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BT VR Service Manual 174803-040

$30.00

Type Of Manual: Service Manual
Manual ID: 174803-040
: Service Manual PDF
Number of Pages: 446
Size: 17.6MB
Format: PDF

Category: BT Service Manual PDF

Model List:
- VR

1. Contents
2. General product information – M2
2.1. Presentation of BTs narrow aisle trucks
2.2. Application areas for BTs narrow aisle trucks
2.3. Prohibited applications for BTs narrow aisle trucks
2.4. Truck data
2.5. Truck dimensions
2.6. Identification plate, truck
2.7. Capacity plate
2.8. Modification plate
2.9. Identification plate, mast
2.10. Main components
2.11. Warning and information plates and symbols
3. Technical data – M4
4. Introduction and safety, maintenance – P1
4.1. Safety regulations with maintenance work
4.1.1. Tilting the cab up on cold store trucks
4.1.2. Tilting the cab down on cold store trucks
4.2. Cleaning and washing
4.2.1. External cleaning
4.2.2. Cleaning the motor compartment
4.2.3. Electrical components
4.3. Safe lifting
5. Preventive maintenance – P2
5.1. Maintenance Schedule
6. Oil and grease specification – P3
7. Tools – P4
7.1. Electrical contacts
7.1.1. Super Seal contacts
7.1.2. AMP contacts
7.2. Miscellaneous tools
8. Chassis – 0000
8.1. General
8.2. List of tools
8.3. Transporting the truck
8.4. Assembling the mast
8.5. Installation in narrow aisles
8.5.1. General
8.5.2. Track-guided truck
8.5.3. Wire guided truck
8.5.4. General adjustment
9. Frame, mounted components – 0400
9.1. General tightening torque
9.1.1. Galvanised, non oiled bolts
9.1.2. Untreated, oiled bolts
10. Driver Protection – 0840
10.1. General
10.2. Tilt Stops
11. Electric Pump Motor – 1710
11.1. General
11.2. Dismantling the Pump Motor
11.3. Removing and Replacing the Pump Motor
11.3.1. Dismantling
11.3.2. Assembling
11.4. Bearing Replacement
11.4.1. Dismantling
11.4.2. Re-Assembly
11.5. Installation Instructions for External Temperature Sensor
12. Electric Steering Motor – 1730
12.1. General
12.2. Replacing the Steering Motor
12.2.1. Dismantling
12.2.2. Re-Assembly
12.3. Removing and Replacing the Carbon Brushes
13. Electric Drive Motor – 1760
13.1. General
13.2. Dismantling the Drive Motor
13.3. Dismantling and Assembling the Drive Motor
13.3.1. Removing the gear wheel
13.3.2. Removing the brakes
13.3.3. Assembling the Drive Motor
13.4. Bearing Replacement
13.4.1. Dismantling
13.4.2. Assembling
13.5. Installation Instructions for External Temperature Sensor
14. Mechanical Drive Gear Unit
14.1. General
14.2. Drive/Transmission Assemblys Main Components and Technical Data
14.2.1. Position of Components
14.2.2. Technical data
14.2.3. Dismantling the Transmission
14.3. Replacing the Drive Motor/Drive Transmission
14.3.1. Dismantling the Drive Motor
14.3.2. Removal of the Drive Transmission
14.3.3. Assembling the Drive Transmission
14.3.4. Installing the Drive Motor
14.4. Checking/Replacing the Oil
14.4.1. Changing the Oil
14.5. Repairs
14.5.1. Dismantling
14.5.2. Re-Assembly
14.5.3. Leakage from the Upper Cover
14.5.4. Leakage from the Lower Cover
14.5.5. Replacing Wheel Bolts
15. Travel brake system – 3100
15.1. Brake system
15.1.1. General
15.2. Description of function
15.2.1. Releasing the accelerator
15.2.2. Changing travel direction
15.2.3. Pressing the brake pedal (without support arm brake)
15.2.4. Pressing the brake pedal (with support arm brakes)
15.2.5. Parking brake
15.2.6. Emergency braking
15.3. Electromechanical disc brake, drive motor
15.3.1. Assembling
15.3.2. Dismantling
15.3.3. Maintenance
15.4. Multiple disc brake, support arm
15.4.1. Assembly
15.4.2. Dismantling
15.4.3. Maintenance
16. Drive wheel – 3530
16.1. General
16.2. Dismantling the drive wheel
16.3. Assembling the drive wheel
17. Fork/support arm wheel – 3550
17.1. General
17.2. Dismantling the wheel
17.3. Assembling the wheel
17.4. Dismantling/assembling the wheel bearings
