BL SL 2.0 Product family SL Master Service Manual 170422-040 - PDF DOWNLOAD

Master Service Manual Product family SL

%7 6/

& &RGH UHYLVLRQ © BT Industries AB

Part number: 170422-040 Issued : 1998-12-18 SSD

F-code

Section

C-code

6/

,QWURGXFWLRQ WR %7¶V 6HUYLFH 0DQXDO IIssued by

Approved by

66'

,UpQH .DUOVVRQ

Version no

T-code

,QWURGXFWLRQ WR %7¶V 6HUYLFH 0DQXDO This Service manual contains product information regarding the current trucks including the technical data and instructions for maintenance and service. It includes the operator’s Instruction Manual, Spare Part Handbook and oil and grease specifications: M

Machine information

P

Preventive maintenance

S

Service instructions

O

Options

At the top of each page you can find information on which section the page belongs: 6HFWLRQ M 5.0 means that it is Product improvements; ) FRGH means it deals with this specific truck family; 7 FRGH means specific products; 'DWH and 9HUVLRQ QXPEHU give information on when the page was issued and which version.

It is our ambition to send modification notifications concerning improvements to you as soon as possible. It’s stated on the notifications which section/s in the binder should be replaced; note that the HQWLUH section should be replaced! Notifications should be inserted immediately so that the binder always contains current service information.

When contacting BT’s technical support always have the actual Service Manual close at hand. If you have any views regarding the Service Manual, please contact your training officer at BT who will forward your views to the technical documentation department.

This document can be available on different media and will have different part numbers. Please see the following example: 123456-040 = An English document on paper 123456-04F = The same document but on fiche 123456-04C = The same document but on CD-ROM

© BT Industries AB

Service Manual

1998-09-23

English

1 (2)

F-code

Section

Version no

T-code

C-code

6/

,QWURGXFWLRQ WR %7¶V 6HUYLFH 0DQXDO

2 (2)

Service Manual

1998-09-23

English

F-code

Section

C-code

6/

&RQWHQWV 0DVWHU 6HUYLFH 0DQXDO 060

IIssued by

66'

Approved by

*|UDQ )UDQ]pQ

Version no

T-code

&RQWHQWV 0DVWHU 6HUYLFH 0DQXDO 060

3DUW QXPEHU

,VVXHG

Valid from serial number: 7 FRGH

0RGHO

6HULDO 1R

378

SL 2.0

326301AA-

1RWHV

'RFXPHQW OLVW 6HFWLRQ

'RFXPHQW

,VVXHG

Introduction

1998-09-23

M

Contents M

1998-11-04

M1

Operators manual

1998-12-18

M2

General product information

1998-05-07

M4

Technical service data

1998-05-07

M6

Ordering Spare Parts

1998-11-04

M7

Quality Parts

1998-12-18

P

Contents P

1998-11-04

P1

Introduction, maintenance

1998-10-28

P2

Service schedule

1998-05-07

P3

Oil and grease specification

1998-06-22

S

Contents S

1998-11-04

S3

3370

Brakes

1998-08-20

S5

5000

Electrical system

1998-06-24

5460

Transistor panel

1998-07-27

5710

Elektronic card

1998-07-31

6000

Hydraulics

1998-08-19

S6

© BT Industries AB

& FRGH

Service Manual

1998-12-18

English

1 (2)

F-code

Section

Version no

T-code

C-code

6/

&RQWHQWV 0DVWHU 6HUYLFH 0DQXDO 060

2 (2)

Service Manual

1998-12-18

English

F-code

Section

6/ IIssued by

66'

Approved by

0

Version no

C-code

&RQWHQWV 0

T-code

&RQWHQWV 0 7UXFN LQIRUPDWLRQ

© BT Industries AB

M1

Operator’s Manual

M2

Product information

M3

Product sheet

M4

Technical data

M5

Product improvements

M6

Spare Part ordering

M7

Quality Parts

M8

Recommended Spare Parts

Service Manual

1998-11-04

English

1 (2)

F-code

Section

Version no

T-code

6/ 0 &RQWHQWV 0

2 (2)

C-code

Service Manual

1998-11-04

English

F-code

Section

6/ IIssued by

Approved by

66'

Version no

* )UDQ]pQ

C-code

0 2SHUDWRU¶V PDQXDO T-code

2SHUDWRU¶V PDQXDO Valid from serial number: 7 FRGH

0RGHO

6HULDO 1R

378

SL 2.0

326301AA-

1RWHV

*HQHUDO An Operator´s Manual is supplied with every truck. If, for any reason, the customer does not obtain an Operator´s Manual, they can be ordered from BT. In the table below, you can see which Operator´s Manuals are available for this machine series.

