BT Vector VR 334965AA Master Service Manual 174803-040 – PDF DOWNLOAD

Description

BT Vector VR 334965AA Master Service Manual 174803-040 – PDF DOWNLOAD

FILE DETAILS:

BT Vector VR 334965AA Master Service Manual 174803-040 – PDF DOWNLOAD

Size: 11.3 MB
Fomat: PDF
Language: English
Brand: BT
Type of machine: Forklift – Vector
Type of document: Service Manual
Model: BT Vector VR
Serial Number: 334965AA
Order Nubmer: 174803-040
Page of number: 372 pages

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

BT Vector VR 334965AA Master Service Manual 174803-040 – PDF DOWNLOAD

Contents 3
General product information 9 3
1 Presentation of BT’s narrow aisle trucks 9 3
2 Application areas for BT’s narrow aisle trucks 9 3
3 Prohibited applications for BT’s narrow aisle trucks 10 3
4 Truck data 11 3
5 Truck dimensions 12 3
6 Identification plate, truck 14 3
7 Capacity plate 15 3
8 Modification plate 15 3
9 Identification plate, mast 16 3
10 Main components 17 3
11 Warning and information plates and symbols 20 3
Technical data 23 3
Introduction and safety, maintenance 27 3
1 Safety regulations with maintenance work 27 3
2 Cleaning and washing 30 3
3 Safe lifting 31 3
Preventive maintenance 33 3
1 Maintenance Schedule 33 3
Oil and grease specification 43 3
Tools 45 3
1 Electrical contacts 45 3
2 Miscellaneous tools 47 3
Chassis 49 4
1 General 49 4
2 List of tools 49 4
3 Transporting the truck 50 4
4 Assembling the mast 51 4
5 Installation in narrow aisles 55 4
Frame, mounted components 57 4
1 General tightening torque 57 4
Driver Protection 59 4
1 General 59 4
2 Tilt Stops 60 4
Electric Pump Motor 61 4
1 General 61 4
2 Dismantling the Pump Motor 61 4
3 Removing and Replacing the Pump Motor 62 4
4 Bearing Replacement 64 4
5 Installation Instructions for External Temperatur Sensor 66 4
Electric Steering Motor 69 4
1 General 69 4
2 Replacing the Steering Motor 69 4
3 Removing and Replacing the Carbon Brushes 69 4
Electric Drive Motor 71 5
1 General 71 5
2 Dismantling the Drive Motor 72 5
3 Dismantling and Assembling the Drive Motor 73 5
4 Bearing Replacement 75 5
5 Installation Instructions for External Temperature Sensor 77 5
Mechanical Drive Gear Unit 81 5
1 General 81 5
2 Drive/Transmission Assembly’s Main Components and Technical Data 82 5
3 Replacing the Drive Motor/ Drive Transmission 85 5
4 Checking/Replacing the Oil 88 5
5 Repairs 90 5
Travel brake system 95 5
1 Brake system 95 5
2 Description of function 96 5
3 Electromechanical disc brake, drive motor 100 5
4 Multiple disc brake, support arm 104 5
Drive wheel 109 5
1 General 109 5
2 Dismantling the drive wheel 109 5
3 Assembling the drive wheel 109 5
Electric steering wheel/lever 111 5
1 General 111 5
2 Replacement of the steering generator 111 5
Wire guidance 113 6
1 General 113 6
2 Generator 114 6
3 Wire guidance system overview 115 6
4 Wire guidance components 116 6
5 Operating description 123 6
6 Error Codes 131 6
Electrical System 143 6
1 General 143 6
2 Electronics Card, Frequency Inverter A1 and A2 145 6
3 Electronics Card, Fork Apparatus, A4 148 6
4 Electronics Card, Main Card, A5 152 6
5 Electrical System, Overview 160 6
6 Symbol List and Wiring Diagrams 162 6
7 Functional Description 202 6
8 Parameter 221 6
9 Instrument Panel and Display 240 6
10 Codes 243 6
Hydraulic system 279 6
1 General 279 6
2 Hydraulic schematics 280 6
3 Hydraulic components, positioning 284 6
Hydraulic pump 291 6
4 General 291 6
5 Replacing the hydraulic pump 292 6
Hydraulic connections 295 7
