 713 919699- 2008-04-25 227761-040
7.5.4 Support arm collision guards

Assembling the guards during truck installation
Upon delivery of the truck, two support arm collision guards are sup-
plied in the cab. Be sure to assemble one collision guard on each sup-
port arm. Assembly is done as shown in the picture using two bolts for
each collision guard. Apply Locktite when assembling the guards.

Removal/reassembly of rear chassis, including bearings
227761-040 2008-04-25 919699- 712, 713
7.6 Removal/reassembly of rear

chassis, including bearings
These instructions explain how to disassemble and reassemble the
rear chassis and replace the bearings in the pivots.
7.6.1 Special tools

• Mast tool set V10-16169 (blocking of mast and cabin)
• Remote control 214303 (lifting cabin from outside)
• Stabilising block set – part no.245344
Front blocks: 2x 245314 (weight approx. 40 kg each)
Rear blocks: 2x 245286
Bolts: 8x 20002 (M12x30)
Washers: 8x 21394
• Lift aid: a CB truck or reach truck with minimum 2,000 kg lifting ca-
pacity
(for removal of battery)
• Mandrel rod, diameter 30 mm, length 650 mm
(to knock out the axles in the pivot)
• Threaded rod M16. Length = 650 mm
M16 nut with flange
Washer dia 90 mm, thickness 10 mm, hole 17 mm
(to mount the axles in the pivot)
7.6.2 Standard hand tools

• Allen keys 2-14 mm
• Allen key socket set 5-14 mm for 1/2” locking handle
• 1/2” locking handle
• 1/2” torque wrench 0 - 320 Nm
• Socket wrench set, 10-32 mm
• Spanner wrench set, 8-24 mm
• 27 mm spanner wrench
• Sledge hammer
• Lifting loop 2,000 kg
• Rags
• Absorption agent
• Cable ties

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7.6.3 Disassembly
Jack up the truck to prepare for disassembly
1. Remove the battery cover and the plastic panels over the mo-
tor compartment from the rear chassis.
NOTE:
Do not forget to remove the battery cover stop bar before dismount-
ing the hinge bolts.
2. Remove the battery from the battery compartment.
• Use the recommended lift truck if the battery have fork tunnels.
If the battery has a flat bottom, use a 2-ton rated lifting bridle.
• Place the battery next to the truck, sufficiently close to be able to
connect the battery cable.

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3. Fit the pivot lock pin
• The pivot lock pin must be mounted to prevent the pivot from bend-
ing while jacking up the truck.
4. Lift up the cabin approximately 300 mm
• This will provide access for mounting the front stabilising blocks.
5. Jack up one side of the truck
• Place the jack under the chassis side in a straight line with the mast.
• Place one “rear support”, 245286, under the support arm wheel
frame as shown in the picture, and lower the machine on to the sup-
port.

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6. Jack up the other side of the truck

• Jack it up the support arm wheel frame until the underside is approx-
imately 115 mm above the ground.
• Place the front support, 245314, as shown in the picture below and
secure with the M12 bolts. Tighten only the lower bolts slightly, as
there will be an angle between the machine and the support.
GAP
• When lowering the machine, make sure that the frame rests on the
inner plate of the front support.
7. Place the jack on the first side again
• Jack up the truck until the underside of the support arm wheel frame
is approximately 115 mm above the ground.
• Place the front support, 245314, as shown in the picture below and
secure with the M12 bolts. Tighten the bolts slightly.
• When lowering the machine, make sure that the frame rests on the
inner plate of the front support.
NOTE:
The machine should not be “tilting” backwards.

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8. Jack up the rear end of the truck, placing the jack under the
rear end chassis.
• Place the rear support blocks, 245286, under the rear end of the
front chassis as shown in the picture below.
• Lower the machine on to the blocks.

• Now tighten the front support mounting bolts firmly on both sides.
Tightening torque = 77 Nm
WARNING!
Risk of injury The truck can topple over.
If the front support mounting bolts are not sufficiently tightened, this
could cause instability of the truck during the remainder of the proce-
dure to change the rear chassis.
Always make sure the front support mounting bolts are tightened to
the specified tightening torque.

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9. Lift up the cabin and mount the cabin and mast stops as de-
scribed in the instructions under C code 7100 of the service
manual.
• Preferably use the remote control, 214303, to lift the cabin before
mounting the stops.
10. Depressurise all hydraulic lines on the truck
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.
• Cabin lift system

• Steering system

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• B cylinder accumulator system
7.6.4 Disassembly of components

1. Remove the drive wheel covers.
2. Remove the plastic panels supports
3. Remove the B cylinder accumulator pipes
• This hydraulic pipe must be removed to be able to lift out the rear
chassis.
• If the truck is equipped with two accumulators, the corresponding

pipe on the right side must also be removed.
• For better access to the pivot area, the right side accumulator can be
removed with its mounting bracket.
4. Remove the hydraulic hoses from the valves
• Use plugs of the type shown in the picture below to seal off all hoses
and connections on the valve blocks and minimise oil spillage.

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• If plugs are not at hand, drain the oil tank by pumping the oil into two
clean (new) plastic cans. First remove the oil filter holder
• Attach the lifting loop in the holes in the console side plates (next to
the oil tank). Use a lift truck to carefully lift the console free from the
rear chassis.
• Make sure that none of the previously dismounted hoses will be

caught and damaged.
• Place the console on the floor next to the truck.
5. Remove the potentiometer from the upper pivot axle
• Disconnect the potentiometer wiring from the main wiring harness.
• Remove the potentiometer assembly by removing the small bracket

mounted on the axle.

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6. Remove the hoses running through the pivot

• Remove the cover plate and loosen the hose connections in the
front chassis under the cabin.
• Cut all the ties securing the wiring harnesses to the hoses inside the
chassis.
• Remove the holding clamp for the hoses.

• Also remove the clamps for the main wiring harness (opposite side).
Then remove the entire holder from the chassis.

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• Put the hoses down through the holes in the rear chassis and pull
them out in the front chassis.
7. Remove the wiring running through the pivot

• Remove the wiring connector from the B cylinder system pressure
sensor and cut all the cable ties. Then pull it out into the front chas-
sis.
• Remove all the main wiring harness connectors from the connection
block under the cabin.
For wire-guided trucks, cut all ties securing the antenna cable all the
way up to the antenna, and then disconnect the antenna connector.
• Put the wires that were disconnected from the electrical connection
block on the console down through the hole in the rear chassis.
• For wire-guided trucks, put the X132 wire guidance connector from
the MCU though the hole.
• Pull out the main wiring harness, and if wire guided also the antenna
cables, to the front of the machine.

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8. Remove the steering cylinders

• Remove the pivot lock pin so that the chassis can be moved side-
ways while removing the steer cylinders.
• Remove the split pins from the cylinder mounting pins. Pull out the
mounting pins.
• Pull the cylinders out backwards trough the hole in the chassis.

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7.6.5 Dismantle the rear chassis

• Turn the chassis to one side to access the lock bolt of the lower pivot
axle.
• Loosen the bolt and remove the washer.
• Loosen the bolts and remove the cover plate from the upper pivot
axle.
• Before removing any of the pivot axles, place a hand pallet truck or
the forks of a lift truck under the rear chassis to provide necessary
support.

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• Knock out the upper pivot axle.
• Knock out the lower pivot axle using the 30 mm mandrel rod and the
sledge hammer.
NOTE:
The lower axle may have a very tight fit due to small tolerances.
• Pull out the rear chassis from front chassis.

Replace the pivot bearings
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7.7 Replace the pivot bearings
7.7.1 Remove the old bearings

1. Remove the upper bushing
• Remove the sealing rings on both sides of the bushing.
• Knock out the bushing using a mandrel and a hammer.
• Clean the bushing seat.
2. Remove the lower dual conical roller bearings
• Remove the bottom bearing holder plate and the upper sealing
sleeve.
• Use the 30 mm long mandrel rod to knock out the roller bearings.
• Place the mandrel on the spacer ring, as shown in photo 2, if the

bearing if to be reused.
• Clean the bearing seat.

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7.7.2 Install new bearings

1. Assemble the lower dual conical roller bearings
• Fit a new O-ring to the sealing sleeve.
• Insert the spacer ring in the sealing sleeve, then insert the sealing
sleeve in the bearing seat.
• The dual conical roller bearing consists of two separate conical roller
bearings and a spacer ring. They can be separated after cutting the
tie.
• Take the bearings apart and fill them with high temperature bearing
grease (BT P/No. 242328).
• Place the outer race of one bearing in the pivot as shown in the pic-
ture. Knock it into place until it is flush with the chassis surface.
• Then fit the inner race, including the roller cage and the spacer ring.
Knock the race into place until it is flush with the chassis surface.
• Fit the second bearing with the outer race pointing outwards. Knock
the race into place until it is flush with the chassis surface.
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• Mount the bottom bearing holder and its bolts.
• Tighten the bolts diagonally.

Tightening torque 52,5 Nm
2. Fit the upper pivot bushing and seals
• Place the bushing at the hole entrance.
Make sure that the slot or the hole in the bushing do not point for-
ward or backward.
• The lower pivot axle can be used as a tool when fitting the bushing.
• Make sure that the bushing ends are level with the edge of the seal
seats.
• The lower pivot axle can also be used when fitting the seals.
• Make sure that the seals are below the surface of the pivot surface.
227761-040 2008-04-25 919699- 712, 713
7.7.3 Reassemble the pivot

• Fill the upper bearing bushing with E-type grease (BT order no.
243531) as specified in the lubrication chart in the service manual.
Warning
Risk of damaging the bushing.
Normal gearing grease will destroy the bushing.
Special type E grease must be used.
• Use a fork lift truck or a hand pallet truck to position the rear chassis
in the front chassis.
• Insert the lower pivot axle.

First apply a thin layer of grease for easier mounting.
• Insert the M16 threaded rod in the hole in the axle. Fit the 90 mm
washer and the nut as shown in the picture.
NOTE:
Because of the tight fit between the axle and the bearing, it may be
hard to pull the axle through.
• While pulling through the axle, use the fork lift truck (or hand pallet
truck) to keep the rear chassis horizontal as the chassis otherwise
could move in the vertical direction when tightening the nut.
• When the axle has been fully inserted, remove the M16 rod.

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• Fit the top washer and the locking bolt.

Tightening torque for the locking bolt: 306 Nm
• Insert the top pivot axle.
Apply a thin layer of type E grease on the bolt.
Use the M16 rod to pull it through the axle as previously done for the
lower axle.
NOTE:
The position of the grease nipple must be 90 degrees to the right side
to fit in the cover plate.
• Fit the cover plate and secure it with the bolts.
Tightening torque 45 Nm
• Apply grease in the bushing until the grease comes out. Use E type
grease (BT order no. 243531) as specified in the lubrication chart in
the service manual.
Warning
Risk of damaging the bushing.
Normal gearing grease will destroy the bushing.
Special type E grease must be used.

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7.7.4 Reassemble the truck

Reassembly of the truck is done in the reverse order of disassembly.
Because of this, these reassembly instructions are abridged, and only
describe the working order and specific items like tightening torques
and safety measures. For descriptive pictures, refer to the disassembly
section.
1. Fit the steering cylinders.

Use new split pins.
2. Install the pivot lock pin.
3. Route the main wiring harness, and the wire guidance cable
on wire-guided trucks, through the pivot.
Fit the wiring connector to the B cylinder pressure sensor.
4. Route the hoses for the main lift and the initial mast system
through the pivot.
The main lift hoses should be the two bottom ones.
Fit the hose clamp and clamp the main wiring harness.
Secure loose cables with cable ties inside the chassis.
5. Install the pivot potentiometer.
6. Place the console on the rear chassis and secure it with the
bolts.
NOTE:
Be careful not to damage the steering cylinder hoses and the pivot
hoses when placing the console on the chassis.
Also note the correct hose routing under the console.
7. Connect all hoses to the valve blocks.
If the oil was drained from the tank, refill the oil though the oil
filter.
8. Connect all electrical connectors to the connection block, and
the MCU if wire guided.
9. Reassemble the plastic panels supports.
10. Fit the wheel covers.