,VVXHG RSHUDWRU¶V PDQXDOV 7 FRGH

0RGHO

6HULDO QXPEHU

2UGHU QXPEHU

,VVXHG

378

SL 2.0

326301AA-

845250-040

1998-07-07

In this Master Service Manual can be found a typical Operator´s Manual for the machine series. We have chosen this for your own safety when working with the truck.

© BT Industries AB

Service Manual

1998-12-18

English

1 (2)

F-code

Section

Version no

T-code

6/ 0 2SHUDWRU¶V PDQXDO

2 (2)

C-code

Service Manual

1998-12-18

English

F-code

6/ IIssued by

66'

Approved by

)UHGULN :LJK

Section

C-code

0 *HQHUDO SURGXFW LQIRUPDWLRQ

Version no

T-code

*HQHUDO SURGXFW LQIRUPDWLRQ Valid from serial number: 7 FRGH

0RGHO

6HULDO 1R

378

SL 2.0

326301AA-

1RWHV

3UHVHQWDWLRQ RI WKH WUXFN Good driver ergonomics have a positive influence on productivity and this knowledge has been a guiding star in the development of BT’s stand-on vehicles.

SL 2.0 has a lifting capacity of 2000 kg.

The truck is equipped with mini-wheel and progressive electrical servo. The throttle is ergonomically positioned on a control panel. All the instruments are placed together on a clear display unit which provides the driver with all the necessary information in order to successfully operate the truck, e.g. hour meter, battery indicator and error codes.

The stand-on vehicle’s construction is based on the same techniques used for BT’s reach trucks, with easy access to components and simple servicing.

,QWHQGHG DSSOLFDWLRQ RI WKH WUXFN The truck is solely designed and manufactured to handle goods. The trucks should be fitted with the appropriate accessories relevant to the application.

)RUELGGHQ DSSOLFDWLRQ RI WKH WUXFN The truck is designed for handling goods indoors. It is not permitted to use the truck for other purposes including the following: - In areas that contain dust or gases which can cause fires or explosions - As a tow-truck for trailers - To tow other trucks - To transport/lift passengers - To drive on gravel or grass © BT Industries AB

Service Manual

1998-05-07

English

1 (8)

F-code

Section

Version no

T-code

C-code

6/ 0 *HQHUDO SURGXFW LQIRUPDWLRQ

7UXFN GDWD The table provides information regarding some technical data, which is of value with daily use of the truck.

7UXFN W\SH

6/

Lifting capacity with rated load, kg

2000

Operating speed without load, m/s

2,9

Operating speed with rated load, m/s

2,0

Max. operating gradient with rated load, %

8

Time of lifting, without load, s

2,5

Time of lifting, with rated load, s

3,0

Time of lowering, without load, s

2,8

Time of lowering, with rated load, s

2,8

Weight without battery, kg

630

Battery (5h discharge)

300 / 450

Weight of battery, kg

280 / 400

Truck’s calculated equivalent acoustic pressure level according to CE prEN 12053, dB (A)

< 70

Truck’s calculated equivalent acoustic pressure level according to ASME B56.11.5_1992, dB (A) 65 Vibration level, m/s2

0,7

The truck’s lifting capacity, lift height and weight can be found on the truck’s identification plate.