1 General 295 7
2 Tightening torque for hydraulic connections 295 7
3 Quick connection 300 7
Main lift chain system 303 7
1 General 303 7
2 Checking the chain adjustment 303 7
3 Checking the chain wear 304 7
4 Lubrication 305 7
Turret Head Fork Apparatus 307 7
1 General description 307 7
2 Inspection and maintenance 312 7
3 Adjustment of turret head fork apparatus 313 7
4 Replacing components 319 7
Charger BTCM 323 7
1 General 323 7
2 Installation 324 7
3 Function and use 324 7
4 Display and keyboard 327 7
5 Service and maintenance 333 7
6 Trouble shooting 336 7
7 Service actions 338 7
8 Preventive maintenance 339 7
Control/computer equipment 341 8
1 General 341 8
2 Connection 341 8
3 Layout 342 8
4 Function 344 8
5 Specifications 353 8
Position sensors 355 8
1 Height Indication and Height Pre-Set 355 8
2 Components for Height Indication/ Height Pre-Set 356 8
3 Height Indication 357 8
4 Height Indication 358 8
5 Display A8 359 8
6 Height Pre-Set 359 8
7 Function 360 8
8 Display A7 361 8
9 Assembly of height preset 363 8
10 Programming 363 8
11 Automatic operations 364 8
12 Parameters 366 8
13 Programming parameters 369 8
14 Error codes 371 8
General product information 9
1 Presentation of BT’s narrow aisle trucks 9
2 Application areas for BT’s narrow aisle trucks 9
3 Prohibited applications for BT’s narrow aisle trucks 10
4 Truck data 11
Truck type 11
VR 11
5 Truck dimensions 12
Dimensions (mm) 13
Dimensions, depending on lift height (mm) 13
6 Identification plate, truck 14
Item 14
Text 14
Unit 14
Item 14
Text 14
Unit 14
7 Capacity plate 15
Item 15
Text 15
Unit 15
8 Modification plate 15
Item 15
Text 15
9 Identification plate, mast 16
Item 16
Text 16
10 Main components 17
1 Mast: The mast is a hi-lo model for minimal mast height, see measurement h1 on the dimension d 17
2 Three-way fork carriage: The three-way fork carriage has two home positions that allow full sp 17
3 Battery: 48 V with different Ah values The dimensions of the battery tray conform to DIN-stan 17
4 Recharging connector: The battery is charged using a permanent recharging connector which is c 17
5 Control circuit fuse: 10A, BT part no 161640-100 Fuse for electrical steering wheel: 30 A, B 17
6 Hydraulic unit: Pump motor, pump and oil tank integrated in a compact unit 17
7 Hydraulic valves: The hydraulic valves are located in two different places on the truck depend 17
8 Drive unit with brake: Drive motor, gears and drive wheel combined into a compact unit Steeri 17
9 Electrical steering motor: Mounted with the drive gear to provide a compact design 17
10 Identification plate: With model designation, serial number, year of manufacture, weight with 17
11 Operator’s seat: The seat is fully adjustable to provide optimal operator comfort 17
12 Serial number: The serial number plate fitted to the chassis 17
13 Cover: Easily swivelled to provide good access for servicing 18
14 Pedals: Accelerator with optional direction selector, travel brake and safety pedal 18
15 Control console: The control console can be adjusted to a suitable height and angle to obtain 18
16 Instrument panel: This provides information on the truck’s running time, time indication, err 18
17 Roof panel: Panel with displays for height and length indication and push buttons for working 18
18 Electronics: Electronic equipment for lifting and driving functions is housed under the armre 18
19 Drive motor fuse: 160 A BT part no 29223 18
20 Pump motor fuse: 300 A, BT part no 29674 18