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7.7.5 Lower the truck to the ground

When lowering the truck to the ground, work in the reverse order of the
jacking up procedure.
7.7.6 Final assembly

• Place the battery in the battery compartment.
.
• Fit the battery cover (B) on the hinges.

NOTE:
B C Do not forget to refit the battery cover stop bar.
• Insert the gas spring (C) into the chassis pivot sleeve, between the
right drive motor and the hydraulic oil reservoir, then secure it to the
battery cover.
z
• Remove the locking pin from the pivot.

• Verify correct operation by operating the lifting and lowering func-
tions and all other truck functions.
• Inspect the truck to make sure there is no oil leakage from the hy-
draulic hoses.
• Dry off any spilled oil from the truck and make sure the truck is clean.
• Calibrate the hydraulic pressure in the lifting accumulator(s) accord-
ing to the instructions in C code 5000.
• If necessary, perform the other calibrations according to the instruc-
tions in C code 5000.

Battery locking device
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7.8 Battery locking device

Trucks with machine numbers until 6039547 have a battery locking
device as shown in the picture below.
In an effort to further improve quality, a new battery locking device has

been developed. On trucks from machine number 6039548, the new
battery locking device is installed at the factory. The new battery locking
device can also be post-fitted in the field if problems should arise with
the older version.
This is the order number for the field mounting kit: 260578.
This kit includes: axle (249696), guide pin (249697), nut (20170), wash-
ers (126723-013), locking nut (20130), cylinder bolt (299323), split cot-
ter (21471), washer (29940).
Install according to the drawing. Apply Molycote on the surfaces A. Drill
a 16.5 mm diameter hole not longer than 50 mm at position B.

Battery locking device
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Frame pivot – 0320
Greasable axle
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8- Frame pivot – 0320
8.1 Greasable axle

To reduce wear on the articulated centre axle, it has been replaced by a
greasable axle (A) with a recessed nipple (B).
B A
When replacing the articulated centre axle, use the tool kit depicted
below.

Greasable axle
712, 713 919699- 2008-04-25 227761-040
Lock the mast with the mast stopper (see the service manual, C code
7100).
Provide support of the chassis to prevent it from bending.
Insert a long bolt in the axle. Knock out the axle downwards.

Greasable axle
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When replacing the axle with a greasable articulated centre axle, the
axle bracket must also be replaced. Remove the old axle bracket.

Greasable axle
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Assemble the axle by pushing it into place using bolts and spacers.

Greasable axle
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Assemble the axle with a torque of 45 Nm.

45Nm
Lubricate the axle at every 1000 h service interval. Use Klüber Polylub
Gly801 grease (BT number 243531). Apply grease in the indicated
grease nipple.

Greasable axle
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General tightening torque – 0400
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9- General tightening torque – 0400

Millimetre threads.
The following applies under ideal conditions, e.g. steel against steel.
9.0.1 Galvanised, non-oiled bolts
Thread A M3 M4 M5 M6 M8 M10
Tightening torque Mv in Nm for 8.8 1.15 2.8 5.5 9.5 23.0 45
Tightening torque Mv in Nm for 12.9 2.0 4.7 9.3 16.3 38.5 75.8
Thread A M12 M14 M16 M20 M24
Tightening torque Mv in Nm for 8.8 77.7 123 189 369.6 638.5
Tightening torque Mv in Nm for 12.9 130.5 208 319.7 623 1075
9.0.2 Untreated, oiled bolts
Thread A M3 M4 M5 M6 M8 M10
Tightening torque Mv in Nm for 8.8 1.2 2.9 5.7 9.8 24.0 47
Tightening torque Mv in Nm for 12.9 2.1 4.9 9.7 17.0 40.0 79.0
Thread A M12 M14 M16 M20 M24
Tightening torque Mv in Nm for 8.8 81 128 197 385 665
Tightening torque Mv in Nm for 12.9 136 217 333 649 1120
A = Strength grade
NOTE: Experience has shown that if the torque wrench is adjusted to
the values applying to untreated bolts, then the correct tightening
torque is achieved for galvanised bolts.
Do not tighten more than the values set out in the table, otherwise the
bolts can be destroyed.

General tightening torque – 0400
Tightening torque
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9.1 Tightening torque

Description Number Tightening C code
torque
Tool 1/2” 0-270 Nm 0000
on page 1
Screws 8 198 Nm 0000
on page 12
Screw on the bearing 6 Nm 1710
bush 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 20 Nm 1760
the gearbox on page 4
Screws for bearing bush 6 Nm 1760
and bearing plate on page 6
Stud screws 5 Nm 1760
on page 6
Connections 15 Nm 5000
on page 29
M8 screws 3 16.3 Nm 5000
M8 Transistor panel on page 31
connections

Electric pump motor – 1710.1
General
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10- Electric pump motor – 1710.1
10.1 General
The pump motor is a three-phase motor used for main lifts. 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.
10.2 Disassembled pump motor

Disassembly and assembly of the pump motor
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10.3 Disassembly and assembly of the

pump motor
WARNING!
Pressurised system.
bar.
1. Open the drain valve for the steering accumulator

2. Open the drain valve for the lifting accumulator(s)

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10.3.1 Dismantling
• Disconnect the battery plug.
1 • Lower the operator's cabin to its bottom position to relieve the pres-
2 sure in the hoses and pump.
• Pump out the oil in the hydraulic fluid reservoir using the filter pump
3 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
4 the reservoir behind the pump.
5 • Fasten a lifting eye in the motor axle.
6 • Lift out the pump motor and place it on a clean surface.
7 • Remove the lifting loop.
• Remove the four bolts (10) from the pump motor brackets.
8
• Remove the valve plate from the pump using the four hex bolts (4).
• Disassemble the pump from the motor.
9
10

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10.3.2 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).
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
13 overhead travelling crane if required.
• Lift the hydraulic pump into the truck.
• Remove the lifting loop.
• 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 lift-
ing 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.

Replacing the ball bearing
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10.4 Replacing the ball bearing

19 16 6 2 1 26 25 10 36
13 22 17 9 4 11 24 27
3
8
23
D N
30 28 20 21
10.4.1 Dismantling
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 one pulse transducer bearing will be replaced, proceed
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.

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10.4.2 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.
• Fit the rotor in the bearing shield (2).
• Screw on the bearing bush (9) using the screws (22) and tighten 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.

Assembly instruction for the external temperature sensor
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10.5 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.

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• Apply steel plastic on top of the sensor. Make sure the entire sensor
is covered by steel plastic.

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• 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 a cable tie to prevent in-
terference and possible damage.

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General
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11- Electric pump motor – 1710.2
11.1 General
The pump motor is a single phase DC motor with model
designation TTL
180C-P3A.
the shaft seal and carbons.
11.2 Disassembled pump motor
11.2.1 Connection

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pump motor
WARNING!
Pressurised system.
bar.


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11.3.1 Dismantling
2 1 • Lower the forks and the cabin to the bottom position to relieve the
pressure in the hoses and pump.
• Disconnect the battery plug.
• 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 re-
turn hose (4) and disconnect the hose from the pump.
• Fasten a lifting eye in the motor axle.
• 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).
6 • Loosen the screws and disassemble the pump (7).
5 • Remove the carrier.
3
4

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11.3.2 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 eye into the end of the motor axle and connect it to an
overhead crane.
• 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.

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11.4.1 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).
11.4.2 Assembly
Make sure all parts are complete and clean before mounting.
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).
11.4.3 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).

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11.4.4 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 ar-
mature 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).
11.4.5 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)
• Place medium-coarse abrasive paper (not emery cloth) between the
carbons and the commutator, with the paper side facing the commu-
tator.
• Apply the usual spring-load on the carbons. Allow the abrasive pa-
per to slip on the commutator surface. Free the carbons after they
have smoothened. 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).

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Truing the commutator

When it becomes necessary to turn down a worn or uneven commuta-
tor, 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 cut-
ting 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
µm. For actual operation, maximum 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 R0,2

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Electric drive motor – 1760
General
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12- Electric drive motor – 1760
12.1 General
The drive motor is a three-phase AC motor. The motor contains a ther-
moelectric 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.

Disassembled drive motor
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12.2 Disassembled drive motor

Disassembly and assembly of the drive motor
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drive motor
14, 63, 12.3.1 Disassembly of the drive motor

31 • Disconnect the battery connector.
60 • Loosen the temperature, brake and speed measurement connec-
tors (14, 31, 63) and the power cables (60) from the motor.
• Loosen and remove the motor mounting bolts (62).
29 • Lift out the motor using an overhead travelling crane and place the
27 motor on a clean surface.
NOTE:
Risk of damaging the gear wheel (51).
The gear wheel on the motor end could become damaged.
62 7 Exercise great care when lifting out the motor.
51 • To prevent objects from falling into the gear case, cover the gear
case opening once the motor has been lifted out.
54
Disassemble the gear wheel
• Knock out the nut (54) locking and unscrew the nut using tool
10-15639.
• 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

Disassembly and assembly of the drive motor
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12.3.2 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

16 • Fit the bearing cage (29) onto the motor axle.
• Fit the locking ring (27).
• Fit the key (7).
• Set the gear wheel (51) in place.
29
• Fit a new nut (54).
27
• Use tool 10-15639 and tighten to a torque of 60 Nm.
• Centre punch the nut to lock it in the key groove.
62 7 • Attach a lifting loop in the motor axle and lift the motor axle into the
gear box using an overhead travelling crane.
51
NOTE:
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.
• 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

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14 31
23 24 8 55 33
54 51 12 11 2 4 10 1 9 22 25 3 34 6 38
7 27 26 50 28 29 30 21 20 17 5 18 16
Dismantling
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.

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12.4.1 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).

Assembly instructions for the external temperature sensor
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12.5 Assembly instructions 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 ac-
cess.
• Scrape the surface, where the new temperature sensor will be
mounted, clean.

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• 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.

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• 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 a cable tie to prevent in-
terference and possible damage.

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Drive unit/gear – 2550
General
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13- Drive unit/gear – 2550
13.1 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 bear-
ings for the drive shaft and pinion. The bearings are pre-tensioned
approx. 5/100th of a millimeter to minimise the risk of play in the bear-
ings.
These service instructions cover descriptions for dismantling the gear
from the truck and refitting, 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 spe-
cially trained personnel.
13.2 Components/data of the drive unit

and gear
The main components and data of the drive gear are shown in the pic-
ture and tables below.

Components/data of the drive unit and gear
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13.2.1 Component identification
24
31
7
30
8 29
28
27
26
25
24
6
3
1 2 9 23
10
22
11
21
12
20
4 18
19
13 15 16 17

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Pos. no. Component

1 Screw
2 Washer
3-7 Screw
8 Gear wheel
9 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

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13.2.2 Technical data

Gear type 2-step angular gear
Gear ratio 17.33:1
Oil volume, litre 3.3
Oil type Hypoid oil
Viscosity, normal temperature SAE 80 W/90
Viscosity, < -15oC SAE 75 W
13.2.3 Dismantled gear

Replacing the drive motor/drive gear
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13.3 Replacing the drive motor/drive gear
13.3.1 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 meas-
urement 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.
13.3.2 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 339 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.

Replacing the drive motor/drive gear
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13.3.3 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.
13.3.4 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 damag-
ing 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 cross-
wise at a torque of 130 Nm.

Oil level check/replacement
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13.4 Oil level check/replacement
13.4.1 Oil inspection/replenishment

• 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 litres
13.4.2 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.