17.4.1. Dismantling the bearing
17.4.2. Assembling the bearing
18. Electric steering wheel/lever – 4310
18.1. General
18.2. Replacement of the steering generator
18.2.1. Dismantling
18.2.2. Assembly
19. Steering angle sensor – 4350
19.1. General
19.2. Adjustment of directional sensor
19.3. Adjustment of the steering angle sensor
20. Wire guidance – 4500
20.1. General
20.2. Generator
20.2.1. Technical data
20.3. Wire guidance system overview
20.4. Wire guidance components
20.4.1. Antennae, W1, W2
20.4.2. Control unit, A3
20.4.3. Home position sensor, S85
20.4.4. Steering angle sensor, U15
20.4.5. Diverse
20.5. Operating description
20.5.1. Run mode
20.5.2. Service mode
20.5.3. Parameter 36
20.5.4. Parameter 71
20.5.5. Parameter 72
20.5.6. Parameter 73
20.5.7. Parameter 74
20.5.8. Parameter 75
20.6. Error Codes
20.6.1. Error codes detected by electronic card A5
20.6.2. Error code detected by electronic card A3, WG-control unit
21. Electrical System – 5000
21.1. General
21.2. Electronics Card, traction controller A1 and lift controller A2
21.2.1. General
21.2.2. Terminal Connections and Pole Bolts
21.2.3. Technical Data
21.2.4. Installation of New Controller on Truck
21.2.5. Programming
21.3. Electronics Card, Fork unit, A4
21.3.1. General
21.3.2. Terminal Connections
21.3.3. Installation of New Card on Truck
21.3.4. Programming
21.4. Electronics Card, Main Card, A5
21.4.1. General
21.4.2. Terminal Connections and Voltages on A5
21.4.3. Installation of New Card on Truck
21.4.4. Programming
21.5. Electrical System, Overview
21.6. Symbol List and Wiring Diagrams
21.6.1. Symbol List
21.6.2. Wiring Diagram (1/25)
21.6.3. Wiring Diagram (2/25)
21.6.4. Wiring Diagram (3/25)
21.6.5. Wiring Diagram (4/25)
21.6.6. Wiring Diagram (5/25)
21.6.7. Wiring Diagram (6/25)
21.6.8. Wiring Diagram (7/25)
21.6.9. Wiring Diagram (8/25)
21.6.10. Wiring Diagram (9/25)
21.6.11. Wiring Diagram (10/25)
21.6.12. Wiring Diagram (11/25)
21.6.13. Wiring Diagram (12/25)
21.6.14. Wiring Diagram (13/25)
21.6.15. Wiring Diagram (14/25)
21.6.16. Wiring Diagram (15/25)
21.6.17. Wiring Diagram (16/25)
21.6.18. Wiring Diagram (17/25)
21.6.19. Wiring Diagram (18/25)
21.6.20. Wiring Diagram (19/25)
21.6.21. Wiring Diagram (20/25)
21.6.22. Wiring Diagram (21/25)
21.6.23. Wiring Diagram (22/25)
21.6.24. Wiring Diagram (23/25)
21.6.25. Wiring Diagram (24/25)
21.6.26. Wiring Diagram (25/25)
21.6.27. Component List, Standard Truck
21.6.28. Component identification
21.7. Functional Description
21.7.1. Key in Position 0
21.7.2. Key in Position I, Driver Seated
21.7.3. Direction of Travel Selection
21.7.4. Driving
21.7.5. Travel speeds
21.7.6. Steering
21.7.7. Braking
21.7.8. Aisle-End Slowdown
21.7.9. Fork Lifting
21.7.10. Height Indication
21.7.11. Lift height limit
21.7.12. Height Pre-Set
21.7.13. Fork Lowering
21.7.14. Lateral Movement/Traversing of Forks
21.7.15. Rotating the Forks
21.7.16. Simultaneous Traversing and Rotation Movement
21.7.17. Extra Hydraulic Functions
21.7.18. Weighing
21.7.19. Driver Identification
21.8. Parameter
21.8.1. Parameter Settings
21.8.2. Parameter 1
21.8.3. Parameter 2
21.8.4. Parameter 3
21.8.5. Parameter 4
21.8.6. Parameter 5
21.8.7. Parameter 6
21.8.8. Parameter 7
21.8.9. Parameter 8
21.8.10. Parameter 10
21.8.11. Parameter 11
21.8.12. Parameter 12
21.8.13. Parameter 13
21.8.14. Parameter 14
21.8.15. Parameter 15
21.8.16. Parameter 16
21.8.17. Parameters 17 and 18
21.8.18. Parameter 19
21.8.19. Parameter 20
21.8.20. Parameter 21
21.8.21. Parameter 22
21.8.22. Parameter 23
21.8.23. Parameter 24
21.8.24. Parameter 25
21.8.25. Parameter 26
21.8.26. Parameter 27
21.8.27. Parameter 28
21.8.28. Parameter 29
21.8.29. Parameter 36
21.8.30. Parameter 37
21.8.31. Parameter 38
21.8.32. Parameter 39
21.8.33. Parameters 40 to 42
21.8.34. Parameter 43
21.8.35. Parameter 44
21.8.36. Parameter 45
21.8.37. Parameter 46
21.8.38. Parameter 47
21.8.39. Parameter 48
21.8.40. Parameter 50