2 (8)

Service Manual

1998-05-07

English

F-code

Section

C-code

6/ 0 *HQHUDO SURGXFW LQIRUPDWLRQ Version no

T-code

7UXFN GLPHQVLRQV The illustration shows external dimensions for the truck in its standard design.

h6

h7 m1

W

h3 h13

D

b5

b1 e l

l2

© BT Products AB

Service Manual

1998-05-07

English

3 (8)

F-code

Section

Version no

T-code

C-code

6/ 0 *HQHUDO SURGXFW LQIRUPDWLRQ

'LPHQVLRQV PP

6/

b1 Chassis

770

b5 Width across fork

450-685

e Fork width

180

h3 Lift hight

235

h6 Height of truck

1260

h7 Instep height

235

h13 Height of lowered fork

90

l Fork length

1000, 1150, 1450, 2350

l2 Truck length excl. forks Medium chassis

874

m1 Floor clearance

36

Wa Turning radius medium chassis

1855

0DLQ FRPSRQHQWV 1. &RQWURO FRQVROH Steering, raise/lower, signal, travel direction, accelerator/ brake, and all hydraulic functions are operated from the control console.The control console also includes the emergency switch off, the ignition key and the display.

The display provides information relating to the truck’s operating time in a display window, error codes and indicators: steering position forward, parameter control and battery charge status.

2. ,GHQWLILFDWLRQ SODWH With model designation, serial number, year of manufacture, weight without battery, battery weight, rated capacity, battery voltage and manufacturer.

3. 6HULDO QXPEHU The serial number plate fitted to the chassis.

4. &RYHU Easily swivelled to provide good access for servicing.

5. 3HGDO Safety pedal with automatic parking brake.

4 (8)

Service Manual

1998-05-07

English

F-code

Section

C-code

6/ 0 *HQHUDO SURGXFW LQIRUPDWLRQ Version no

T-code

6. /HIW IRRW SHGDO Safety pedal for the left foot.

7. 'ULYH PRWRU IXVH 160A, BT part no. 29223.

8. 3XPS PRWRU IXVH 200A, BT part no. 29673.

9. &RQWURO FLUFXLW IXVH 10A, BT part no. 122308-100.

10. )XVH IRU HOHFWULFDO VWHHULQJ ZKHHO 20A BT part no.122308-200.

11. (OHFWURQLFV All the electronics are located together in a protected area of the motor.

12. (OHFWULFDO VWHHULQJ PRWRU Mounted with the drive gear to provide a compact design.

13. %DWWHU\ 24V with different Ah values.

14. 5HFKDUJLQJ FRQQHFWRU The battery is recharged via this permanently attached recharging connector.

15. +\GUDXOLF XQLW Pump motor, pump, valve and oil tank.

16. 'ULYH XQLW ZLWK EUDNH Drive motor, gears and drive wheel integrated in a compact unit. Steering bearings between the motor and gears.

© BT Products AB

Service Manual

1998-05-07

English

5 (8)

F-code

Section

Version no

T-code

C-code

6/ 0 *HQHUDO SURGXFW LQIRUPDWLRQ

1 13 2

14

3 4

5 6

7 15 8 9 10

16

11 12

6 (8)

Service Manual

1998-05-07

English

F-code

Section

C-code

6/ 0 *HQHUDO SURGXFW LQIRUPDWLRQ Version no

T-code

:DUQLQJ DQG LQIRUPDWLRQ SODWHV DQG V\PEROV The figure shows the position and significance of the plates and symbols located on the truck.

1.

2.

3.

4.

5.

6.

7.

8.

9.

© BT Products AB

Identification plate Modification plate Serial number Hydraulic oil filling Lifting points Travel control Brake control Horn Hydraulic control: Lifting/Lowering

Service Manual

1998-05-07

English

7 (8)

F-code

Section

Version no

T-code

C-code

6/ 0 *HQHUDO SURGXFW LQIRUPDWLRQ

8 (8)

Service Manual

1998-05-07

English

F-code

6/ IIssued by

66'