Repairs
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13.5 Repairs
24
31
7
30
8 29
28
27
26
25
24
6
3
1 2 9 23
10
22
11
21
12
20
4 18
19
13 15 16 17

Repairs
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13.5.1 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.
Tighten the axle bolt to a torque of 700 Nm, and lock it with one
centre punch in the axle 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 before fitting.
Fill up oil in accordance with filling instructions.
Repairs
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13.5.2 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 “Re-
placing 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 sur-
faces 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 before fitting.
• Fill up oil in accordance with filling instructions.
• 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”.
13.5.3 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.

Repairs
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13.5.4 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.
• Dismantling 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 ex-
tractor drill out the bolt:
- Make a centre punch in the bolt being careful to punch in the ab-
solute 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

Repairs
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• 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.
• Reconnect the battery disconnector.

Service brake system – 3100.1
General
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14- Service brake system – 3100.1
14.1 General
The truck’s 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 mo-
tor.
14.2 Functional description

The service brake system’s primary braking function relies on the
regenerative motor brake from the drive motor. Braking can be actuat-
ed 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

Functional description
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14.2.1 Releasing the accelerator pedal

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 fol-
lows:
• 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, pro-
viding a low braking force.
• Braking at a high speed, the accelerator is released halfway, provid-
ing medium braking force.
14.2.2 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.
14.2.3 Depressing the brake button

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

The parking brake is activated/is active when:
• When the truck comes to a standstill or when the brake button has
been depressed, the parking brake is applied automatically.
The brakes are released when the accelerator is pressed down.
• The parking brake is activated automatically when the operator re-
leases the right dead man's handle.
• The parking brake remains active after the truck switch is switched
on with the start key.
14.2.5 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 interact with emergency braking on the condi-
tion that the voltage supply works.

Functional description
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Brake performance with support arm brakes
Support arm brake

Brake Force
Regenerative motor brake
0% 25% 50% 75% 100%

Required brake performance

Electromechanical disc brake, drive motor
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14.3 Electromechanical disc brake,

drive motor
The brake is a single stage electromechanical spring-force assisted
brake that is applied when the magnetic coil is energised.
The brake acts as a parking brake and emergency brake.
The resistance in the coil is approx. 32 ohms at 20 degrees Celcius.
14.3.1 Assembly
• Fit the brake on the motor shaft.

• Before assembly of the brakes, ensure that the friction disc (4) is
centred in relation to the magnet housing.
It may be necessary to energise the magnet coil with 48 V DC to po-
sition 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 unit’s three securing bolts.
• Check the play between the magnet housing and the pressure plate
with the brake applied. The play should be 0.20-0.40 mm.
The play may need to be adjusted, see section adjustment.
• Connect the brake cable (11) to the truck’s 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.

Maintenance
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14.3.2 Dismantling
• Dismantle the brake in the reverse order.
• Place the brake on a clean, 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 com-
ponent parts.
14.3.3 Inspection
Investigate the parts for 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) for wear.
• Check the grooves in the hub (3) and friction disc (4) for damage.
• Check for any signs of swelling or damage to the magnet (1) and
pressure plate (2).
14.3.4 Assembly
• 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 correspond-
ing 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.
14.4 Maintenance
The brake is included as an inspection item in the truck’s maintenance
chart. For the required maintenance interval, please refer to the mainte-
nance section in section P2.
Maintenance comprises inspection of wear and braking force, inspec-
tion and adjustment of the play between the pressure plate and magnet
housing, and cleaning.
NOTE:
The friction surfaces must not come into contact with oil or grease as
this will considerably impair braking performance.

Maintenance
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14.4.1 Adjustment of play
• The play must be checked every 1000 operating hours.

• Adjust the play by removing shims.
• Nominal play with correct adjustment is 0.3 +0.1/-0.05 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 the play using the feeler gauges by placing them next to
the adjuster sleeve when adjusting.
Turn anticlockwise to reduce play and clockwise to increase 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 per-
mitted deviation from the set play is 0.075 mm.
14.4.2 Wear
• Check the friction disc for wear every 3000 operating hours.
• Strip the brake as explained in the section “Dismantling”.

Disc brake with multiple discs, support arms
227761-040 2008-04-25 919699- 712, 713
• Measure the thickness of the friction disc. Minimum thickness = 8.0

mm.
14.4.3 Inspect the braking force

The braking force must be checked at least every 1000 operating
hours.
• Lift up the truck until the drive wheel clears the ground
• Open the motor compartment covers.
Tools
• Set the torque wrench to 54 Nm and use an M12 flange bolt, or a
standard bolt with a flat washer.
NOTE:
The bolt quality should be minimum 10.9.
• Screw in the M12 bolt in the hole (for the lifting hole) in the motor ax-
le.
• Turn the motor axle using the torque wrench until the brakes re-
lease.
• 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.
14.5 Disc brake with multiple discs,

712, 713 919699- 2008-04-25 227761-040
support arms
The brake is an analogue electromagnetic multiple disc brake, and it is
applied by energising the magnet coil. The current in the magnet coil is
regulated by a potentiometer in the brake, thereby regulating the brak-
ing force. The multiple discs are of steel. The brake acts as a secondary
service brake and is applied when the operator 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 actu-
al magnet coil, which can be done with the wheel fitted. All instructions
given below assume that the wheel has been dismantled.
14.5.1 Assembly
• Check that the brakes apply and release as they should. Connect
the brake to 48 V DC. 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:
Inspect the play in two positions 180 degrees opposite each other.
• 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 the instructions
in C code 3550.
Ensure the locking heel (8) is positioned in the cut-out in the support
arm.
• Connect the brake cable (14) and check the brake function by press-
ing down the brake fully.

227761-040 2008-04-25 919699- 712, 713
14.5.2 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:
Be careful so that the components and cables do not become dam-
aged in this and subsequent steps.
• Loosen and remove the six M6x40 socket head screws (12) and
their washers
• Remove the aluminium end plate (6).
NOTE:
Record the number of shims (11) on each washer (5).
• Lift out the pressure disc (2) and disc assembly, i.e. 3 outer discs (3)
and 2 inner discs (4).
• Remove the brass disc (7).
14.5.3 Inspection
• Inspect the disc thickness.
Rated thickness, new disc = 2.0 mm
Wearing limit = 1.4 mm
• When replacing discs. Do NOT replace only one disc at a time.
• Also check that the discs are flat and that the splines or cut-outs are
not damaged.
• Check the magnet coil’s electrical resistance. Rated resistance =
47.7 Ohms at 20oC.

712, 713 919699- 2008-04-25 227761-040
NOTE:
Measurement of the electrical resistance can be doe while the brake/
wheel is fitted on the truck.
14.5.4 Assembly
NOTE:
Only clean with a wire brush and a dry rag.
• Assemble the brake in the reverse order.
• Connect the brake to 48 V DC.
• Check the play between the end plate and pressure plate (brake ap-
plied). Adjust the play if necessary.

Maintenance
227761-040 2008-04-25 919699- 712, 713
14.6 Maintenance
Maintenance comprises inspection of wear, inspection and adjustment
of the play between the pressure plate and end plate as well as the
magnet coil’s resistance, and cleaning.
• Cleaning and inspection/adjusting of the play should be done every
1000 operating hours.
• Check for wear and the magnet coil’s resistance should be done
every 3000 operating hours.

• Dismantle the support arm wheel from the truck and remove the
brake.
• Check the play, measurement A, with the brake applied.

NOTE:
• 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.

Maintenance
712, 713 919699- 2008-04-25 227761-040
• Clean the shim washers during adjustment as a result of wear, or

place more shim washers when fitting a new disc.
Each shim washer is 0.127 mm thick.
• Fit the aluminium end plate, connect to 48 V DC and check the play.
• When the play is within the nominal permitted value, fit the brake in
the wheel and mount the wheel on the truck.

227761-040 2008-04-25 919699- 712, 713
15- Service brake system – 3100.2
15.0.1 General
The truck’s 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 mo-
tor.
15.0.2 Functional description

The travel brake system’s primary braking function is the regenerative
motor brake from the drive motor. Braking can be actuated in three dif-
ferent ways:
• When the accelerator is released
• By switching the travel direction using the travel direction selector,
normal motor braking.
• By pushing the brake pushbutton
15.0.3 Releasing the accelerator pedal

The regenerative motor brake is automatically engaged when the
speed control is released.
The braking force can be set via a parameter by the operator.
The motor braking force is regulated progressively in relation to the
speed and the amount the speed control is actuated. This functions as
follows:
• When the speed control is completely released at high speed, this
provides maximum braking force.
• When the speed control is completely released at low speed, this
provides small braking force.
• When the speed control is released halfway at high speed, this pro-
vides moderate braking force.
15.0.4 Travel direction selector

The braking force is regulated by the position of the speed control, i.e.
the more the control is actuated the greater the braking effect.

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15.0.5 Depressing the brake button

Full regenerative motor braking is obtained when the brake pushbutton
is pressed down. Depending on the travel speed, the support arm
brakes are also activated.
Brake performance with support arm brakes
Support arm brake

Brake Force
Regenerative motor brake
0% 25% 50% 75% 100%

Required brake performance
15.0.6 Parking brake
The parking brake is activated/is active when:
• When the truck comes to a standstill or when the brake button has
been depressed, the parking brake is applied automatically.
The brakes are released when the speed control is operated again.
• The parking brake is activated automatically when the operator re-
leases right dead man's handle.
• The parking brake remains active after the truck is switched on with
the start key.

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15.0.7 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 interact with emergency braking under the con-
dition that the voltage supply works.
15.0.8 Electromechanical disc brake, drive

motor
This is a single-acting electromagnetic spring-force assisted brake,
which is applied when the magnet coil in the brake does not receive
electric power. The brake acts as a parking brake and emergency
brake.
Technical data
Description
Rated torque 62 Nm
Rated play 0.3 +/-0.1 mm
Maximum play 0.40 mm
Tightening torque, bolts 20 Nm
Minimum thickness, friction disc 8.0 mm
Coil resistance 33 Ohms at 20°C
WARNING!
The brake is a safety related component. Avoid any kind of intervention
on the brake components.
15.0.9 Dismantling
• Switch off the truck
• Disconnect the brake cable (8) from the electric system of the truck.
• Loosen the brake unit's mounting bolts.
• Disassemble the brake unit from the axle and remove it from the
truck.
• Place the brake on a clean, dry work bench with the magnet housing
(1) facing up.
• Loosen the 3 mounting bolts (9).
• The brake unit can now be disassembled for inspection of the vari-
ous parts.

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1
2
7
8
3
9
10

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15.0.10 Inspection
• Inspect the parts for damage and/or wear.
• Inspect the rotor disc (4) and the wearing surfaces on the pressure
discs (2 and 5) scrupulously. Check to make sure the friction materi-
al has not worn down and is free of damage.
• Check whether the springs are intact.
• Inspect for damage in the key groove (7) and in the grooves in the
hub (3) and friction disc (4).
15.0.11 Assembly
• Assemble the brake in the reverse order to dismantling.
• Bear in mind the following:
• Match the hole in the pressure disc (2) with the corresponding hole
in the magnet housing.
• Be sure to install the correct number of springs.
• Correctly adjust the play. Some adjustment may be necessary.
• Fit the brake on the motor shaft.
• Before assembly of the brake unit, check to make sure the friction
disc (4) is centred in relation to the magnet housing.
• To position the brake disc in the correct position, it may be neces-
sary to apply 48 V DC to the magnet coil.
• Install the brake unit in the truck. Check that the friction disc groove
has not been damaged during installation.
• Insert the brake unit's mounting bolts and tighten them to a torque of
20 Nm.
• Check the play between the magnet housing and the pressure plate
when the brake is applied.
• Connect the brake cable (8) to the electric system of the truck.
• Start the truck and release the parking brake.
• Check to make sure the friction disc rotates freely.
• Switch off power, and check that the pressure disc locks the friction
disc and that the play is correct.