21.8.41. Parameter 51
21.8.42. Parameter 53
21.8.43. Parameter 54
21.8.44. Parameter 55
21.8.45. Parameter 56
21.8.46. Parameter 57
21.8.47. Parameter 58
21.8.48. Parameter 59
21.8.49. Parameter 60
21.8.50. Parameter 61
21.8.51. Parameter 62
21.8.52. Parameter 63
21.8.53. Parameter 64
21.8.54. Parameter 65
21.8.55. Parameter 66
21.8.56. Parameter 67
21.9. Instrument Panel and Display
21.9.1. Show
21.9.2. Operating Time
21.9.3. Programming
21.10. Codes
21.10.1. Warning Codes
21.10.2. Error mode
21.10.3. Safety Logic
21.10.4. Warning Codes without Registration
21.10.5. Warning Codes with Registration
21.10.6. Error Codes
21.10.7. Error Codes with Registration
22. Hydraulic system – 6000
22.1. General
22.2. Hydraulic schematics
22.2.1. Symbols
22.2.2. Hydraulic schematics
22.2.3. Component description
22.3. Hydraulic components, positioning
22.3.1. Overview
22.3.2. Hydraulic unit
22.3.3. Fork unit
22.3.4. Cab tilt function (cold store cab)
23. Hydraulic pump – 6140
23.1. General
23.2. Replacing the hydraulic pump
23.2.1. Dismantling
23.2.2. Assembling
24. Hydraulic connections – 6230
24.1. General
24.2. Tightening torque for hydraulic connections
24.2.1. Conical connection with O-ring
24.2.2. Tredo seal
24.2.3. Pipe couplings
24.2.4. Connections screwed into aluminium
24.2.5. Connections screwed into steel
24.3. Quick connection
24.3.1. Assembling
24.3.2. Dismantling
25. Main lift chain system – 7120
25.1. General
25.2. Checking the chain setting
25.3. Chain inspection
25.3.1. Noise
25.3.2. Surface rust
25.3.3. Rusty links
25.3.4. Stiff links
25.3.5. Bolt rotation
25.3.6. Loose bolts
25.3.7. Outline wear
25.3.8. Stretching
25.3.9. Damage
25.3.10. Damaged discs
25.3.11. Damaged bolts
25.3.12. Dirty chain
25.4. Cleaning
25.5. Lubrication
26. Turret Head Fork Apparatus – 7700
26.1. General description
26.1.1. Main Components
26.1.2. Fork turning
26.1.3. Side-shift movement
26.2. Inspection and maintenance
26.2.1. External inspection
26.2.2. Inspection
26.2.3. Maintenance
26.3. Adjustment of turret head fork apparatus
26.3.1. Fork carriage, end position rotation
26.3.2. Setting tooth flank play
26.3.3. Adjusting the apparatus lateral play on the mast guide
26.3.4. Potentiometer for the turning movement
26.3.5. Inductive sensor for the home position, side-shift
26.4. Replacing components
26.4.1. Turning chain
26.4.2. Turning bearing
27. Charger BTCM – 8340
27.1. General
27.2. Installation
27.3. Function and use
27.3.1. Shut-off conditions
27.3.2. Delayed start and charging
27.3.3. Extra charging
27.3.4. Equalisation charge
27.3.5. Current and voltage characteristics
27.3.6. Safety shut-off
27.4. Display and keyboard
27.4.1. Reading analog measurement values
27.4.2. Error indication and error messages
27.4.3. Reading statistics from the previous charging process
27.4.4. Reading long-term statistics
27.4.5. Saving parameters in general.
27.4.6. Reading parameters
27.4.7. Battery specific parameters
27.4.8. Charger specific parameters
27.4.9. Mains voltage codes
27.4.10. Other functions
27.4.11. Changing of parameters
27.5. Service and maintenance
27.5.1. Resetting the statistics, code 31
27.5.2. Calibrating measurement values
27.5.3. Modifying the charging characteristics
27.5.4. Printing to a printer
27.6. Trouble shooting
27.6.1. Error messages, analysis and actions
27.7. Service actions
27.7.1. Switching to timer charging
27.7.2. Replacing the display card
27.7.3. Replacing the computer board
27.7.4. Replacing the motherboard
27.7.5. Replacing the diodes
27.8. Preventive maintenance
28. Control/computer equipment – 8700
28.1. General
28.2. Connection
28.3. Layout
28.3.1. Main program screen
28.3.2. Nodes
28.3.3. Icons
28.3.4. Tool buttons and menu bar
28.3.5. Information window
28.3.6. Status bar
28.4. Connection function
28.5. Disconnection function
28.6. Downloading program function

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