11 Warning and information plates and symbols 20
1 Modification plate 20
2 Identification plate 20
3 Capacity plate 20
4 Serial number 20
5 Hydraulic oil filling 20
6 Parking brake 20
7 Lifting points 20
8 Hydraulic controls: Lift-lower, fork traverse, rotation and auto-rotation 20
9 Do not walk under elevated load 20
10 Maximum height for rated capacity 20
11 Identification plate, mast 20
12 Risk of crushing 20
Technical data 23
Model 23
VR SF VR SF C 23
VR VR C 23
NOTE: 26
Introduction and safety, maintenance 27
1 Safety regulations with maintenance work 27
WARNING! 27
WARNING! 28
WARNING! 28
NOTE! 28
CAUTION! 28
11 Tilting the cab up on cold store trucks 29
WARNING! 29
NOTE! 29
12 Tilting the cab down on cold store trucks 29
WARNING! 29
2 Cleaning and washing 30
NOTE! 30
21 External cleaning 30
NOTE! 30
22 Cleaning the motor compartment 30
NOTE! 30
23 Electrical components 31
NOTE! 31
3 Safe lifting 31
WARNING! 31
Preventive maintenance 33
1 Maintenance Schedule 33
Oil and grease specification 43
Pos 43
Type of lubricant 43
Specification 43
Application 43
Tools 45
1 Electrical contacts 45
11 Super Seal contacts 45
Illustration 45
Number 45
Application 45
12 AMP contacts 46
Illustration 46
Number 46
Application 46
2 Miscellaneous tools 47
Illustration 47
Number 47
Application 47
Chassis 49
1 General 49
2 List of tools 49
3 Transporting the truck 50
4 Assembling the mast 51
NOTE 52
NOTE! 53
NOTE! 53
5 Installation in narrow aisles 55
51 General 55
52 Track-guided truck 55
53 Wire guided truck 55
54 General adjustment 55
Frame, mounted components 57
1 General tightening torque 57
11 Galvanised, non oiled bolts 57
12 Untreated, oiled bolts 57
Driver Protection 59
1 General 59
WARNING 59
2 Tilt Stops 60
21 Inspection and Adjustment 60
Electric Pump Motor 61
1 General 61
2 Dismantling the Pump Motor 61
3 Removing and Replacing the Pump Motor 62
31 Dismantling 62
32 Assembling 63
4 Bearing Replacement 64
41 Dismantling 64
42 Re-Assembly 65
NOTE 65
5 Installation Instructions for External Temperature Sensor 66
Electric Steering Motor 69
1 General 69
2 Replacing the Steering Motor 69
21 Dismantling 69
22 Re-Assembly 69
3 Removing and Replacing the Carbon Brushes 69
Electric Drive Motor 71
1 General 71
2 Dismantling the Drive Motor 72
3 Dismantling and Assembling the Drive Motor 73
31 Dismantling the Drive Motor 73
NOTE 73
311 Removing the gear wheel 73
312 Removing the brakes 73
32 Assembling the Drive Motor 74
321 Assembling the brakes 74
322 Assembling the gear wheel 74
NOTE 74
4 Bearing Replacement 75
41 Dismantling 75
411 N-side 75
412 D-side 75
42 Assembling 76
421 N-side 76
422 D-side 76
5 Installation Instructions for External Temperature Sensor 77
Mechanical Drive Gear Unit 81
1 General 81
2 Drive/Transmission Assembly’s Main Components and Technical Data 82
21 Position of Components 82
Position Nr 83
Component 83
22 Technical data 84
Type of Truck 84
VR, VR SF 84
23 Dismantling the Transmission 84
3 Replacing the Drive Motor/Drive Transmission 85
31 Dismantling the Drive Motor 85
NOTE 85
311 Removing the gear wheel 85
32 Removal of the Drive Transmission 86
33 Assembling the Drive Transmission 86
34 Installing the Drive Motor 87
341 Assembling the gear wheel 87
NOTE 87
4 Checking/Replacing the Oil 88
41 Checking/Refilling the Oil 88
42 Changing the Oil 88
5 Repairs 90
51 Replacing the Drive Shaft Gasket 90
511 Dismantling: 90
NOTE 90
512 Re-Assembly: 91
52 Leakage from the Upper Cover 92
53 Leakage from the Lower Cover 92
54 Replacing Wheel Bolts 93