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15.0.12 Maintenance
Maintenance comprises inspection of wear and braking force, inspec-
tion and adjustment of the play between the pressure plate and magnet
housing, and cleaning.
NOTE:
The friction surfaces must not come into contact with oil or grease as
this will considerably impair braking performance.

• The play must be checked every 1000 operating hours.
• Adjust the play by replacing the friction disc.
• Prior to adjustment, play must not exceed the maximum allowed val-
ue. Use a feeler gauge to measure the play.
• Maximum allowed play: 0.40 mm. Rated play: 0.3+/0.1 mm.
• Disassemble the brake unit from the truck.
• Screw in the three M6 screws (transport screws). To release the
brake, pull together to prevent the springs from jumping out.
• Remove the three mounting screws (10) on the underside holding
together the brake assembly.
• Replace the friction disc.
• Reinsert the mounting screws (10) on the underside and tighten to a
torque of 20 Nm.
• Following installation, remove the three M6 screws.
15.0.14 Wear
• Check the friction disc for wear every 3000 operating hours.
• Strip the brake as set out in the section “Dismantling”.
• Measure the thickness of the friction disc. Minimum thickness = 8.0
mm

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15.0.15 Inspect the braking force

The braking force must be checked every 1000 operating hours.
• Lift up the truck until the drive wheel clear the ground
• Open the motor compartment covers.
Tools
• Set the torque wrench to 62 Nm and use an M12 flange bolt, or a
standard bolt with a flat washer.
NOTE:
The bolt quality should be minimum 10.9.
• Screw in the M12 bolt in the hole (for the lifting hole) in the motor ax-
le.
• Turn the motor axle using the torque wrench until the brakes re-
lease.
• If the brake releases before the torque wrench trips, the braking
force is too low.
• Adjust the braking force. See the section Adjustment of play.
• Check the braking force again using the torque wrench.

712, 713 919699- 2008-04-25 227761-040
Troubleshooting chart
Error Reason Action
The brake does Applied current too low Inspect current supply.
not release Play too large/small Adjust play
Worn friction discs/ Replace/adjust play
rotor disc
Defective coil Replace the brake
Corrosion between the This could occur in humid environments if the truck has
friction discs and rotor not been used for a couple of days. Try carefully driv-
ing the truck until corrosion disappears. In this case,
inspect the brake unit for loose friction material. If the
fault cannot be remedied, replace the brake.
Brake is not Voltage in switched off Inspect current supply.
applied position.
Grease on friction sur- Replace/adjust play
faces
One of the springs is Replace the brake.
broken
Unreliable brak- Applied current too low Inspect current supply.
ing effect

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15.0.16 Disc brake with multiple discs,

support arms
The brake is an analogue electromagnetic multiple disc brake, and it is
applied by energising the magnet coil. The current in the magnet coil is
regulated by a potentiometer in the brake, thereby regulating the brak-
ing force. The multiple discs are of steel. The brake acts as a secondary
service brake and is applied when the operator 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 instruc-
tions given below assume that the wheel has been dismantled.
15.0.17 Assembly
• Check that the brakes apply and release as they should. Connect
the brake to 48 V DC. 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:
• 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 the instructions
in C code 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 press-
ing down the brake fully.

712, 713 919699- 2008-04-25 227761-040
15.0.18 Dismantling
• Lift the brake out of the support arm wheel.

• Place the brake on a clean, dry work bench with the magnet housing
(6) facing upward.
NOTE:
Be careful so that the components and cables do not become dam-
aged in this and subsequent steps.
• Loosen and remove the six M6x40 socket head screws (12) and
their washers
• Remove the aluminium end plate (6).
NOTE:
Record the number of shims (11) on each washer (5).
• Lift out the pressure disc (2) and disc assembly, i.e. 3 outer discs (3)
and 2 inner discs (4).
• Remove the brass disc (7).

227761-040 2008-04-25 919699- 712, 713
15.0.19 Inspection
• Inspect the disc thickness.
Rated thickness, new disc = 2.0 mm
Wearing limit = 1.4 mm
• When replacing discs. Do NOT replace only one disc at a time.
• Also check that the discs are flat and that the splines or cut-outs are
not damaged.
• Check the magnet coil’s electrical resistance. Rated resistance =
47.7 Ohms at 20oC.
NOTE:
Measurement of the electrical resistance can be doe while the brake/
wheel is fitted on the truck.
15.0.20 Assembly
NOTE:
Only clean with a wire brush and a dry rag.
• Assemble the brake in the reverse order.
• Check the play between the end plate and pressure plate (brake ap-
plied). Adjust the play if necessary.
15.0.21 Maintenance
Maintenance comprises inspection of wear, inspection and adjustment
of the play between the pressure plate and end plate as well as the
magnet coil’s resistance, and cleaning.
• Cleaning and inspection/adjusting of the play should be done out
• Check for wear and the magnet coil’s resistance should be done

712, 713 919699- 2008-04-25 227761-040

• Dismantle the support arm wheel from the truck and remove the
brake.
• Check the play, measurement A, with the brake applied.

NOTE:
• Maximum permitted play = 2.25 mm
• Nominal play of newly adjusted brakes should be 1.0-1.25 mm.
• Before adjusting, dismantle the aluminium end plate.
• Clean the shim washers during adjustment as a result of wear, or
place more shim washers when fitting a new disc.
Each shim washer is 0.127 mm thick.
• Fit the aluminium end plate, connect to 48 V DC and check the play.
• When the play is within the nominal permitted value, fit the brake in
the wheel and mount the wheel on the truck.

Support arm brake – 3180
Location of support arm brake
227761-040 2008-04-25 919699- 712, 713
16- Support arm brake – 3180
16.1 Location of support arm brake

The support arm brake is positioned on the outer or inner wheel posi-
tion. The wheel on which the brake operates is positioned 1 mm lower.
On trucks where the brake is placed at the inner wheel position, cases
of the support arm brake causing interference in the magnet sensor
have been reported. As a result and for quality improvement, on newer
trucks the support arm brake has been moved to the outer wheel posi-
tion.

Support arm brake – 3180
Location of support arm brake
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Drive wheel – 3530
General
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17- Drive wheel – 3530
17.1 General
The drive wheel consists of a cast rim with a vulcanised tread. When
changing the drive wheel, make sure the wheel nuts are tightened to
the correct torque.
The wheel size of this truck is 350x130 mm.
17.2 Dismantling the drive wheel

• Lift up the truck on blocks so the drive wheel is clear of the ground.
• Unscrew the four bolts securing the guard plate.
• Remove the guard plate.
• Unscrew the nuts securing the drive wheel in position.
• Lift off the drive wheel.
17.3 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.

Drive wheel – 3530
Assembling the drive wheel
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Fork/support arm wheel – 3550
Dismantling the wheel
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18- Fork/support arm wheel – 3550
18.1 Dismantling the wheel

• Lift up the truck and support it using blocks so the support arm wheel
is clear of the ground.
• Unscrew the bolts securing the guard plate above the wheel.
• Remove the guard plate.
• Disconnect the connector/cable from 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.

Dismantling the wheel
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• 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.

Assembling the wheel
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18.2 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 brake’s locking shoe into its cut-
out.
• 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 be-
come loose while driving.
Always fit the wheel with a new clamping ring on the wheel axle.
• Fit the extension punch on tool 08-13585 and insert it through the
wheel hub.
• 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 brake’s locking shoe and connect the
brake cable. Secure the cable with a tie so that it does not rub
against the wheel.

Dismantling/assembling the wheel bearings
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18.3 Dismantling/assembling the wheel

bearings
18.3.1 300 mm wheel with brake and 350 mm

wheel
Dismantling the bearing
• Loosen the sleeve nut (1). Tool: Socket 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.
1 2 6 7 8 8 3 4 5
7 6 5 4
1 1 3

Dismantling/assembling the wheel bearings
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Assembling bearings
• Fit the bearing cups in the hub.
Use an assembly sleeve of the same outside diameter as the bear-
ing cup’s 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 washer’s tabs down into
the nut’s cut-out.

Support arm wheel axle
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18.4 Support arm wheel axle

To prevent travel of the support arm wheel axle in the support arm when
steering the truck, apply shims on the outer wheel (A). Drill a hole (B)
and apply a suitable number of shims to achieve suitable thickness.

Hydraulic system – 6000
General
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20- Hydraulic system – 6000
20.1 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 pres-
sure 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 of (approx. 1/3) of the mast and cabin weight.
WARNING!
Pressurised system.
bar.


General
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20.1.1 Symbols
The table explains the various symbols that are use in the hydraulic
flow diagram.
Symbol Description Symbol Description

Single-acting hydraulic cylin- Single-acting hydraulic cylin-
der der with purging
Double-acting hydraulic cylin- Reservoir

der with damper (reducer)
Filter Air drier
Accumulator Pressure sensor, analogue
Non-return valve, spring- Non-return valve

loaded (hose rupture valve)
Hydraulic lock Shuttle valve
Cut-off valve (emergency Routing valve 2/2, two

lowering) ports, two distinct positions,
electromagnetic operation

General
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Symbol Description Symbol Description

Routing valve 2/2, two ports, Routing valve 4/2, two dis-
drain, two distinct positions, tinct positions, spring back
electromagnetic operation function, electromagnetic
operation
Routing valve 4/3, four Proportional valve, controlled
ports, three distinct posi- by electromagnet
tions, electromagnetic opera-
tion
Proportional valve, controlled Proportional valve, controlled
by electromagnet by electromagnet
Priority valve, self-adjusting Back-pressure valve, with

proportional valve type integrated non-return valve
Pressure-limiting valve Pressure compensating

valve, closing action
Throttling
Electric motor and one pump Hydraulic motor with fixed

M with fixed displacement, two displacement, two flow direc-
flow directions tions
Framing of two or more func- Pilot conduit (control)

tions concentrated in one sin-
gle unit
Operational conduit Operational conduit, cross-
operation
Operational conduit, connec-

tion

Cabin lifting
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20.2 Cabin lifting
20.2.1 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 cab-
in.
20.2.2 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 sen-
sor B6. In case of too high pressure, the pressure limiting valve (3)
opens, i.e. hydraulic oil flows towards the reservoir.
When the cabin is lifted, the accumulated hydraulic pressure in the B
cylinder system is utilised as an auxiliary lifting aid. The B cylinder pro-
S44 vides 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 increas-
es.
20.2.3 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. Generated current is returned to the truck battery, i.e.
regenerative lowering.
When the cabin is lowered, the pressure increases in the B cylinder
system accumulator as a result of the compression of the B cylinder.
S70
The valve plate features a manually operated emergency lowering
valve (4).
Each lifting cylinder also has a hose rupture valve at the base insert.

Cabin lifting
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20.2.4 AC hydraulic unit, components
B5 M
R
Y21 C1 4
Y29 C2

Cabin lifting
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Pos. Designation Remark

1 Pump motor
2 Hydraulic pump
3 Main valve plate
4 Pressure-limiting valve 250 bar
5 Emergency lowering valve
B5 Analogue pressure sensor
Y21 Routing valve, cabin lower-
ing
Y29 Routing valve, cabin lower-
ing
C1 Cabin lifting cylinder con-
nection
C2 Cabin lifting cylinder con-
nection
M Measurement connection For analogue pressure
sensor B6
R Reservoir port Return oil flow to the res-
ervoir

Cabin lifting
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20.2.5 Hydraulic flow diagram, cabin lifting

Huvudlyft/
Main lift
Vänster/ Höger/
Left Right
B5
M C1 C2 R
5 5
Y21 4 Y29
P1
2

Cabin lifting
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Symbol list, chassis
Pos. Designation Function Remark

B5 Pressure sensor Measures the hydraulic pressure in the
cabin lifting system
P1 Pump Hydraulic pump
Y21 Magnetic valve Routing valve, cabin lowering
Y29 Magnetic valve Routing valve, cabin lowering
1 Filter Air filter
2 Filter Air drying filter Only cold store spec-
ifications
3 Pressure-limiting valve Opens in case of overloading 250 bar
4 Valve Emergency lowering valve
5 Non-return valve

Cabin lifting
227761-040 2008-04-25 919699- 712, 713
20.2.6 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.
1
2
When calibrating the hydraulic system pressure, the DC pump is used

to charge the accumulators on the hydraulic side. The calibration pro-
cedure 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.

