BT VCE100, VCE135 Service Manual 239880-040

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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: BT Service Manual PDF

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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