Travel brake system 95
1 Brake system 95
11 General 95
1 Regenerative motor braking with the drive motor 95
2 A one-step electromechanical disc brake fitted to the motor 95
3 Four analogue electromechanical multiple disc brakes fitted in the support arm wheels (option) 95
2 Description of function 96
21 Releasing the accelerator 96
22 Changing travel direction 96
23 Pressing the brake pedal (without support arm brake) 97
24 Pressing the brake pedal (with support arm brakes) 98
25 Parking brake 99
26 Emergency braking 99
3 Electromechanical disc brake, drive motor100
31 Assembling100
NOTE!101
32 Dismantling101
321 Inspection101
NOTE!101
322 Assembling101
33 Maintenance102
NOTE!102
331 Adjustment of play102
332 Wear102
333 Checking the braking force103
NOTE!103
4 Multiple disc brake, support arm104
41 Assembly104
NOTE!104
42 Dismantling105
NOTE!105
NOTE!105
421 Inspection106
NOTE!106
422 Assembling106
NOTE!106
43 Maintenance106
431 Adjusting the amount of play107
NOTE!107
Drive wheel109
1 General109
2 Dismantling the drive wheel109
3 Assembling the drive wheel109
Electric steering wheel/lever111
1 General111
2 Replacement of the steering generator111
21 Dismantling111
22 Assembly111
Wire guidance113
1 General113
2 Generator114
21 Technical data114
3 Wire guidance system overview115
4 Wire guidance components116
41 Antennae, W1, W2116
411 Installation of new antenna117
NOTE!117
412 Antenna cable117
42 Control unit, A3118
421 Connections118
422 Display121
423 Installation of a new WG-control unit121
43 Home position sensor, S85121
NOTE!121
431 Adjusting the sensor121
44 Steering angle sensor, U15122
441 Straight wheel, electrically-mechanically122
45 Diverse123
5 Operating description123
51 Run mode123
511 Manual mode124
512 Auto mode124
52 Service mode125
521 Parameters126
No 126
Parameter type126
Unit126
Min/ max126
Std value126
Comments126
53 Parameter 36126
531 Parameter value 0126
532 Parameter value 1127
533 Parameter value 2127
534 Parameter value 3, “Learn offset“127
NOTE!127
NOTE!127
NOTE!128
535 Parameter value 4, “Learn frequency“128
54 Parameter 71129
Parameter value129
kHz129
mA RMS129
Notes129
Note:129
55 Parameter 72129
56 Parameter 73130
57 Parameter 74130
NOTE!130
58 Parameter 75130
NOTE!130
6 Error Codes131
61 Error codes detected by electronic card A5131
62 Error code detected by electronic card A3, WG-control unit134
Electrical System143
1 General143
2 Electronics Card, Frequency Inverter A1 and A2145
21 General145
22 Terminal Connections and Pole Bolts146
Term146
Cable A1/A2146
Designation146
Active146
Input/ output146
23 Technical Data147
Parameter147
Setting147
Unit147
Description147
24 Installation of New Frequency Inverter on Truck147
25 Programming147
3 Electronics Card, Fork Apparatus, A4148
31 General148
32 Terminal Connections149
Term149
Cable149
Designation149
Active149
Input/ output149
321 Status of inputs and outputs151
33 Installation of New Card on Truck151
34 Programming151
4 Electronics Card, Main Card, A5152
41 General152
42 Terminal Connections and Voltages on A5153
421 10X153
Term153
Cable153
Description153
Active (V)153
LED153
422 20X154
Term154
Cable154
Designation154
Active (V)154
LED154
423 30X154
Term154
Cable154
Designation154
Active (V)154
LED154
424 40X155
Term155
Cable155
Designation155
Active (V)155
LED155
425 50X155
Term155
Cable155
Designation155
Active (V)155
LED155
426 60X156
Term156
Cable156
Designation156
Active (V)156
LED156
427 70X156
Term156
Cable156