Cabin lifting
712, 713 919699- 2008-04-25 227761-040
Hydraulic flow diagram, B cylinder system

Balanscylinder/
Counter balance cylinder
5 5
B A C B5
4 M
4
3
B5
2
1 1
2 R1 R2
P1 P2
Symbol list, B cylinder system

B6 Pressure sensor Measures the hydraulic pressure in
the B cylinder system
1 Valve Manually operated valve for closing Opens when calibrating
the pressure side the hydraulic system pres-
sure
2 Valve Manually operated valve for closing Opens when draining the
the return side hydraulic system
3 Non-return valve
4 Pressure-limiting valve Opens in case of overloading 250 bar
5 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.
6 Cylinder Balance cylinder

Fork units and steering
227761-040 2008-04-25 919699- 712, 713
20.3 Fork units and steering
20.3.1 General
The turret head fork unit and truck steering rely on a hydraulic system,
completely separated from the cabin lifting system. It uses an electric
DC motor, pumps, valves, etc. The oil flow is controlled by routing
valves and proportional valves to achieve fork lifting, traversing and
rotation of the fork unit thanks to a valve plate mounted under the oper-
ator's chair in the cabin. The oil flow for this control is controlled by pro-
portional valves in a valve plate mounted in the rear chassis of the
truck. To ensure hydraulic control is always available, an accumulator
has been integrated in the controller 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 sys-
tems is in the manifold for traversing, initial lift and lowering functions
and in the shuttle fork unit that differs from the standard fork unit. The
manifold for traversing and initial lift and lowering functions utilises
many of the same components as the manifold for traversing, initial lift,
lowering and fork rotation. The manifold is mounted in the same loca-
tion in both units. The biggest difference is in the inlet block, which on
the VCE125ASF manifold is just an inlet block, while on the VCE150A
the block also includes valves for fork rotation. Additionally, the
VCE125ASF features a double load holding valve.

712, 713 919699- 2008-04-25 227761-040
20.3.2 Hydraulic flow diagram, DC system (T

code 712)
Gaffelvridning/ Initiallyft/ Traversering/
Fork turning Initial lift Horizontal move
A B
Vänster/ Höger/
Left Right
B1 A1
240 bar
B2 A2
100 bar 100 bar
90 bar
M H
90 bar
30 bar 30 bar
Styrning/
Steering
P R
Vänster/ Höger/
Left Right
B A C
M A2 B2
R1 R2 250 bar
P1 P2
A1 B1
30 bar
250 bar
P1 R1
M1
S
2.0
250 bar
250 bar
M2
P R

1 2 3 4 5 6 7 8 9 10 11 12
Order no.
227761-040
Initial lyft/ Traversering

Initial lift Horizontal move
A A
© BT Europe AB
Balanscylinder/
A B Counter balance cylinder
B A
Not1/ Styrning/
B Note 1 Steering B
Date
Vänster/ Höger/
B7 B A C
B6 Left Right
M H
2008-04-25
C 2 C
Y11 Y10 A2 B2
Y25 R1 1 R2
Y9
P1 P2
A1 B1
Service manual
Y8
919699-
D P1 R1 D
M1
Y3
S
P R
Y4 Y7
B4
E E
Hydraulledningar genom stativet/ Y31
M2
Hydraulic lines through the mast
Applies from machine no.
P R
F F
T code
712, 713
G G

Not1/ Denna ackumulator ansluts för
Note 1 korghöjder > 8600/
20.3.3 Hydraulic diagram (T code 713)
This accumulator is connected for

cabin heights > 8600
H H
1 2 3 4 5 6 7 8 9 10 11 12
20- 13
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Symbol list, fork unit and steering

B4 Pressure sensor Measures the hydraulic pressure in 90 - 250 bar
the steering system Shutoff limit = 70 bar
B7 Pressure sensor Measures the hydraulic pressure in Used for weight indication
the initial lift system
Y3 Proportional valve Steering right
Y4 Proportional valve Steering left
Y7 Routing valve Opens the steering accumulator cir-
cuit
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, counter-clockwise (T
code 712)
Y28 Proportional valve Fork rotation, clockwise (T code 712)
Y31 Routing valve Steering lock, negative side of steer-
ing cylinders
1 Pressure-limiting Opens in case of overloading 250 bar
valve
2 Valve Manually operated valve for closing Opens when draining the
the return side hydraulic system
3 Accumulator Hydraulic pressure storage Steering pressure accu-
mulator
4 Non-return valve
5 Pressure compensat- Provides constant pressure reduction
ing valve (flow) via proportional valve Y3/Y4
6 Back-pressure valve Oil flow damper (cylinder movement) Opening pressure: 30 bar
7 Cylinder Steering cylinder Single-acting
valve
9 Hydraulic motor Traversing movement
10 Cylinder Initial lifting
11 Priority valve Distributes the oil flow between the Self-adjusting proportional
rotational operations and other turret valve type.
head operations Priority is always 4 l/m for
fork rotation.
12 Shuttle valve Provides a balancing counter pres-
sure for the priority valve (11)

227761-040 2008-04-25 919699- 712, 713

13 Hydraulic lock Locks the hydraulic pressure on the
cylinder side when rotational move-
ment has stopped
14 Back-pressure valve Oil flow damper (cylinder movement) Opening pressure: 100 bar
valve
16 Cylinder Turret head cylinder for fork rotation
17 Non-return valve
Turret head fork unit valve (T code 712)

20- 16
T code
712, 713
1 2 3 4 5 6 7 8 9 10 11 12
A A
Ventilblock för balanscylinder/
Valve block for counter balance cylinder
B B
919699-
Ventilblock för shuttle forks aggregat/

C Valve block för shuttle forks unit C
Ventilblock för midjestyrning/

Valve block for the articulated steering
Service manual
D D
Y25
Applies from machine no.
EM21V
Y11
Y10
EMP21V20
HAWE
B
... ...
E E
A
Y8
Y9
/2AL..BL-AS..BS..
Date
2008-04-25
F F
G G

Order no.
227761-040
H H
20.3.4 Shuttle fork valve blocks (T code 713)
1 2 3 4 5 6 7 8 9 10 11 12
© BT Europe AB
227761-040 2008-04-25 919699- 712, 713
20.3.5 Fork rotation (T code 712)

The turret head cylinders and the chain rotate the fork unit mast, mount-
ed 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 propor-
tional valve affects the position of the priority valve via the pilot con-
duits, 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 cylin-
der, 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 move-
ment.
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.
20.3.6 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.
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

712, 713 919699- 2008-04-25 227761-040
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.
20.3.7 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.
20.3.8 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.

227761-040 2008-04-25 919699- 712, 713
20.3.9 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 pres-
sure. 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 accumu-
lator 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 direc-
tion 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 coun-
ter-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 res-
ervoir, 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.

712, 713 919699- 2008-04-25 227761-040
Steering valve

Extra hydraulic function (T code 712)
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20.4 Extra hydraulic function (T code

712)
20.4.1 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.

Extra hydraulic function (T code 712)
712, 713 919699- 2008-04-25 227761-040
20.4.2 Hydraulic diagram, extra hydraulic

function (T code 712)

Hydraulic pump – 6140
General
227761-040 2008-04-25 919699- 712, 713
21- Hydraulic pump – 6140
21.1 General
There is one pump size in the truck that has a max. flow of 60 litres per
minute.
These service instructions contain a description on how to replace the
hydraulic pump.

Replacing the hydraulic pump
712, 713 919699- 2008-04-25 227761-040
3 21.2 Replacing the hydraulic pump

6
7 21.2.1 Dismantling
• Disconnect the battery connector.
12
• Lower the forks to the lowest position to reduce pressure in the hos-
4 es and pump.
• Pump the oil out of the hydraulic reservoir (3) using 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.
• Remove the bolts (5) holding the pump mounting (15) to chassis.
• Lift out the hydraulic pump and place it on a clean surface.

227761-040 2008-04-25 919699- 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.

712, 713 919699- 2008-04-25 227761-040
21.2.2 Assembly
• 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 the torque specified in C code 0400.
• Assemble the valve block (17) on the pump unit.
Tighten the bolts to the torque specified in C code 0400.
• Fit the hose coupling (16) on the pump unit (19).
• Replace both mountings (15) on the pump motor (8).
• Assemble the suction hose (9) on the hose coupling (16).
Tighten the hose clip.
• Screw a lifting eye into the end of the motor axle and connect it to an
overhead crane.
• Lift the hydraulic unit into the truck while simultaneously refitting the
hydraulic hose (9) on the tank (3).
• Tighten the hose clip (10).
• Secure the two pump mountings (15) to the chassis using the bolts
(5).
• Unscrew the lifting eye.
• Connect the hydraulic hoses (13 and 14) on the valve block's under-
side and the return hoses (11 and 12
) as well as the temperature gauge/speedometer connectors (6) and
the power cables (7).
• Fill the hydraulic tank (3) with 38 litres of new oil.
• Test the hydraulic functions up to the overflow pressure, and check
that all connections do not leak.

Accumulators – 6280
Charging of the lifting and steering accumulators
227761-040 2008-04-25 919699- 712, 713
22- Accumulators – 6280
22.1 Charging of the lifting and steering

accumulators
To measure the accumulator pressure and to enable charging of the
accumulators, the following equipment is required>
• Charging and test unit (A)
• Adapter (B)
• Country-specific adapters, In some countries, the adapter is includ-
ed in the basic kit. In some countries the adapter is an optional ac-
cessory. See table below.
• Hose (D)
These items are included in the 214431 kit. An O-ring kit, with order
number 214432, is also available for the charging equipment.
C A
D
N2 N2

712, 713 919699- 2008-04-25 227761-040
22.1.1 Preparations
WARNING!
Prior to commencing inspection or charging of the accumulators, be
sure to disconnect the battery connector.Drain the accumulators of
all oil as shown in the pictures below.
WARNING!
Risk of injury unless the locking pin for the articulated centre is in-
serted prior to commencing work.

227761-040 2008-04-25 919699- 712, 713
22.1.2 Measuring the pressure in the lifting

accumulator
1. Remove the protective cover from the accumulator.

712, 713 919699- 2008-04-25 227761-040
2. Unscrew the covered nut.
3. Carefully remove and straighten out the accumulator.

227761-040 2008-04-25 919699- 712, 713
4. Screw the charging and test unit (A) onto the adapter (B).
Screw the assembly onto the accumulator.
5. Screw the large knob on the charging and test unit counter-
clockwise to return it to the original position and close the ac-
cumulator valve. Read off the indicated pressure.
6. Then screw the small knob counter-clockwise to slightly re-
lease the pressure in the charging and test unit.
NOTE:
When inspecting the gas pressure, use the adapter (B) and screw it
onto the accumulator and charging unit together with the manometer
(A).
To inspect the pressure, the hose D and gas bottle are not required
since a non-return valve prevents the gas from escaping into the air.
7. Remove the charging and test unit together with the adapter.
Reassemble the accumulator, install the covered nut and the
protective cover. Refill the accumulator with oil.