Approved by

)UHGULN :LJK

Section

C-code

0 7HFKQLFDO 6HUYLFH 'DWD

Version no

T-code

7HFKQLFDO 6HUYLFH 'DWD Valid from serial number: 7 FRGH

0RGHO

6HULDO 1R

378

SL 2.0

326301AA-

0RGHO

1RWHV

6/

'ULYH PRWRU Type

TTL 140BB-D21

Power, kW

2.2

Intermittence, %

60

Min. carbon brush length, mm

12

Min. commutator diameter, mm

60

7UDQVPLVVLRQ JHDU Type

2-step angle gear

Gear ratio

17.04:1

Oil volume, liter

1.75

Oil type Normal temperature Temperatur < -15o C

Hypoid oil SAE 80W/90 SAE 75W

:KHHO

© BT Industries AB

Drive wheel, mm

Dia 250x95

Axle pressure without load, kg

770

Axle pressure with calssified load, kg

1210

Wheel bolts’ tightening torque, Nm

90

Support arm wheels, mm

2x Dia 85x75

Axle pressure without load, kg

225

Axle pressure with classified load, kg

1750

Castor wheel, mm

Dia 150x40

Axle pressure without load, kg

770

Axle pressure with classified load, kg

1210

Service Manual

1998-05-07

English

1 (4)

F-code

Section

Version no

T-code

6/ 0 7HFKQLFDO 6HUYLFH 'DWD

C-code

0RGHO

6/

+\GUDXOLF V\VWHP Power, kW

2.0

Intermittents, %

20

Min. carbon brush length

12

Min. commutator diameter

43

Pressure at classified load, bar

120

Overflow pressure, bar

130

Pump flow, cc/r

2.5

Tank volume, litres

1.2

Oil type: at normal temperature at temperature <-15° C

ISO-L-HM32 ISO-L-HV32

6WHHULQJ PRWRU Power, W

160

Intermittents, %

60

Min. carbon brush length, mm

9

Min. commutator diameter

-

)XVHV Control circuits

10 A / 122308-100

Steering motor

20 A / 122308-200

Drive motor

160 A / 29223

Pump motor

200 A / 29673

%DWWHU\ Dimensions WxLxH

280x614x600-775

Capacity, Ah

330-400

Weight, kg

288-400

'ULYLQJ VSHHG

2 (4)

Without load

10.5 km/h, 2.9 m/s

With classified load

7.5 km/h, 2.1 m/s

Service Manual

1998-05-07

English

F-code

6/

Section

Version no

T-code

0RGHO

C-code

0 7HFKQLFDO 6HUYLFH 'DWD

6/

/LIWLQJ ORZHULQJ VSHHG Lifting without load, sec.

2.5

Lifting with classified load, sec.

3.0

Lowering without load, sec.

2.8

Lowering with classified load, sec.

2.8

3RZHU FRQVXPSWLRQ

© BT Products AB

Driving without load, A

55

Driving with classified load, A

65

Lifting without load, A

65

Lifting with classified load, A

130

Service Manual

1998-05-07

English

3 (4)

F-code

Section

Version no

T-code

6/ 0 7HFKQLFDO 6HUYLFH 'DWD

4 (4)

C-code

Service Manual

1998-05-07

English

F-code

Section

6/ IIssued by

66'

Approved by

Version no

C-code

0 2UGHULQJ 6SDUH 3DUWV T-code

2UGHULQJ 6SDUH 3DUWV • Localise the fault on the truck.

• Find out the machine type and machine number.

• Find the machine type and machine number in the spare part catalogue’s list of contents.

• Look up the page with the exploded diagram and locate the position number for the part you require.

• Look up the position number in the table. Select the column with regard to the actual machine type and machine number.

• Note the article number.

• Call the Truck Centre and state the article number.

The Truck Centre will now order the actual article via computer from BT Parts. The article is delivered by DDD during the night and the next day you will have the part (If you place the order after 4.30 pm the delivery will be delayed).

If you cannot find the machine type, machine number or the article number call the Truck Centre and they will help you.

© BT Industries AB

Service Manual

1998-11-04

English

1 (2)

F-code

Section

Version no

T-code

6/ 0 2UGHULQJ 6SDUH 3DUWV

2 (2)

C-code

Service Manual

1998-11-04

English

F-code

Section

6/ IIssued by

66'

Approved by

0

Version no

* )UDQ]pQ

C-code

4XDOLW\ 3DUWV

T-code

4XDOLW\ 3DUWV Valid from serial number: 7 FRGH

0RGHO

6HULDO 1R

378

SL 2.0

326301AA-

1RWHV

,VVXHG 4XDOLW\ 3DUWV 7 FRGH 0RGHO

6HULDO 1R

2UGHU QXPEHU ,VVXHG

378

SL 2.0

326301AA-

166972

1998-09-28

378

SL 2.0

329900AA-

168326

1998-12-21

© BT Industries AB

Service Manual

1998-12-18

English

1 (2)

