BT VCE100, VCE135 Service Manual 239880-040
BT VCE100, VCE135 Service Manual 239880-040 - Image 2
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BT VCE100, VCE135 Service Manual 239880-040 - Image 5

BT VCE100, VCE135 Service Manual 239880-040

$30.00

  • Type Of Manual: Service Manual
  • Manual ID: 239880-040
  • : Service Manual PDF
  • Number of Pages: 536
  • Size: 27.3MB
  • Format: PDF
Category:

Product details

  • Model List:

    • VCE100, VCE135
  • 1. Table of contents
  • 2. Preventative maintenance
  • 2.1. General maintenance instructions
  • 2.2. After the first 100 and 500 operating hours
  • 2.2.1. After 100 operating hours
  • 2.2.2. After 500 operating hours
  • 2.3. Daily maintenance before driving
  • 2.4. Maintenance and lubrication intervals
  • 2.4.1. General maintenance plan
  • 2.4.2. Maintenance plan swivel/travese fork
  • 2.4.3. Maintenance plan swivel/traverse fork
  • 2.4.4. Maintenance plan telescopic fork
  • 2.5. Lubrication equipment
  • 2.5.1. Consumption-type materials
  • 2.5.2. Reference values oils
  • 2.5.3. Reference values lubricants
  • 2.5.4. General lubrication schedule
  • 2.5.5. Lubrication schedule swivel/traverse fork
  • 2.5.6. Lubrication schedule telescopic fork
  • 2.5.7. Lift chains
  • 2.5.8. Toothed belt lift sensor (if present)
  • 2.5.9. Hydraulic hoses
  • 2.5.10. Required special tools
  • 3. Safety
  • 3.1. General safety instructions
  • 3.2. Electrical system
  • 3.3. Safe lifting
  • 3.4. Truck modifications
  • 3.5. Maintenance instructions
  • 3.5.1. General safety instructions, maintenance and repair
  • 3.5.2. Parking the truck
  • 3.5.3. Before performing work on the truck
  • 3.5.4. Putting the truck in motion
  • 3.5.5. Warning and instruction signs on the truck
  • 3.5.6. Conditions for use
  • 3.5.7. Safety regulations for work
  • 3.5.8. Personnel requirements
  • 3.6. Load capacity
  • 3.6.1. Application
  • 3.6.2. Regulations
  • 3.6.3. Truck geometry
  • 3.6.4. Load capacity tables acc. to Truck geometry on page 3-12
  • 3.6.5. Extra lift height h9
  • 3.6.6. Truck geometrys effect on load capacity
  • 3.7. Electrostatic hazards
  • 3.7.1. Work instructions for handling components or assemblies sensitive to electrostatic discharge (EDSD)
  • 3.8. Inspections
  • 3.8.1. For the operators
  • 4. Product description
  • 4.1. Assembly arrangement
  • 4.1.1. Components of the electrical system
  • 4.2. Components in the drive compartment (rear view)
  • 4.3. Swivel/traverse fork
  • 4.3.1. Functional description
  • 4.4. Telescopic fork
  • 4.4.1. Functional description
  • 4.5. Technical data
  • 4.5.1. Technical vehicle data
  • 4.5.2. Adjusting and test values
  • 4.5.3. Type structure
  • 4.5.4. Fuses
  • 5. Lifecycle
  • 5.1. Safety
  • 5.2. Moving loads, unloading and reloading
  • 5.3. Qualification
  • 5.3.1. Securing the freight and truck
  • 5.4. Disassembly work
  • 5.4.1. Removing the battery
  • 5.4.2. Shutting down the hydraulic system
  • 5.5. Overview transport options
  • 5.5.1. Transport types
  • 5.6. Standing transport
  • 5.7. Lying transport
  • 5.7.1. Establishing the transport state
  • 5.7.2. Safely load the VCE100, VCE135
  • 5.7.3. Unloading
  • 5.8. Container loading
  • 5.8.1. Prerequisites
  • 5.8.2. Required tools
  • 5.8.3. Weight overview approx. values
  • 5.8.4. Size determination for container shipping
  • 5.8.5. Corrosion protection
  • 5.8.6. Preparation and pole disassembly