712, 713 919699- 2008-04-25 227761-040
22.1.3 Charging the lifting accumulator

WARNING!
Exercise extreme caution when charging the accumulators. Pressu-
rised nitrogen gas constitutes a risk of injury. Abstain from work in
confined areas since inhaling nitrogen gas is unadvisable..
1. Carry out steps 1-6 under the heading “Measuring the pres-
sure in the lifting accumulator”.
2. Screw the adapter (C) onto the hose (D).
NOTE:
Please note that safety legislation in many countries prescribes in-
stallation of an additional adapter; the basic kit does not include all
adapters. The following table indicates the adapters prescribed in dif-
ferent countries and the corresponding order numbers.
3. Connect the hose (D) to the nitrogen bottle.
4. Screw the large knob on the charging and test unit clockwise
until the pressure can be read.
5. Open the nitrogen gas bottle. Close the nitrogen gas bottle
again when the charging and test unit indicates 100 bar.
clockwise to close the accumulator valve.
7. Screw the small knob on the charging and test unit to depres-
surise the test unit and hose.
Reassemble the accumulator, install the covered nut and the
protective cover. Refill the accumulator with oil.
NOTE:
To be able to connect the hose to the nitrogen gas bottle, legislation
in some countries requires use of an additional adapter (C). The
standard equipment differs between countries. See the following ta-
ble for the equipment required in different countries and the corre-
sponding order numbers.

227761-040 2008-04-25 919699- 712, 713
22.1.4 Order numbers for country-specific

adapter kits.
Order Country
no.:
Included in Austria, Belgium, the Czech Republic, Denmark, Finland, Ger-
kit many, the Netherlands, Norway, Poland, Sweden, Switzerland
214433- Argentina, Australia, the Bahamas, Bangladesh, Barbados, Bot-
002 swana, Burma, Costa Rica, Cyprus, Ethiopia, Fiji, Gambia, Ghana,
Great Britain, Greece, Hong Kong, India, Indonesia, Ireland,
Jamaica, Kenya, Malawi, Malaysia, Malta, New Zealand, Pakistan,
the Philippines, Portugal, Singapore, South Africa, Spain, Sri
Lanka, Sudan, Surinam, Swaziland, Tanzania, Thailand, Turkey,
Vietnam, Zambia
214433- Algeria, Bahrain, Bulgaria, Djibouti, Egypt, France, Gabon, Guinea,
003 Hungary, Iran, Iraq, Israel, the Ivory Coast, Jordan, Kuwait, Leba-
non, Libya, Mauritius, Mexico, Morocco, Mozambique, Nigeria,
Oman, Qatar, Romania, Saudi Arabia, Syria, Tunisia, United Arab
Emirates, Yugoslavia
214433- Canada, Puerto Rico, U.S.A.
004
214433- Italy
005
214433- Japan
006
214433- Korea
007
214433- Bolivia, Brazil, Chile, Columbia, the Dominican Republic, Ecuador,
008 Guatemala, Guyana, Honduras, Paraguay, Peru, Uruguay
214433- Taiwan
009
214433- Russia, Trinidad/Tobago, Venezuela
010
214443- China
011

Measuring the pressure in the steering accumulator
712, 713 919699- 2008-04-25 227761-040
22.2 Measuring the pressure in the

steering accumulator
WARNING!
Prepare the truck according to the instructions under the heading
“Preparations” above. The truck must be switched off and the battery
connector disconnected. The locking pin for the articulated centre
must be inserted.
1. Depressurise the steering accumulator.
2. Remove the protective cover from the steering accumulator.

Attach the charging and test unit on the steering accumulator.
The adapter (B) is not needed.
clockwise. Read off the indicated pressure. Then close the
valve by turning the knob clockwise.

227761-040 2008-04-25 919699- 712, 713
4. Screw the small knob counter-clockwise to slightly release

the pressure in the charging and test unit.
NOTE:
To inspect the pressure, the hose D and gas bottle are not required
since a non-return valve prevents the gas from escaping into the air.
5. Remove the charging and test unit. Reattach the protective
cover. Refill the accumulator with oil.

712, 713 919699- 2008-04-25 227761-040
22.2.1 Charging the steering accumulator

WARNING!
Exercise extreme caution when charging the accumulators. Pressu-
rised nitrogen gas is used. Abstain from work in confined areas since
inhaling nitrogen gas is unadvisable.
1. Carry out steps 1-4 under the heading “Measuring the pres-
sure in the lifting accumulator”.
2. Screw the adapter (C) onto the hose (D).
NOTE:
Please note that safety legislation in many countries prescribes in-
stallation of an additional adapter; the basic kit does not include all
adapters. The following table indicates the adapters prescribed in dif-
ferent countries and the corresponding order numbers.
3. Connect the hose (D) to the nitrogen bottle.
clockwise until the pressure can be read.
5. Open the nitrogen gas bottle. Close the nitrogen gas bottle
again when the charging and test unit indicates 80 bar.
6. Screw the large knob on the charging and test unit clockwise
to close the accumulator valve.
7. Screw the small knob on the charging and test unit to depres-
surise the test unit and hose.
Reattach the protective cover. Refill the accumulator with oil.
NOTE:
To be able to connect the hose to the nitrogen gas bottle, legislation in
some countries requires use of an additional adapter (C). The standard
equipment differs between countries. See the table above for the equip-
ment required in different countries and the corresponding order num-
bers.

Main lift cylinder – 6610
Replacing the seal in the B cylinder
227761-040 2008-04-25 919699- 712, 713
23- Main lift cylinder – 6610
23.1 Replacing the seal in the B cylinder

The tools used to replace the seal in the ”B cylinder” are included
in the V10-16169 tool kit.
Dismantling
1. Lift and lock the cabin using the stopping devices (B). See C
code 7100
2. Completely lower the mast.
NOTE:
Do not forget to depressurise the B cylinder accumulator(s).See C
F code 6000
D 3. Unfasten the hydraulic pipe for the B cylinder, disassemble
the pipe coupling and install the plate (D) using the pipe cou-
G pling (G).
4. Ensure the flange interlocks inside the ”square pipe”.
5. Completely drain the cylinder of all oil by unscrewing the
bleeding screws (F).
E 6. Raise the mast until the ”rod” (E) can be inserted to support
the B cylinder piston rod. The rod can be split into two and
also has adjustable length.
7. Remove the plate D.
8. Loosen the B cylinder top nut. Allow the top nut to drop onto
and over the rod E.
9. Install the plate D to keep the piston rod in position.
10. Remove the rod E and the top nut.
Assembly
Assemble in the reverse order.

Main lift cylinder – 6610
Replacing the seal in the B cylinder
712, 713 919699- 2008-04-25 227761-040

Main mast and mast – 7100
Setting the cab and mast stoppers
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24- Main mast and mast – 7100
24.1 Setting the cab and mast stoppers
24.1.1 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/lower-
ing.
Connect the control unit to the X10 terminals (the terminal on the elec-
tric panel on the chassis) and the X27 terminal (spare connector in the
cabling between the electric panel and the MCU).
Connect TruckCom to the CAN connector in the motor compartment.
To electronically connect the control unit, call up the TruckCom 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.

712, 713 919699- 2008-04-25 227761-040
24.1.2 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.

227761-040 2008-04-25 919699- 712, 713
The tool set V10-16169 contains the various tools used when working
under the cab. Use part A as the cab stopper.

712, 713 919699- 2008-04-25 227761-040
Set the cab stoppers on both sides of the cab.
Use the control unit to lower the cabin onto the catches.
When the cab rests against the catches, use the TCSE to switch off the
truck with the ctrl +O command.
Disconnect the battery connector.
Connect the battery and use the TCSE to switch on the truck with the
ctrl + I command.

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24.1.3 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. Raise 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.

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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 com-
pleted. Then tighten the nuts to a torque of 80-100 Nm.

Main lift chain system – 7120
General
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25- Main lift chain system – 7120
25.1 General
Applies to all machines with a mast.
VARNING!
When replacing the chain, be sure to also replace the anker bolt.
25.2 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.
25.3 Chain inspection

The chains are exposed to two types of wear, outline wear and stretch-
ing. Wear to the bolts and disc holes is caused by stretching. The
chains are also affected by the environment they are used in.
25.3.1 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.
25.3.2 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
25.3.3 Rusty links

Fretting corrosion results in a reddish brown powder being visible by
the outer discs. It can also appear as if the chain is bleeding when lubri-
cated.

Chain inspection
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25.3.4 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.
25.3.5 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
.
25.3.6 Loose bolts

If a bolt is loose it will protrude from the side of the chain, which is due
to a stiff link or bolt rotation.

Chain inspection
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25.3.7 Outline wear
H2 H3
P = Pitch
H2 = Nominal disc height.
H3 = Minimum disc height.
A new lift chain has a specific nominal disc height, defined as H2 in the
figure. As the truck is used the lift chain wears radically, on the side that
runs over the chain sprocket. The minimum disc height is define as H3
in the figure and denotes the minimum permitted value of the disc
height.
Maximal permitted outline wear is 5% of the height H2. If a lift chain
reaches the maximum level of wear, the chain should be replaced.
The nominal and minimum disc heights for respective lift chains are
stated in the table in the chapter “Stretching”.

Chain inspection
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25.3.8 Stretching
The amount of stretch on a lift chain is measured on the part of the
chain that runs over the chain sprocket. The amount of stretch may, at
the most, be 2% on the most worn section of the chain. Measurement is
suitably made over 300-1000 mm of the chain.
The nominal and maximum permitted chain lengths for lift chains are
stated in the table below.
Type of Nominal Minimum Pitch P Nominal chain Maximum permitted

chain disc height disc height (mm) length for 20/30/ chain length for 20/
H2 ( mm) H3 (mm) 50 discs (mm) 30/50 discs (mm)
3/4”, 2x3 17.8 16.9 19.05 381/572/953 389/583/972
3/4”, 3x4 17.8 16.9 19.05 381/572/953 389/583/972
3/4”, 4x6 17.8 16.9 19.05 381/572/953 389/583/972
1”, 4x4 23,6 22,4 25,4 508/762/1270 518/777/1295
1”, 6x6 23,6 22,4 25,4 508/762/1270 518/777/1295
Wear to the bolts and around the holes on the discs are a reason why
the chain stretches. The chain should be replaced if stretching is
more than 2%.
25.3.9 Damage
The chain should be replaced if damaged in any way.

Cleaning
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25.3.10 Damaged discs

If a disc has broken on the chain, this can be due to overloading or cor-
rosion.
25.3.11 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.
25.3.12 Dirty chain

If a chain is very dirty it is first and foremost recommended that it is
replaced. It can also be dismantled and cleaned as set out in the chap-
ter “Cleaning”.
25.4 Cleaning
If a chain is very dirty it is recommended that it is replaced.
Dirty chains should be cleaned before they are lubricated, e.g. by
washing with solvent such as diesel or petrol.
The chain should be blown dry using compressed air and lubricated
directly after cleaning
NOTE!
Exercise care with degreasing agent as these can contain abrasives.

Lubrication
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25.5 Lubrication
Mineral and synthetic oils can be used to relubricate Rexnord chains.
NOTE!
Lubricant must not contain substances such as molybdenum disul-
phide, PTFE or the like.
A lift chain should be offloaded from the weight of the fork carriage
(hanging free) when lubricated.
• Lubrication intervals:
- 500 hours with normal operations
- 100 hours when driving in rugged environments such as cold
stores and corrosive environments.
The chains are sprayed with lubricant. Note the entire chain must be
lubricated, even the fastening bolts. It is especially important that the
part of the chain which runs over the chain sprocket is well lubricated.
The lubricate must comply with the viscosity demands at respective
temperatures as set out in the table below. The following lubricants are
recommended:
Ambient Viscosity Recommended Products*
temperature class
> - 40°C VG 15 Klüberoil 4UH 1-15, Klüber Lubrica-
tion
< - 30°C
> - 30°C VG 68 Klüberoil 4UH 1-68N, Klüber Lubri-
cation
< + 5°C
Anticorit LBO 160 TT, Fuchs DEA
> + 5°C VG 150 Klüberoil 4UH 1-150N, Klüber
Lubrication
< + 45°C
Anticorit LBO 160, Fuchs DEA
>+ 45°C VG 220 Klüberoil 4UH 1-220N, Klüber
Lubrication
<+ 80°C
* Equivalent products from another manufacturer may be used.
NOTE!
Do not use a special rust protective agent to prevent
rust on the lift chains.
These agents impair the lubrication of the chains. Regular lubrication
is the best method to prevent rust attack.