Designation156
Active (V)156
LED156
428 80X157
Term157
Cable157
Designation157
Active (V)157
LED157
429 90X157
Term157
Cable157
Designation157
Active (V)157
LED157
LED158
Colour158
Function158
Potentiometer158
Function158
43 Installation of New Card on Truck158
44 Programming158
5 Electrical System, Overview160
6 Symbol List and Wiring Diagrams162
61 Symbol List162
Symbol162
Description162
Symbol162
Description162
62 Wiring Diagram (1/25)165
63 Wiring Diagram (2/25)166
64 Wiring Diagram (3/25)167
65 Wiring Diagram (4/25)168
66 Wiring Diagram (5/25)169
67 Wiring Diagram (6/25)170
68 Wiring Diagram (7/25)171
69 Wiring Diagram (8/25)172
610 Wiring Diagram (9/25)173
611 Wiring Diagram (10/25)174
612 Wiring Diagram (11/25)175
613 Wiring Diagram (12/25)176
614 Wiring Diagram (13/25)177
615 Wiring Diagram (14/25)178
616 Wiring Diagram (15/25)179
617 Wiring Diagram (16/25)180
618 Wiring Diagram (17/25)181
619 Wiring Diagram (18/25)182
620 Wiring Diagram (19/25)183
621 Wiring Diagram (20/25)184
622 Wiring Diagram (21/25)185
623 Wiring Diagram (22/25)186
624 Wiring Diagram (23/25)187
625 Wiring Diagram (24/25)188
626 Wiring Diagram (25/25)189
627 Component List190
Symbol190
Description/function190
Component figure190
628 Component identification197
6281 Figure 1197
6282 Figure 2197
6283 Figure 3197
6284 Figure 4198
6285 Figure 5199
6286 Figure 6200
6287 Figure 7201
7 Functional Description202
Description202
Diode number202
71 Key in Position 0203
Description203
Diode number203
72 Key in Position I, Driver Seated203
Description204
Diode number204
73 Direction of Travel Selection204
Description204
Diode number204
74 Driving205
Description205
Diode number205
75 Travel speeds206
751 Outside narrow aisles and the forks in the “home position”206
752 Rail guided trucks206
753 Wire guided truck208
76 Steering209
Description209
Diode number209
761 Steering wheel indicator209
762 Track-guided narrow aisle210
Description210
Diode number210
763 Wire guidance210
77 Braking210
771 Auto-brakes210
772 Motor brakes (electric)210
773 Foot brakes211
774 Support arm brakes211
Description211
Diode number211
775 Parking brakes211
78 Aisle-End Slowdown212
79 Fork Lifting212
Description212
Diode number212
710 Height Indication213
Description213
Diode number213
711 Lift height limit213
Description213
Diode number213
712 Height Pre-Set214
Description214
Diode number214
713 Fork Lowering214
Description215
Diode number215
714 Lateral Movement/Traversing of Forks215
Description215
Diode number215
7141 Parameters to check/adjust216
Parameter216
Function216
715 Rotating the Forks216
Description216
Diode number216
7151 Parameters to check/adjust217
Parameter217
Function217
716 Simultaneous Traversing and Rotation Movement217
7161 Manual217
7162 Auto-rotation217
NOTE217
Description217
Diode number217
7163 Parameters to check/adjust218
Parameter218
Function218
7164 Auto-rotation right (traversing right/rotation counter clockwise)218
7165 Auto-rotation left (traversing left/rotation clockwise)218
7166 Auto-rotation with stop straight ahead, 90o218
717 Extra Hydraulic Functions219
NOTE219
Description219
Diode number219
7171 Parameters to check/adjust219
Parameter219
Function219
718 Weighing219
719 Driver Identification220
Description220
Diode number220
8 Parameter221
81 Parameter Settings221
NOTE:221
Nr221
Parameter type221
Unit221
Min/ max221
Std value221
Comments221
82 Parameter 1227
83 Parameter 2227
84 Parameter 3227
85 Parameter 4227
86 Parameter 5227
87 Parameter 6227