  • 5.8.7. Loading and securing of boxes
  • 5.8.8. Loading and securing of chassis
  • 5.8.9. Loading and securing pole with cab
  • 5.8.10. Loading and securing disassembled attachment
  • 5.8.11. Unloading the components, pole assembly and commissioning
  • 5.8.12. Depreserving
  • 5.9. Assembly work on-site
  • 5.9.1. Assembling the hydraulic system
  • 5.9.2. Prepare the brakes for commissioning
  • 5.9.3. Battery installation
  • 6. Initial commissioning
  • 6.1. Individual components
  • 6.2. Basic unit
  • 6.2.1. After setting up the vehicle
  • 6.3. Lift frame
  • 6.3.1. For delivery with disassembled lift frame
  • 6.4. Load lifting device (LLD)
  • 6.4.1. For delivery with disassembled load lifting device (LLD)
  • 6.5. Battery equipment
  • 6.6. Hydraulics
  • 6.6.1. Pump aggregate
  • 6.6.2. Hydraulic system
  • 6.7. Inspections
  • 6.8. Supplied documentation
  • 6.8.1. Documentation behind drivers seat in storage box (plastic cover)
  • 7. Mechanical parts
  • 7.1. Safety instructions
  • 7.1.1. Working under lifted frame
  • 7.1.2. Activating the hoist frame lock device
  • 7.1.3. Working at dangerous heights
  • 7.1.4. Gas-pressure springs
  • 7.2. Torque values for screwed connections
  • 7.3. Ground requirements
  • 7.3.1. Specification
  • 7.3.2. Measurement tolerances
  • 7.4. Evenness
  • 7.4.1. Basics
  • 7.4.2. Checking floor evenness
  • 7.5. Vehicle guidance
  • 7.5.1. Rail guidance
  • 7.5.2. Overview of guide rail variants
  • 7.5.3. Lateral floor rail forces of VCE
  • 7.5.4. Induction guidance
  • 7.5.5. Aisle detection
  • 7.5.6. Aisle end stop
  • 7.5.7. Placement of floor magnets
  • 7.5.8. Routing the guide wire
  • 7.5.9. Guide wire routing and wire design
  • 7.5.10. Safety regulations and tolerances for narrow aisle
  • 7.6. Lift frame and cabin
  • 7.6.1. Chassis and lift frame
  • 7.6.2. Backward tilting of the mast
  • 7.6.3. Guide rollers pole / cabin and auxiliary lift / load carriage
  • 7.7. Chassis
  • 7.7.1. Lateral guidance (RG-rail guided vehicles)
  • 7.7.2. Perform crack detection at chassis
  • 7.8. Load axles and load wheels
  • 7.8.1. Load axle<and multiple disc brake
  • 7.9. Load wheel
  • 7.9.1. Testing of brake effectiveness of the load wheel brake system
  • 7.9.2. Dismounting of the brake
  • 7.9.3. Checking the release play and the lining thickness
  • 7.9.4. Exchanging the brake plates
  • 7.9.5. Visual check of the load wheel brake
  • 7.10. Mechanically released spring- loaded brake (magnet brake)
  • 7.10.1. Components of the magnetic brake
  • 7.10.2. Adjustment of the air gap
  • 7.10.3. Minimum brake lining thickness
  • 7.10.4. Adjusting the brake action
  • 7.10.5. Brake test
  • 7.11. Traction drive
  • 7.11.1. Removal and installation of the drive aggregate
  • 7.12. Swivel/traverse fork
  • 7.12.1. Adjustment of the tooth backlash
  • 7.12.2. Adjustment of the swivel chains
  • 7.13. Telescopic fork
  • 7.13.1. Standard telescopic fork (TF)
  • 7.13.2. Flat telescopic fork (FTF)
  • 7.13.3. Auxiliary lift pole
  • 7.13.4. Mechanical design of the telescope
  • 7.14. Fork test
  • 7.14.1. Inspection protocol for fork tine test
  • 7.15. Lift chains
  • 7.15.1. INSPECTION
  • 7.15.2. LIFT CHAIN LUBRICATION
  • 7.15.3. LIFT CHAIN REPLACEMENT
  • 7.16. Slack chain switches
  • 7.17. Master Speed Plus testing instruction
  • 7.17.1. Setting and test of the Master Speed Plus control with vmax/2.5 reversing curve