Lubrication
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25.5.1 Chain adjustment
25.6 Tool list

• Hexagon spanners, 2 x 36 mm
• Allen key set
• Side cutting pliers
• Sliding calliper
25.7 Main lift chain adjustment

• Remove the switch from the slack chain guard.
• Remove the split cotter from the slack chain guard sleeve and
loosen the lock nut for the chain adjustor.

Lubrication
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• Lift the cabin approx. 100 mm, and place a 6 mm steel spacer (see
picture) along the rear edge of the mast between the inner guide
and the intermediate guide. Then lower the cabin to the stop posi-
tion.
• Adjust the chain on one side at a time as follows:
• Adjust the chain until the steel spacer can be moved.
• Release the chain until the spacer is clamped in position again.
• Adjust the chain on the other side the same way.
NOTE:
If adjustment is not possible by using the upper adjustors,
then adjustment can also be made by using the lower adjus-
tors.
• Once the chain has been correctly adjusted and the play is 6 mm,
retighten the lock nut.
• Replace the sleeve and the slack chain guard switch, and lock
using the split cotter. The play between the sleeve and switch
should be
1 -2 mm.
• Prior to operating the truck again, be sure to check that the lower
chain bolt is set straight.

Lubrication
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25.8 Cabin chain adjustment

• Loosen the lock nut and adjust the chain.
• The play between the lower edge of the cabin floor and the chassis
between the support arms should be approx. 35 mm.
• Once the play has been correctly adjusted, lock the chain adjustors
using the lock nut.
25.9 Initial mast chain adjustment

• Loosen the lock nut and adjust the chain.
• The play between the top fork surface and the floor should be 70 -80
mm.
• Once the play has been correctly adjusted, lock the chain adjustor
using the lock nut.

Lubrication
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Initial mast – 7160
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25.10 Initial mast – 7160

The distance between the fork bridle and hose holder, tension spring
and tension spring bracket has proved to be too short. On versions with
an extra hydraulic function, there is a risk that the hoses at the top of the
initial mast become worn as a result of abrasion.
In case of abrasion damage, to prevent further abrasion and achieve
improved control of the hydraulic hoses, on versions with an extra
hydraulic function the bracket can be replaced with one that holds the
hose outside the gear wheels, thus preventing abrasion on the hose.
On versions without an extra hydraulic function, use bracket 238844,
while on versions with an extra hydraulic function, use bracket 238845.
This kit includes a bracket, required screws (recessed socket head cap
screws) and nuts.
Bracket 238844, for versions without an extra hydraulic function
Bracket 238845, for versions with an extra hydraulic function

On new trucks, the hose holder is 1 mm more narrow, and the
tension spring has been replaced with a spring with a smaller di-
ameter.
© BT Europe AB Service manual VCE150A, 150AC, 125ASF, 125ACSF 1

Initial mast – 7160
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2 Service manual VCE150A, 150AC, 125ASF, 125ACSF © BT Europe AB

Initial mast/Turret head fork unit – 7200 (T code 712)
General
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26- Initial mast/Turret head fork unit

– 7200 (T code 712)
26.1 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 reser-
voir 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, tra-
versing (side shifting) and turning the forks. Please also see C codes
5000 and 6000.

Assembly/disassembly of the initial mast
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26.2 Assembly/disassembly of the initial

mast
26.2.1 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 folded belt must be replaced since it is very likely that the belt cord
has been damaged.

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• Set the friction plates A in the upper and lower part of the mast hold-
er.
• 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.

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• 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.
• 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.

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• 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 times and then re-
verify that belt tensioning is correct.

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26.2.2 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 oth-
er end pieces of the belts.
• Install the adjusting screws on 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 disas-
sembled at the factory prior to delivery.

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• 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".

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26.2.3 Installing the hydraulic hoses and

electric cabling
4 3
• Install the coupling chain (1) in the initial mast bracket (2).
• Connect the hydraulic hoses (3) as shown below.
11
12
13
11 14
15
12 14
15
13
Pos. Connection for+ Marking

(with a silver marker
pen)
11 Initial lift cylinder
12 Traversing to the left I
13 Traversing to the right II
14 Left rotation cylinder L
15 Right rotation cylinder R

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• Connect the electric cable connectors (4) as shown below.
X61 X59
X62
X61
X59
X62
X60
X58
X60
X70
X58
X70
Termi- Connection for

nal
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
26.2.4 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.

Inspection and replacement of belts used for fork traversing
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26.3 Inspection and replacement of

belts used for fork traversing
26.3.1 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".

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26.3.2 Replacing the belt

Disassembly of the belt
• If possible, traverse the initial mast to the centre.
1
1
5
2
6 3
7 4
1 6
• 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.

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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 oth-
er 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.

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• 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 ini-
tial mast is leaning.
- Then adjust the adjusting screw on the other side until mast pos-
ture 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 direc-
tion 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.

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26.3.3 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 Traversing belt, Drive belt, Drive belt,

belt, 220210 217388-001/-002 200190 stand- 217885 cold
standard cold stores ard stores
Weight, g/m 005,4 004,7 005,4 004,7
Width, mm 085,0 085,0 (217388-001) 050,0 036,0
080,0 (217388-002)
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 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 me-
ter.

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Tension measurement of the traversing belt

• Press the Measure key.
• Lightly tap the belt with a “tool” while holding the belt tensioning me-
ter 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 re-
placed.
Tension measurement of the drive belt

• Press the Measure key.
• Lightly tap the belt with a “tool” while holding the belt tensioning me-
ter 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.

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• 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 re-
placed.

Friction plate adjustment
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26.4 Friction plate adjustment

1. Unscrew the locking screws securing the adjusting screws
2. Tighten the adjusting screws of the lower friction plates se-
curely.
3. Tighten the adjusting screws of the upper friction plates se-

curely.
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 ad-
justing screws.

Parallel adjustment of forks
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26.5 Parallel adjustment of forks

Two new adjusting screws and two new lock nuts are being introduced
to enable parallel adjustment of the forks. To measure fork parallelism,
please follow the instructions below.
255956
20148

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26.5.1 Measuring fork parallelism
C2
B2
C1
B1
A
1. Make sure the back of fork is perfectly aligned with the fork yoke.
2. Raise the forks to the level of the aluminium edge (A).

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3. Verify fork parallelism by measuring the distance between the forks

at points far out and far in on the forks. Deviation in parallelism be-
tween the B1 measurement and the B2 measurement should be
max. 2 mm per 125 mm fork length.
Example: Fork length 1150 mm:
(1150/125) x 2 =18.4
This means that with a 1150 mm long fork, fork parallelism deviation
should be max. 18.4 mm.
4. Measure the distance between the inner fork and the aluminium
edge. Measure the distance at points far out and far in on the fork.
The maximum deviation allowed between the (C1) measurement
and the (C2) measurement is 1 mm per 150 mm fork length.
Example: Fork length 1200 mm:
(1200/150) x 1 = 8
This means that the deviation in distance between the fork and the alu-
minium edge should be max. 8 mm when measuring as far out and as
far in on the fork as possible.
5. Use the adjustment screws to adjust the distance.
6. Rotate the forks 180° and repeat the measurement.
Use the adjustment screws to adjust the distance.

Shuttle fork – 7800 (T code 713)
Assembly of the shuttle fork
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27- Shuttle fork – 7800 (T code 713)
27.1 Assembly of the shuttle fork
Mount the shuttle fork unit using a reach truck. See the arrows.
Warning!
If work is required under the cabin, first secure it using the cab stop-
per. See C code 7100
Insert the axle journals and locking strips.
Tighten the bolts to a torque of 181 Nm.

Assembly of the shuttle fork
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Tighten the locking nuts to a torque of 78 Nm (±19).
Install the hoses.
Connect the cables.

Maintenance
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Perform an operational test of the truck and adjust the speed and
ramps.
27.2 Maintenance
This section covers all necessary inspection items that should be per-
formed regularly to keep the machine in good operational condition.
Regular maintenance work must be performed according to the inspec-
tion list.
Defects and damage should be remedied immediately.
Damaged components/parts should only be replaced with original
spare parts.
Warranty claims will be automatically rejected if original spare parts
have not been used.
The owner shall also remain responsible for injuries and property as a
result of this.

Maintenance
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27.2.1 Maintenance chart

The service life of each component has been assessed and all items
must be checked before machine performance is affected. This means
that the various components have different maintenance intervals and
that the inspection list as such is unique for each service intervention.

no. Interval in hours – can vary depending Initially 500 1000 2000 3000
on application 250 h
7800 Reach carriage
7800.1 Lubricate the drive chain LA LA
7800.2 Lubricate shuttle fork chain LA LA
7800.3 Lubricate the gear rods on the guide LF LF
7800.4 Lubricate contact surfaces on guide rollers LF LF
7800.5 Check the adjustment of the guide chain I I
7800.6 Check the adjustment of the shuttle fork I I
chain
7800.7 Check the reach carriage play +/- 2 mm I I
7800.8 Check the mounting and wear on the chain I I
wheel
7800.9 Inspect line components and the hydraulic I
motor for leakage
NOTE: 500 h is based on average loads of 700-800 kg.For higher

average loads, the interval should be reduced to 250 h.
The letters A-F indicate the lubricant type to be used. See the sepa-
rate table.

Maintenance
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7800.1
7800.1
7800.2
7800.2 7800.2
7800.3
7800.4
Maintenance
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27.2.2 Lubrication
Oil and grease specification
Pos. Lubricant Ambient Viscosity Component Recommended prod-
temperature class ucts*
A Chain lubrica- > - 40 °C VG 150 Chains Klüber oil 4UH 1-15,
tion < - 30 °C Klüber lubricating
grease
> - 30 °C VG 68 Chains Klüberoil 4UH 1-
< + 5 °C 68N, Klüber lubricat-
ing grease Anticorit
LBO 160 TT, Fuchs
DEA
> + 5 °C VG 150 Chains Klüber oil 4UH 1-
< +45 °C 150N, Klüber lubricat-
ing grease
Anticorit LBO 160,
Fuchs DEA
>+ 45 °C VG 220 Chains Klüber oil 4UH 1-
<+ 80 °C 220N, Klüber lubricat-
ing grease
F Lubricating > - 40 °C EP2 Mast girders Q8 Rubens LT
grease < - 15 °C
> -15 °C EP2 Mast girders Q8 Rembrandt EP2
< +45 °C

Maintenance
227761-040 2008-04-25 919699- 712, 713
27.2.3 Chain adjustment

2
• Adjusting the drive motor chain

• Operate the forks (1) all the way to the end position in the direction of
the arrow.
• Adjust the tension of the drive motor chain using the nut (2). Tension
is correct when chain deflection is 10 mm when a force of 10 kg is
applied in the centre of the chain section.
• Do not overtension the drive motor chain since this will cause the
bearing and plastic wheels to quickly wear down.
Adjusting the fork chains

• Operate the forks (1) completely to the end position.
• Adjust the tension of chain using the screw (3). Tension is correct
when chain deflection is 13 mm (+/- 1 mm) when a force of 5 kg is
applied at the centre guide.
• Do not overtension the fork chain since this will cause the bearing
and plastic wheels to quickly wear down.
• Repeat the above procedure for the other fork chain by operate the
forks to the end stop.