88 Parameter 7228
89 Parameter 8228
810 Parameter 10228
Value228
Driver number228
811 Parameter 11228
812 Parameter 12228
813 Parameter 13229
814 Parameter 14229
815 Parameter 15229
816 Parameter 16229
817 Parameters 17 and 18229
818 Parameter 19230
Lift height230
Basic settings, free lift height230
819 Parameter 20230
820 Parameter 21230
Value231
Function231
Battery (Ah)231
WARNING231
821 Parameter 22232
822 Parameter 23232
1 Warning signal sounds when the truck moves in the steering wheel-direction only232
2 Warning signal sounds when the truck moves in the fork- direction only232
3 Warning signal sounds for motion in both directions232
4 Only the waring signal when the truck travels in the steering wheel direction outside of the n232
5 Only the waring signal when the truck travels in the fork direction outside of the narrow aisle232
6 Warning signal sounds for travel in both directions outside narrow aisles232
823 Parameter 24232
824 Parameter 25232
825 Parameter 26232
826 Parameter 27233
827 Parameter 28233
828 Parameter 29233
829 Parameter 36233
830 Parameter 37233
831 Parameter 38234
8311 Calibration of acceleration and braking potentiometers234
NOTE234
8312 Calibration of fork movement234
NOTE234
832 Parameter 39235
8321 Show/programming choices with parameter 39235
Para- meter235
Key S17 switched on, then switch I235
Switch I and key S17 switched on simultaneously235
833 Parameters 40 to 42235
834 Parameter 43235
NOTE235
835 Parameter 44236
NOTE236
836 Parameter 45236
NOTE236
837 Parameter 46236
838 Parameter 47236
839 Parameter 48236
840 Parameter 50237
841 Parameter 51237
842 Parameter 53237
843 Parameter 54238
844 Parameter 55238
845 Parameter 56238
846 Parameter 57238
847 Parameter 58238
848 Parameter 59239
849 Parameter 60239
850 Parameter 61239
851 Parameter 62239
852 Parameter 63239
853 Parameter 64239
854 Parameter 65240
855 Parameter 66240
856 Parameter 67240
9 Instrument Panel and Display240
91 Show240
92 Operating Time241
Character241
Time241
93 Programming242
931 Clock242
Function242
Value242
NOTE242
932 Driver parameters (1–7)242
10 Codes243
101 Warning Codes243
Character243
Error243
WARNING243
102 Error mode244
Error mode244
Explanations/corrective actions244
103 Safety Logic245
Action: Function:245
K10 open245
Y1 activated245
Reversing with M1245
Steering disabled245
Function at A2 halted245
104 Warning Codes without Registration245
105 Warning Codes with Registration255
106 Error Codes264
Character264
Error264
WARNING264
107 Error Codes with Registration265
Hydraulic system279
1 General279
2 Hydraulic schematics280
21 Symbols280
Symbol280
Description280
Symbol280
Description280
22 Hydraulic schematics282
23 Component description283
Pos283
Description283
Function283
Remark283
3 Hydraulic components, positioning284
31 Overview284
Pos284
Description284
Remark284
32 Hydraulic unit286
Pos287
Description287
Remark287
33 Fork unit288
Pos289
Description289
Remark289
34 Cab tilt function (cold store cab)290
Pos290
Description290
Remark290
Hydraulic pump291
4 General291
5 Replacing the hydraulic pump292
51 Dismantling292
52 Assembling294
Hydraulic connections295
1 General295
2 Tightening torque for hydraulic connections295
21 Conical connection with O-ring295
Dimension ø [mm]295
Tightening torque [Nm]295
Tightening angle []295
22 Tredo seal296
Dimension296
Tightening torque [Nm]296
23 Pipe couplings296
24 Connections screwed into aluminium297
Designation with cutting edge297
Dimension297
Torque [Nm]297