  • 7.17.2. Adjustment test
  • 7.17.3. Load capacity label
  • 7.17.4. Reversing height level vmax/v2.5
  • 7.17.5. Forward
  • 7.17.6. Reversing height level vmax/v2.5
  • 7.17.7. Backward
  • 8. Hydraulics
  • 8.1. General information
  • 8.1.1. Preparation, assembly and putting into operation of the FFZ hydraulics
  • 8.2. Torques
  • 8.3. Description of the hydraulic system
  • 8.3.1. General features
  • 8.3.2. Pump aggregate
  • 8.3.3. VCE135 Hydraulic system diagrams
  • 8.3.4. VCE100 Hydraulic system diagrams
  • 8.3.5. VCE135 Hydraulic installation in the bogie
  • 8.3.6. VCE135 Hydraulic installation in the rear of the vehicle
  • 8.3.7. VCE100 Hydraulic installation in the bogie
  • 8.3.8. VCE100 Hydraulic installation in the rear of the vehicle
  • 8.3.9. Tank
  • 8.3.10. Filler and breather
  • 8.3.11. Return flow filter
  • 8.3.12. Pump
  • 8.3.13. Lift module block
  • 8.3.14. Main lift/Auxiliary lift
  • 8.3.15. Auxiliary lift movement
  • 8.3.16. Return flow pressure control valve
  • 8.3.17. Lift module block H3
  • 8.4. Lift cylinders (main and auxiliary lift)
  • 8.4.1. Design of the cylinders
  • 8.4.2. Deairing the cylinder
  • 8.4.3. Replacing the sealing
  • 8.4.4. Removing and installing the main lift cylinder
  • 8.4.5. Replacing the lower cylinder rod guide
  • 8.4.6. Pipe-break protection / Load-lowering valve
  • 8.5. Hydraulic installation of the traverse fork (RFZ)
  • 8.5.1. Side view
  • 8.5.2. Front view
  • 8.5.3. Setting the shock valves (sideshift)
  • 8.5.4. Setting the load stabilizer valve (swiveling)
  • 8.5.5. Swivel cylinder
  • 8.5.6. Replacing the sealing
  • 9. Electrical equipment
  • 9.1. Block diagram of the control concept
  • 9.2. CAN bus description
  • 9.2.1. CAN bus features
  • 9.3. Components of the control systems
  • 9.3.1. General information concerning the components
  • 9.3.2. Drive compartment processing unit A14 / A18 with signal collector and distribution card
  • 9.3.3. Cabin processing unit with signal collector and distribution card
  • 9.3.4. Plug arrangement distributor board drive compartment
  • 9.3.5. Plug arrangement distributor board cabin
  • 9.4. Control panel
  • 9.4.1. Design of the Right Control Panel (UDR)
  • 9.5. Design of the left control panel (UDL)
  • 9.5.1. Bottom cover of UDL
  • 9.5.2. Removal of UDL
  • 9.5.3. Removal of the 2-keys board
  • 9.5.4. Removal of UDL main board
  • 9.5.5. Structure of the APE
  • 9.6. Operation of the APE
  • 9.6.1. Displays and menus on the APE
  • 9.6.2. Basic display
  • 9.6.3. Key functions in editable menus
  • 9.6.4. Information display
  • 9.6.5. Control panel test page
  • 9.6.6. Service menu
  • 9.7. Brakes
  • 9.7.1. Braking system description
  • 9.7.2. Spring-loaded brake system
  • 9.7.3. Load brake system
  • 9.7.4. Actuation of the load wheel brake
  • 9.7.5. Setting of the load wheel brake
  • 9.7.6. Electrical braking system
  • 9.7.7. General emergency stop
  • 9.7.8. Functional emergency stop
  • 9.8. Driving
  • 9.8.1. Drive speeds
  • 9.8.2. Adjustment of driving motion and electrical brake
  • 9.9. Steering
  • 9.9.1. Adjustment of the steering
  • 9.9.2. Interface for the steering AC-controller
  • 9.10. Triggering of the hydraulic system
  • 9.10.1. Triggering of the pump unit
  • 9.10.2. Proportional valve
  • 9.11. Functional relations
  • 9.11.1. Driving
  • 9.11.2. Manual steering
  • 9.11.3. Lifting / lowering the main lift
  • 9.11.4. Lifting/lowering the auxiliary lift