Maintenance
712, 713 919699- 2008-04-25 227761-040
BF K468170-353
Fig. 1 Chain adjustment

Maintenance
227761-040 2008-04-25 919699- 712, 713

Replacing the shuttle forks
712, 713 919699- 2008-04-25 227761-040
27.3 Replacing the shuttle forks

Unscrew the shuttle forks from the fork carriage. Loosen the eight sock-
et head cap screws (MC6S; M12x90, hardness 12:9)
D

227761-040 2008-04-25 919699- 712, 713
B B B
C
A B
Install the sensor layer by inserting the shaft at the bottom of the sleeve
and then pulling back the axle 20 mm. (A)
Prior to installation, apply a light coat of oil on 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 containing MoS2 on the tensioning unit and surfaces
between the tensioning unit and axle or between tensioning unit and
the sleeve.
Tighten the screws in the tensioning unit diagonally to a tightening
torque of 17 Nm. (C)

712, 713 919699- 2008-04-25 227761-040
Assemble the forks on the fork carriage using 8 x MC6S socket head
cap screws (M12x90, hardness 12:9) prelubricated with MoS2 mount-
ing paste. Tightening torque 140 Nm. (D)

Shuttle fork unit – 7800
227761-040 2008-04-25 919699- 712, 713
27.4 Shuttle fork unit – 7800

On new trucks, to reduce the fork offset, the load booster valve has
been moved closer to the hydraulic motor. To reduce the risk of external
leakage, nuts have been introduced behind the valve plate.
To minimise the risk of external leakage, a support ring has been intro-
duced for the O-ring in the sealing kit.
27.4.1 Shuttle forks coming loose from the

fork carriage holders
If the shuttle forks have a tendency to come loose from the fork carriage
holders, replace the washers as explained below:
Fit a total of 8 washers (order number 126723-006). Lubricate the

screws with MoS2. Tighten to a torque of 123 Nm.
Replace the M8x30 screw with an M8x35 screw (order number 24546),
and add washers (order number 126723-003) (3 pieces). Only fit wash-
ers (order number 126723-003) on the remaining 9 holding points.
Lubricate the screws with MoS2. Tighten to a torque of 25 Nm.

Shuttle fork unit – 7800
712, 713 919699- 2008-04-25 227761-040
Fit washers (order number 126723-004) (36 washers in total). Lubri-

cate the screws with MoS2. Tighten to a torque of 47 Nm.
Apply Locktite 2701 on the threads (8 positions).

Wire guidance equipment – 8200
General
227761-040 2008-04-25 919699- 712, 713
28- Wire guidance equipment – 8200
28.1 General
Wire guidance is used for automatic steering in narrow aisles. A gener-
ator generates alternating current in a cable that is set into the floor and
which the truck follows. The cable runs along the narrow aisles in a
closed circuit from the generator in aisle 1, into aisle 2, etc. It then
returns to the generator from the last aisle in the series. 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 generates 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 control unit that controls the steering. The system
is monitored by the ordinary truck computer, which stops the truck if an
error should occur.

Wire guidance equipment – 8200
Generator
712, 713 919699- 2008-04-25 227761-040
28.2 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.
28.2.1 Technical data

Power supply Model LDU-22 Model LDU-21
220 V 50 Hz 110 V 50/60 Hz
Output current 75 m A +/- 5%
Frequency 6.25 kHz +/- 3.5%
Output current 7.5 V output unloaded
Battery 2 x 12 V 3 Ah
Battery backup > 6 hours
Max. cable length app. 750 m
Cable cross section > 0.75 mm2
Fuse 0.4 A (slow burn) on the voltage card

Height preselection – 9390
General
227761-040 2008-04-25 919699- 712, 713
29- Height preselection – 9390
29.1 General
In firmware version 213017-008, the optional height preselection func-
tion has been introduced. Height preselection 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 pre-
selector. 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

No. Parameter type Unit Min. Max. Std. value Remark
159 Height pre selec- 0 2 0 0: Height preselection not active
tion 1: Height preselection is program-
mable
2: Height preselection is not pro-
grammable

Programming
712, 713 919699- 2008-04-25 227761-040
Parameter 159
Using this parameter, the optional height preselection function can be
activated
- Parameter value 1:
Height preselection is active and is open for programming via the
information menu on the display.
- Parameter value 2:
Height preselection is active, but programming via the informa-
tion 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 the [ i ] button.
• Depress the option button next to the operator symbol
• To enter the programming mode, depress the option button next to
the height preselection symbol.
• Indicate the height preselection level.

Programming
227761-040 2008-04-25 919699- 712, 713
• Confirm the selected height preselection level by depressing the

confirmation button (start button).
NOTE:
It is possible to program a height preselection level without this level
being programmed for pallet handling.
In this case, simply enter the programming mode for the order picking
level.
• It is now 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 pal-
let.
• 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 high-
er, is simultaneously saved as a set-down height for the selected
preselection level.

Programming
712, 713 919699- 2008-04-25 227761-040
”Leaving level”
• If the set-down height that was saved when programming the pick-
up 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 clear-
ance 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 preselection level.
• Depress the option button next to the waste basket symbol.
• The entire level, including all programmed heights, is erased.

Programming
227761-040 2008-04-25 919699- 712, 713
Changing the programmed level

• To change the lifting heights of a previously programmed level, re-
peat the programming procedure for the pick-up level, set-down lev-
el 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 preselection

level and the height preselection symbol is displayed in the upper,
left corner of the display.

Programming
712, 713 919699- 2008-04-25 227761-040
• Enter required height level using buttons 0—9, (e.g. 5 = level 5). The
display will show LE05.
NOTE:
The height preselection symbol starts blinking and the ICP buzzer
sounds to remind the operator that a level was not selected within 5
seconds.
NOTE:
sounds to remind the operator that the selected level was not con-
firmed within 5 seconds.
Warning!
Confirmation not received
If the operator forgets to confirm the preselection height with the con-
firmation (start) button, the operator's cabin will not stop at the select-
ed 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.
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 com-
pleted, the height level meter display will be replaced by the current
lifting height.

Programming
227761-040 2008-04-25 919699- 712, 713
Depositing a load
• Select the set-down pallet function using the “arrow down” button.
• Enter the required height level using buttons 0—9, (e.g. 5 = level 5).
The display will show LE05.
NOTE:
seconds.
NOTE:
Warning!
ed 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.

Programming
712, 713 919699- 2008-04-25 227761-040
• Pull out the forks from the racking. When the cycle has been com-
pleted, the height level meter display will be replaced by the current
lifting height.
Order picking
• Select the order picking mode using the “plus” button.
• Enter the required height level using buttons 0—9, (e.g. 5 = level 5).
The display will show LE05.
NOTE:
seconds.
NOTE:
Warning!
ed height.

Programming
227761-040 2008-04-25 919699- 712, 713

NOTE:
• When the operator's cabin stops, the height level meter display will
be replaced by the current lifting height.

Programming
712, 713 919699- 2008-04-25 227761-040

Programming
227761-040 2008-04-25 919699- 712, 713

© BT Europe AB
SE-595 81 Mjölby
Sweden
www.bt-industries.com

227761-040 Vce150a

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Service Manual en

VCE150A, 150AC, 125ASF, 125ACSF

Order number: 227761-040

Publishing Order Changes

This manual contains information on the following trucks:

T code Model Machine number

3- Preventive maintenance – P2 (T code 713) ........................................ 3-1

4- Oil and grease specifications – P3 (T code 712) ............................... 4-1

5- Oil and grease specification – P3 (T code 713) ................................ 5-1

6- Tools – P4 ............................................................................................. 6-1

7- Chassis – 0000 Truck installation ..................................................... 7-1

8- Frame pivot – 0320 ............................................................................... 8-1

9- General tightening torque – 0400 ....................................................... 9-1

© BT Europe AB Service manual VCE150A, 150AC, 125ASF, 125ACSF 1- 1

10- Electric pump motor – 1710.1 ......................................................... 10-1

11- Electric pump motor – 1710.2 ......................................................... 11-1

12- Electric drive motor – 1760 ............................................................. 12-1

13- Drive unit/gear – 2550 ..................................................................... 13-1

14- Service brake system – 3100.1 ....................................................... 14-1

15- Service brake system – 3100.2 ....................................................... 15-1

16- Support arm brake – 3180 ............................................................... 16-1

© BT Europe AB Service manual VCE150A, 150AC, 125ASF, 125ACSF 1- 3

17- Drive wheel – 3530 .......................................................................... 17-1

18- Fork/support arm wheel – 3550 ...................................................... 18-1

19- Electrical system – 5000 ................................................................. 19-1

1- 4 Service manual VCE150A, 150AC, 125ASF, 125ACSF © BT Europe AB

19.6 DC regulator, DCHI (A32)........................................................... 19-34

© BT Europe AB Service manual VCE150A, 150AC, 125ASF, 125ACSF 1- 5

19.16 Wire guidance .......................................................................... 19-194

1- 6 Service manual VCE150A, 150AC, 125ASF, 125ACSF © BT Europe AB

20- Hydraulic system – 6000 ................................................................. 20-1

21- Hydraulic pump – 6140 .................................................................... 21-1

22- Accumulators – 6280 ....................................................................... 22-1

23- Main lift cylinder – 6610 ................................................................... 23-1

24- Main mast and mast – 7100 ............................................................. 24-1

© BT Europe AB Service manual VCE150A, 150AC, 125ASF, 125ACSF 1- 7

25- Main lift chain system – 7120 ......................................................... 25-1

27- Shuttle fork – 7800 (T code 713) .................................................... 28-1

28- Wire guidance equipment – 8200 ................................................... 29-1

29- Height preselection – 9390 .............................................................. 30-1

© BT Europe AB Service manual VCE150A, 150AC, 125ASF, 125ACSF 1- 9

This page is intentionally left blank

1- 10 Service manual VCE150A, 150AC, 125ASF, 125ACSF © BT Europe AB

© BT Europe AB Service manual VCE150A, 150AC, 125ASF, 125ACSF 2- 1

I: Inspect, adjust and replace if necessary. T: Tighten. C: Clean L: Lubricate.

2- 2 Service manual VCE150A, 150AC, 125ASF, 125ACSF © BT Europe AB

I: Inspect, correct and replace if necessary. T: Tighten. C: Clean L: Lubricate.

© BT Europe AB Service manual VCE150A, 150AC, 125ASF, 125ACSF 2-3

I: Inspect, correct and replace if necessary. T: Tighten. C: Clean L: Lubricate.

2-4 Service manual VCE150A, 150AC, 125ASF, 125ACSF © BT Europe AB

I: Inspect, adjust and replace if necessary. T: Tighten. C: Clean L: Lubricate.

NOTE: 500 h is based on average loads of 700-800 kg. For higher

© BT Europe AB Service manual VCE150A, 150AC, 125ASF, 125ACSF 2- 5

2- 6 Service manual VCE150A, 150AC, 125ASF, 125ACSF © BT Europe AB

© BT Europe AB Service manual VCE150A, 150AC, 125ASF, 125ACSF 2- 7

This page is intentionally left blank

2- 8 Service manual VCE150A, 150AC, 125ASF, 125ACSF © BT Europe AB

I: Inspect, adjust and replace if necessary. T: Tighten. C: Clean. L: Lubricate.

© BT Europe AB Service manual VCE150A, 150AC, 125ASF, 125ACSF 3- 1

I: Inspect, adjust and replace if necessary. T: Tighten. C: Clean. L: Lubricate.

3- 2 Service manual VCE150A, 150AC, 125ASF, 125ACSF © BT Europe AB

I: Check, adjust and replace if necessary. T: Tighten. C: Clean. L: Lubricate.

© BT Europe AB Service manual VCE150A, 150AC, 125ASF, 125ACSF 3-3