25 Connections screwed into steel297
251 Pressure class L298
Designation with cutting edge298
Dimen- sion298
Torque [Nm]298
Designation with EOLASTIC sealing ring298
Dimen- sion298
Torque [Nm]298
252 Pressure class S299
Designation with cutting edge299
Dimen- sion299
Torque [Nm]299
Designation with EOLASTIC sealing ring299
Dimen- sion299
Torque [Nm]299
3 Quick connection300
31 Assembling300
1 Fit the assembly stop (1) on the male fitting and ensure that the dismantling ring (2) runs fr300
2 Press in the male fitting in the female fitting until the assembly stop has contact with the f300
3 The coupling is now made and locked300
32 Dismantling301
1 Remove the assembly stop (by using a screwdriver or the like)301
2 Push the male fitting fully in the female fitting301
3 Pull out the male fitting from the female fitting Fit the assembly stop on the male fitting a301
Main lift chain system303
1 General303
2 Checking the chain adjustment303
3 Checking the chain wear304
31 Outline wear304
32 Stretching305
4 Lubrication305
NOTE!305
NOTE!305
Turret Head Fork Apparatus307
1 General description307
11 Main Components308
Pos309
Description309
Comments309
12 Fork turning310
13 Side-shift movement311
2 Inspection and maintenance312
21 External inspection312
22 Inspection312
23 Maintenance312
3 Adjustment of turret head fork apparatus313
31 Fork carriage, end position rotation313
32 Setting tooth flank play313
1 Set the fork unit in the centre of the stroke length with the forks pointing straight forwards313
2 Dismantle the cover (2) over the valve block and pulse generator bearing313
3 Lock the transmission axle by using a simple tool (see section 321) Fit the tool with a bol314
4 Start by setting the lower rollers The play is measured using an indicator gauge with a magn314
5 The play should be 01-02 mm If the play is more or less the rollers should be adjusted314
6 Use an allen key (14 mm) to adjust the rollers’ eccentric axles314
7 Loosen the nuts and turn the eccentric axles so that the support roller’s are unloaded The co314
8 Turn the axles until the rollers come into contact with the support surface Continuing to tur314
9 When adjusting the upper rollers the eccentric axles are turned so that the cog axle runs into314
10 When adjusted correctly, the axles should be adjusted equally and the column should stand at 314
11 Tighten the nuts on eccentric axles to 220 Nm (22 kpm) Test the apparatus314
12 As little tooth flank play as possible is desirable, but with too hard a contact the apparatu314
13 Lock the locking nuts with the locking strip314
321 Tools315
33 Adjusting the apparatus’ lateral play on the mast guide316
NOTE!316
34 Potentiometer for the turning movement317
35 Inductive sensor for the home position, side-shift318
4 Replacing components319
41 Turning chain319
NOTE!319
42 Turning bearing320
421 Dismantling320
422 Replacing bearings321
NOTE!321
NOTE!321
NOTE!322
423 Assembly322
NOTE!322
NOTE!322
Charger BTCM323
1 General323
2 Installation324
3 Function and use324
31 Charging process324
32 Shut-off conditions325
33 Delayed start and charging325
34 Extra charging325
35 Equalisation charge326
36 Current and voltage characteristics326
37 Safety shut-off326
4 Display and keyboard327
41 General327
411 Reading analog measurement values327
412 Error indication and error messages328
413 Reading statistics from the previous charging process329
414 Reading long-term statistics329
415 Saving parameters in general330
416 Reading parameters330
