BT Veflex VR, VR SF, VRE150, VRE125SF Service Manual 244989-040

BT Veflex VR, VR SF, VRE150, VRE125SF Service Manual 244989-040 - Image 2

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BT Veflex VR, VR SF, VRE150, VRE125SF Service Manual 244989-040 - Image 5

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BT Veflex VR, VR SF, VRE150, VRE125SF Service Manual 244989-040

$30.00

Type Of Manual: Service Manual
Manual ID: 244989-040
: Service Manual PDF
Number of Pages: 682
Size: 21.8MB
Format: PDF

Category: BT Service Manual PDF

Model List:
- Veflex VR, VR SF, VRE150, VRE125SF

1. Table of contents
2. Technical data
3. Maintenance
3.1. Introduction and safety, maintenance
3.2. Safety regulations during maintenance work
3.2.1. Tilting the cab up on a cold store truck
3.2.2. Tilting the cab down on a cold store truck
3.3. Cleaning and washing
3.3.1. External cleaning
3.3.2. Cleaning the motor compartment
3.3.3. Electrical components
3.4. Safe lifting
3.5. Maintenance chart
3.5.1. VRE150, VRE125SF
3.5.2. VR SF/VRE125SF
3.5.3. VR/VRE150
3.5.4. VR SF/VR
3.5.5. VRE150/VRE125SF
3.5.6. VR SF/VRE125SF
3.5.7. VR/VRE150
3.5.8. VR/VRE150
3.6. Oil and grease specifications
4. Tools
4.1. Electrical contacts
4.1.1. Super Seal contacts
4.1.2. AMP contacts
4.2. Miscellaneous tools
5. Chassis – 0000
5.1. General
5.2. List of tools
5.3. Transporting the truck
5.4. Assembling the mast
5.5. Installation in narrow aisles
5.5.1. General
5.5.2. Track-guided truck
5.5.3. Wire guided truck
5.5.4. General adjustment
6. Frame, mounted components – 0400
6.1. General tightening torque
6.1.1. Galvanised, non oiled bolts
6.1.2. Untreated, oiled bolts
7. Driver Protection – 0840
7.1. General
7.2. Tilt Stops
7.2.1. Inspection and Adjustment
8. Electric Pump Motor – 1710
8.1. General
8.2. Dismantling the Pump Motor
8.3. Removing and Replacing the Pump Motor
8.3.1. Dismantling
8.3.2. Assembling
8.4. Bearing Replacement
8.4.1. Dismantling
8.4.2. Re-Assembly
8.5. Installation Instructions for External Temperature Sensor
9. Electric Steering Motor – 1730
9.1. General
9.2. Replacing the Steering Motor
9.2.1. Dismantling
9.2.2. Re-Assembly
9.3. Removing and Replacing the Carbon Brushes
10. Electric Drive Motor – 1760
10.1. General
10.2. Dismantling the Drive Motor
10.3. Dismantling and Assembling the Drive Motor
10.3.1. Dismantling the Drive Motor
10.3.2. Assembling the Drive Motor
10.4. Bearing Replacement
10.4.1. Dismantling
10.4.2. Assembling
10.5. Installation Instructions for External Temperature Sensor
11. Mechanical Drive Gear Unit – 2550
11.1. General
11.2. Drive/Transmission Assemblys Main Components and Technical Data
11.2.1. Position of Components
11.2.2. Technical data
11.2.3. Dismantling the Transmission
11.3. Replacing the Drive Motor/Drive Transmission
11.3.1. Dismantling the Drive Motor
11.3.2. Removal of the Drive Transmission
11.3.3. Assembling the Drive Transmission
11.3.4. Installing the Drive Motor
11.4. Checking/Replacing the Oil
11.4.1. Checking/Refilling the Oil
11.4.2. Changing the Oil
11.5. Repairs
11.5.1. Replacing the Drive Shaft Gasket
11.5.2. Leakage from the Upper Cover
11.5.3. Leakage from the Lower Cover
11.5.4. Replacing Wheel Bolts
12. Travel brake system – 3100
12.1. Brake system
12.1.1. General
12.2. Description of function
12.2.1. Releasing the accelerator
12.2.2. Changing travel direction
12.2.3. Pressing the brake pedal (without support arm brake)
12.2.4. Pressing the brake pedal (with support arm brakes)
12.2.5. Parking brake
12.2.6. Emergency braking
12.3. Electromechanical disc brake, drive motor
12.4. Disassembly
12.5. Inspection
12.6. Assembly
12.7. Maintenance
12.7.1. Adjusting the play
12.7.2. Wear
12.7.3. Checking the braking force
12.8. Multiple disc brake, support arm
12.8.1. Assembly
12.8.2. Dismantling
12.8.3. Maintenance
13. Drive wheel – 3530
13.1. General
13.2. Dismantling the drive wheel
13.3. Assembling the drive wheel
14. Fork/support arm wheel – 3550
14.1. General
14.2. Dismantling the wheel
14.3. Assembling the wheel