F-code

Section

Version no

T-code

6/ 0 4XDOLW\ 3DUWV

2 (2)

C-code

Service Manual

1998-12-18

English

F-code

Section

6/ IIssued by

66'

Approved by

3

Version no

C-code

&RQWHQW 3

T-code

&RQWHQW 3 3UHYHQWLYH 0DLQWHQDQFH

© BT Industries AB

P1

Introduction

P2

Preventive Maintenance

P3

Oil and grease specification

P4

Tools

Service Manual

1998-11-04

English

1 (2)

F-code

Section

Version no

T-code

6/ 3 &RQWHQW 3

2 (2)

C-code

Service Manual

1998-11-04

English

F-code

6/ IIssued by

66'

Approved by

Section

C-code

3 ,QWURGXFWLRQ PDLQWHQDQFH

Version no

T-code

,QWURGXFWLRQ PDLQWHQDQFH All points in the service program should be carried out to attain the highest safety and the least possible downtime. The service intervals are only a guide and do not need to be followed to the letter. The operator may adapt them to local conditions, but it is important that the intervals comply with BT’s minimum requirements.

The service intervals are based on the running times and can be adapted to most normal 8 hour shifts. The following running times have been used when calculating the intervals: Day time: 08.00-17.00 (20 hr./week) 2-shifts:

06.00-14.00, 14.00-22.00 (40 hr./week)

3-shifts:

06.00-14.00, 14.00-22.00, 22.00-06.00 (60 hr./week)

Ensure the truck is given a regular maintenance service after 250 driving hours. The truck´s safety, efficiency and service life is dependent on the service and maintenance it is given.

Only use BT approved spare parts when service and repair work are carried out.

6DIHW\ UHJXODWLRQV ZLWK PDLQWHQDQFH ZRUN Only personnel that have been trained in the service and repair of this type of truck are authorised to carry out service and repair work.

• Do not carry out any maintenance work on the truck unless you have the correct training and knowledge to do so.

• Keep the area where you carry out the service clean. Oil or water makes the floor slippery.

• Never wear loose objects or jewellery when working on the truck. :$51,1*

6KRUW FLUFXLWLQJ %XUQV :KHQ ZRUNLQJ ZLWK WKH WUXFN¶V HOHFWULFDO V\VWHP VKRUW FLUFXLWLQJ EXUQV FDQ RFFXU LI D PHWDO REMHFW FRPHV LQWR FRQ WDFW ZLWK OLYH HOHFWULFDO FRQQHFWLRQV 5HPRYH ZDWFKHV ULQJV RU RWKHU W\SHV RI PHWDO MHZHOOHU\

© BT Industries AB

Service Manual

1998-10-28

English

1 (4)

F-code

Section

Version no

T-code

C-code

6/ 3 ,QWURGXFWLRQ PDLQWHQDQFH

• Always disconnect the battery by pulling out the emergency disconnector when carrying out maintenance work on the truck unless otherwise stated in this Service Manual.

• Always switch off the truck’s power supply before opening the covers on the drive unit or electrical system.

• Relieve the system pressure slowly before starting work on the truck’s hydraulic system.

• Use paper or a rigid sheet of cardboard when checking for oil leakage. Never use your hand.

• Bear in mind that the oil in the transmission or the hydraulic system can be hot. :$51,1*

5LVN RI EXUQV +RW WUDQVPLVVLRQ DQG K\GUDXOLF RLO /HW WKH WUXFN FRRO EHIRUH FKDQJLQJ WKH RLO

• Only fill the hydraulic system with new and clean oil. :$51,1*

7KH K\GUDXOLF V\VWHP FDQ EH GDPDJHG ,I WKH RLO LV FRQWDPLQDWHG K\GUDXOLF FRPSRQHQWV FDQ EH GDPDJHG $OZD\V XVH QHZ DQG FOHDQ RLO LQ WKH +\GUDXOLF V\VWHP

• Store and dispose of changed oil in accordance with local directives.