  • 9.11.5. Sideshift right / left
  • 9.11.6. Swiveling right / left
  • 9.11.7. Automatic synchronous swiveling right / left
  • 9.12. Aisle detection and storage zones
  • 9.12.1. Aisle detection (standard and optional)
  • 9.12.2. Wire guidance with aisle detection (IGwoA)
  • 9.13. Release of options via code numbers
  • 9.14. Aisle end stop (option)
  • 9.15. Functional description
  • 9.15.1. GESI with manual reset (code 0 activated)
  • 9.15.2. GESI with auto-reset (code 8 activated)
  • 9.15.3. GESI with positioning set-up (distance measurement)
  • 9.16. IG (induction guidance)
  • 9.16.1. System overview IG (induction guidance)
  • 9.16.2. Tasks of the IG
  • 9.16.3. Operation of the IG
  • 9.16.4. Safety concept of the emergency stop diamond
  • 9.16.5. Wire signal control
  • 9.16.6. Steering angle control
  • 9.16.7. Mechanical lock device (claw, if available)
  • 9.16.8. Actual driving speed control
  • 9.16.9. Full speed release
  • 9.16.10. Overview of emergency stop conditions
  • 9.16.11. Diagnosis
  • 9.16.12. Setting the IG
  • 9.17. Interface to PPS connection (personnel protection system)
  • 9.17.1. General information
  • 9.17.2. High-rise stacker with control system SECAN 2
  • 9.18. Setup of Sideshift and Swivel
  • 9.18.1. Sideshift
  • 9.18.2. Svivelling
  • 9.19. Automatic swiveling / sideshift synchronization
  • 9.19.1. Geometric adjustment
  • 9.19.2. Hydraulic adjustment (for VCE135)
  • 9.19.3. Hydraulic adjustment (for VCE100)
  • 9.20. Battery discharge monitor
  • 9.20.1. Calibration
  • 9.21. Hour meters
  • 9.22. Cut-outs
  • 9.22.1. Lifting cut-offs and lowering cut-outs (optional)
  • 9.22.2. Sideshift cut-out (second stacking depth)
  • 9.22.3. Driving cut-outs
  • 9.23. Sensor units main lift
  • 9.23.1. Laser odometer
  • 9.23.2. Reference switch 0,3 m
  • 9.23.3. Startup and check of the main lift sensor units
  • 9.24. Sensor units actual value steering
  • 9.24.1. Overview of sensor elements
  • 9.24.2. Adjustment of the steering sensor unit
  • 9.25. Sensor bearing drive- and steering motor (control system)
  • 9.25.1. Sensor bearing on the drive motor
  • 9.25.2. Sensor bearing of the steering motor
  • 9.26. Temperature sensor drive and pump motor
  • 9.26.1. Drive motor
  • 9.26.2. Pump motor
  • 9.27. Sensor unit auxiliary lift (version B)
  • 9.27.1. Sensor element
  • 9.27.2. Assembly and mechanical adjustment
  • 9.27.3. Calibration (Teach- In)
  • 9.27.4. Checking the settings
  • 9.28. Sensor unit sideshift
  • 9.28.1. Sensor element
  • 9.28.2. Assembly and mechanical adjustment
  • 9.28.3. Measuring of the potentiometer-setting
  • 9.28.4. Calibration (Teach- In)
  • 9.28.5. Checking the settings
  • 9.29. Sensor unit swiveling
  • 9.29.1. Sensor element
  • 9.29.2. Assembly and mechanical adjustment
  • 9.29.3. Measuring of the potentiometer-setting
  • 9.29.4. Calibration (Teach- In)
  • 9.29.5. Checking the settings
  • 9.30. Controlling the hydraulic system
  • 9.30.1. Introduction
  • 9.30.2. Overview Control of hydraulic functions by software modules
  • 9.30.3. Fault analysis hydraulic functions
  • 9.31. Control of the hydraulic system (1200-1400)
  • 9.31.1. Valve overview
  • 9.31.2. Overview usage of the valves for individual movements
  • 9.31.3. VCE135 Cyclograms (from the hydraulic point of view)
  • 9.32. Control of the hydraulic system VCE100
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