14.4. Dismantling/assembling the wheel bearings
14.4.1. Dismantling the bearing
14.4.2. Assembling the bearing
15. Electric steering wheel/lever – 4310
15.1. General
15.2. Replacement of the steering generator
15.2.1. Dismantling
15.2.2. Assembly
16. Steering angle sensor – 4350
16.1. General
16.2. Procedure
16.2.1. Adjustment of directional sensor
16.2.2. Adjustment of the steering angle sensor
17. Automatic steering system – 4500
17.1. General
17.2. Generator
17.2.1. Technical data
17.3. Wire guidance system overview
17.4. Wire guidance components
17.4.1. Antennae, W1, W2
17.4.2. Control unit, A3
17.4.3. Home position sensor, S85
17.4.4. Steering angle sensor, U15
17.4.5. Diverse
17.5. Operating description
17.5.1. Run mode
17.5.2. Service mode
17.5.3. Parameter 36
17.5.4. Parameter 71
17.5.5. Parameter 72
17.5.6. Parameter 73
17.5.7. Parameter 74
17.5.8. Parameter 75
17.6. Error Codes
17.6.1. Error codes detected by electronic card A5
17.6.2. Error code detected by electronic card A3, WG-control unit
18. Electrical System – 5000.1
18.1. General
18.2. Electronics Card, traction controller A1 and lift controller A2
18.2.1. General
18.2.2. Terminal Connections and Pole Bolts
18.2.3. Technical Data
18.2.4. Installation of New Controller on Truck
18.2.5. Programming
18.3. Electronics Card, Fork Apparatus, A4
18.3.1. General
18.3.2. Terminal Connections
18.3.3. Installation of New Card on Truck
18.3.4. Programming
18.4. Electronics Card, Main Card, A5
18.4.1. General
18.4.2. Terminal Connections and Voltages on A5
18.4.3. Installation of New Card on Truck
18.4.4. Programming
18.5. Electrical System, Overview
18.6. Symbol List and Wiring Diagrams
18.6.1. Symbol List
18.6.2. Wiring diagrams VR SF
18.6.3. Wiring diagrams VR
18.6.4. Component List, standard truck
18.6.5. Component identification
18.7. Functional Description
18.7.1. Key in Position 0
18.7.2. Key in Position I, Driver Seated
18.7.3. Direction of Travel Selection
18.7.4. Driving
18.7.5. Travel speeds
18.7.6. Steering
18.7.7. Braking
18.7.8. Aisle-End Slowdown
18.7.9. Fork Lifting
18.7.10. Height Indication
18.7.11. Lift height limit
18.7.12. Height Pre-Set
18.7.13. Fork Lowering
18.7.14. Lateral Movement/Traversing of Forks (VR SF)
18.7.15. Lateral Movement/Traversing of Forks (VR)
18.7.16. Rotating the Forks (VR)
18.7.17. Simultaneous Traversing and Rotation Movement (VR)
18.7.18. Extra Hydraulic Functions (VR)
18.7.19. Weighing
18.7.20. Driver Identification
18.8. Parameter
18.8.1. Parameter Settings
18.8.2. Parameter 1
18.8.3. Parameter 2
18.8.4. Parameter 3
18.8.5. Parameter 4
18.8.6. Parameter 5
18.8.7. Parameter 6
18.8.8. Parameter 7
18.8.9. Parameter 8
18.8.10. Parameter 10
18.8.11. Parameter 11
18.8.12. Parameter 12
18.8.13. Parameter 13
18.8.14. Parameter 14
18.8.15. Parameter 15
18.8.16. Parameter 16
18.8.17. Parameters 17 and 18
18.8.18. Parameter 19
18.8.19. Parameter 20
18.8.20. Parameter 21
18.8.21. Parameter 22
18.8.22. Parameter 23
18.8.23. Parameter 24
18.8.24. Parameter 25
18.8.25. Parameter 26
18.8.26. Parameter 27
18.8.27. Parameter 28
18.8.28. Parameter 29
18.8.29. Parameter 35
18.8.30. Parameter 36
18.8.31. Parameter 37
18.8.32. Parameter 38
18.8.33. Parameter 39
18.8.34. Parameters 40 to 42
18.8.35. Parameter 43
18.8.36. Parameter 44
18.8.37. Parameter 45
18.8.38. Parameter 46
18.8.39. Parameter 47 (VR)
18.8.40. Parameter 48 (VR)
18.8.41. Parameter 49 (VR SF)
18.8.42. Parameter 50
18.8.43. Parameter 51 (VR)
18.8.44. Parameter 53 (VR)
18.8.45. Parameter 54
18.8.46. Parameter 55
18.8.47. Parameter 56 (VR)
18.8.48. Parameter 57
18.8.49. Parameter 58 (VR)
18.8.50. Parameter 59 (VR)
18.8.51. Parameter 60 (VR)
18.8.52. Parameter 61 (VR)
18.8.53. Parameter 62 (VR)
18.8.54. Parameter 63 (VR)
18.8.55. Parameter 64 (VR)
18.8.56. Parameter 65 (VR)
18.8.57. Parameter 66 (VR)
18.8.58. Parameter 67
18.9. Instrument Panel and Display
18.9.1. Show
18.9.2. Operating Time
18.9.3. Programming
18.10. Codes
18.10.1. Warning Codes
18.10.2. Error mode
18.10.3. Safety Logic