NOTE!330
417 Battery specific parameters331
418 Charger specific parameters331
419 Mains voltage codes332
4110 Other functions332
4111 Changing of parameters332
5 Service and maintenance333
51 Basic programming, code 30333
52 Resetting the statistics, code 31333
53 Calibrating measurement values333
531 General333
532 Calibrating the current’s zero value and temperature, code 21334
NOTE!334
533 Calibrating the battery current’s measurement value, code 20334
534 Calibrating the charging current, code 25334
535 Calibrating the mains voltage indication, code 26334
54 Modifying the charging characteristics335
55 Printing to a printer335
551 General335
552 Printing data from EE-prom335
553 Automatic print-out of statistics335
554 Automatic logging of the charging process335
6 Trouble shooting336
61 General336
62 Error messages, analysis and actions336
621 E22 = low counter voltage336
622 E30 = high temperature336
623 E25 = low current336
624 E52 = phase fault336
625 E70 = incorrect information in the motherboard’s EE- prom337
626 E72 = error with the motherboard’s EE-prom337
627 E76 = Error with the computer board’s EE-prom337
628 E77 = the data in the computer board and motherboard’s EE-proms is valid but not the same337
629 Faults without indication337
7 Service actions338
71 General338
72 Switching to timer charging338
73 Replacing the display card338
74 Replacing the computer board338
75 Replacing the motherboard339
NOTE!339
76 Replacing the diodes339
8 Preventive maintenance339
Control/computer equipment341
1 General341
11 Production mode341
2 Connection341
3 Layout342
31 Main window342
32 Nodes343
321 Icons343
Icon343
Description343
33 Tool buttons344
34 Information window344
35 Status bar344
4 Function344
41 Connection344
42 Disconnection345
43 Downloading program345
431 Normal downloading346
432 Downloading in old versions of logic card346
433 Emergency downloading346
NOTE!346
44 Truck report347
45 Parameters348
NOTE!348
46 Diagnostics349
NOTE!349
461 Analogue349
462 Temperature350
NOTE!350
463 Digital350
47 User settings350
48 Other functions351
481 Save to file351
482 Download from file351
483 Reset CAN adapter351
484 Delete error code log351
485 Reset hour meter351
486 Read error code log351
487 Adjust date and time351
NOTE!351
488 Adjusting the hour meter on older cards351
49 Help352
491 About TruckCom352
492 Link352
410 Exit352
5 Specifications353
51 CAN interface353
Description353
Value353
Unit353
52 Installation353
53 To uninstall353
Position sensors355
1 Height Indication and Height Pre-Set355
11 General355
2 Components for Height Indication/ Height Pre-Set356
3 Height Indication357
Designation357
Diode number357
4 Height Indication358
5 Display A8359
Terminal Number359
Connection359
Function359
6 Height Pre-Set359
7 Function360
8 Display A7361
Terminal Number361
Connector361
Function361
81 Description of the display symbols362
Symbol362
Function362
9 Assembly of height preset363
10 Programming363
101 Programming a level363
1011 Collection level363
1012 Leaving level363
102 Erasing programmed levels364
11 Automatic operations364
111 Collect load364
112 Leaving a load365
113 Control365
12 Parameters366
NOTE!366
121 P1366
122 P2366
123 P3367
124 P4367
125 P5367
126 P7368
127 P8368
128 P9368
13 Programming parameters369
Parameter Number369
Max/min value369
Factory value369
Unit369
Function369
Position370
Function370
14 Error codes371
Error code371
Remarks371

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S.V 08/24