18.10.4. Warning Codes without Registration
18.10.5. Warning Codes with Registration
18.10.6. Error Codes
18.10.7. Error Codes with Registration
19. Electrical systems – 5000.2
19.1. General
19.1.1. VRE125SF
19.2. Logic card, drive controller A1 and lift controller A2
19.2.1. General
19.2.2. Connection terminal and terminal pillars
19.2.3. Technical data
19.2.4. Installing a new logic card in the truck
19.2.5. Programming
19.3. Logic card, fork unit, A4
19.3.1. General
19.3.2. Connector plug
19.4. Logic card, main card, A5
19.4.1. General
19.4.2. Connection terminals and voltages on A5
19.5. Electric system, overview
19.5.1. VRE125SF
19.6. Symbol list and electric wiring diagram
19.6.1. Symbol list
19.6.2. Electric wiring diagrams VRE125SF
19.6.3. Electric wiring diagrams VRE150
19.6.4. Electric wiring diagrams, cold store cabins VRE150
19.6.5. Component list, standard truck
19.6.6. Component placement
19.7. Functional description
19.7.1. Truck not switched on
19.7.2. Truck switched on
19.7.3. Travel direction selection
19.7.4. Driving
19.7.5. Travel speeds
19.7.6. Steering
19.7.7. Braking
19.7.8. Aisle-end braking
19.7.9. Fork lifting
19.7.10. Height indication
19.7.11. Lift height limit supervision
19.7.12. Height preselection
19.7.13. Fork lowering
19.7.14. Sideshift/traversing of forks (VRE125SF)
19.7.15. Sideshift/traversing of forks (VRE150)
19.7.16. Fork rotation (VRE150)
19.7.17. Simultaneous traversing and rotation movement (VRE150)
19.7.18. Extra hydraulic function (VRE150)
19.7.19. Weight calculation
19.8. Display and programming
19.8.1. Keypad
19.9. Parameter setting of all parameters
19.9.1. Parameters
19.9.2. Parameter 19
19.9.3. Parameter 21
19.9.4. Parameter 38
19.10. Warning codes
19.11. Error codes
19.11.1. Error type
19.11.2. Safety logics
19.11.3. Warning code without recording
19.11.4. Warning codes with logging
19.11.5. Error codes with logging
19.12. Truck log system, code lock
19.12.1. General
19.12.2. SD 16
19.12.3. Components
19.13. I/O module
20. Hydraulic system – 6000
20.1. General
20.2. Hydraulic schematics
20.2.1. Symbols
20.2.2. Hydraulic schematics (VR SF)
20.2.3. Component description (VR SF)
20.2.4. Hydraulic schematics (VR)
20.2.5. Component description (VR)
20.3. Hydraulic components, positioning
20.3.1. Overview
20.3.2. Hydraulic unit
20.3.3. Hydraulic components in the fork unit (VR SF)
20.3.4. Hydraulic components in the fork unit (VR)
20.3.5. Cab tilt function (cold store cab)
21. Hydraulic pump – 6140
21.1. General
21.2. Replacing the hydraulic pump
21.2.1. Dismantling
21.2.2. Assembling
22. Hydraulic connections – 6230
22.1. General
22.2. Tightening torque for hydraulic connections
22.2.1. Conical connection with O-ring
22.2.2. Tredo seal
22.2.3. Pipe couplings
22.2.4. Connections screwed into aluminium
22.2.5. Connections screwed into steel
22.3. Quick connection
22.3.1. Assembling
22.3.2. Dismantling
23. Main lift chain system – 7120
23.1. General
23.2. Checking the chain setting
23.3. Chain inspection
23.3.1. Noise
23.3.2. Surface rust
23.3.3. Rusty links
23.3.4. Stiff links
23.3.5. Bolt rotation
23.3.6. Loose bolts
23.3.7. Outline wear
23.3.8. Stretching
23.3.9. Damage
23.3.10. Damaged discs
23.3.11. Damaged bolts
23.3.12. Dirty chain
23.4. Cleaning
23.5. Lubrication
24. Turret Head Fork Apparatus – 7700 (VR, VRE150)
24.1. General description
24.1.1. Main Components
24.1.2. Fork turning
24.1.3. Side-shift movement
24.2. Inspection and maintenance
24.2.1. External inspection
24.2.2. Inspection
24.2.3. Maintenance
24.3. Adjustment of turret head fork apparatus
24.3.1. Fork carriage, end position rotation
24.3.2. Setting tooth flank play
24.3.3. Adjusting the apparatus lateral play on the mast guide
24.3.4. Potentiometer for the turning movement
24.3.5. Inductive sensor for the home position, side-shift
24.4. Replacing components
24.4.1. Turning chain
24.4.2. Turning bearing
25. Shuttle fork unit – 7800 (VR SF, VRE125SF)
25.1. Maintenance

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