• Do not release solvents and the like, which are used for cleaning/washing, into drains that are not intended for this purpose. Follow the local directives that apply for disposal.

• Disconnect the battery when welding on the truck.

127(

7KH EDWWHU\ FDQ EH GDPDJHG :KHQ ZHOGLQJ XVLQJ DQ HOHFWULF SRZHU VRXUFH WKH ZHOGLQJ FXUUHQW FDQ HQWHU WKH EDWWHU\ 7KH EDWWHU\ VKRXOG WKHUHIRUH EH GLVFRQQHFWHG

• Remove at least 100 mm of paint around the welding/ grinding area through sand-blasting or the use of a paint stripper when welding or grinding on painted surfaces. &$87,21

+DUPIXO JDVHV 3DLQW WKDW LV KHDWHG JLYHV RII KDUPIXO JDVHV 5HPRYH PP RI SDLQW IURP WKH ZRUN DUHD

2 (4)

Service Manual

1998-10-28

English

F-code

6/

Section

C-code

3 ,QWURGXFWLRQ PDLQWHQDQFH

Version no

T-code

&OHDQLQJ DQG ZDVKLQJ Cleaning and washing of the truck is important to ensure the truck’s reliability.

• Carry out general cleaning and washing weekly.

127(

5LVN RI VKRUW FLUFXLWLQJ 7KH HOHFWULFDO V\VWHP FDQ EH GDPDJHG 'LVFRQQHFW WKH EDWWHU\ EHIRUH ZDVKLQJ E\ SXOOLQJ RXW WKH HPHUJHQF\ GLVFRQQHFWRU

([WHUQDO FOHDQLQJ • Remove rubbish, etc. from the wheels daily.

• Use a well-known degreasing agent, diluted to a suitable concentration.

• Rinse off loose grime using tepid water.

127(

-DPPLQJ FRUURVLRQ 0HFKDQLFDO FRPSRQHQWV FDQ EH GDPDJHG $IWHU ZDVKLQJ WKH WUXFN VKRXOG EH OXEULFDWHG DV VHW RXW LQ WKH OXEULFDWLRQ FKDUW LQ FKDSWHU 0DLQWHQDQFH

&OHDQLQJ WKH PRWRU FRPSDUWPHQW • Cover the electric motors, connections and valves before washing.

127(

5LVN RI VKRUW FLUFXLWLQJ 7KH HOHFWULFDO V\VWHP FDQ EH GDPDJHG (OHFWULFDO FRPSRQHQWV PXVW QRW EH FOHDQHG ZLWK D KLJK SUHVVXUH ZDVKLQJ XQLW

• Clean the motor compartment using a well-known degreasing agent, diluted to a suitable concentration.

• Rinse off loose grime using tepid water.

© BT Products AB

Service Manual

1998-10-28

English

3 (4)

F-code

Section

Version no

T-code

C-code

6/ 3 ,QWURGXFWLRQ PDLQWHQDQFH

(OHFWULFDO FRPSRQHQWV • Blow electric motors down using compressed air.

• Clean the electrical panels, electronic boards, contactors, connections, solenoid valves, etc. using a damp cloth and a cleaning agent.

127(

5LVN RI VKRUW FLUFXLWLQJ (OHFWULFDO FRPSRQHQWV FDQ EH GDPDJHG 'R QRW EUHDN WKH JXDUDQWHH VHDO RQ WKH HOHFWURQLF ERDUG

6DIH OLIWLQJ RI WKH WUXFN All lifting must be carried out on a flat, non-slip and firm surface. Avoid new laid asphalt or asphalt on a hot summer’s day.

• Apply the parking brake to prevent the truck from moving during the lift. If the lift applies the brake on the drive wheel, chock the other wheels so that the truck stands still.

• Select a lifting point so that the lift is as easy as possible (one corner at a time). If the truck has marked lifting points on the under side of the chassis these can be used to obtain a well balanced lift.

• Ensure that the surface under the jack is clean and free from oil and grease.

• Ensure that your hands and the jack’s lever are free from oil and grease.

• Use the lever that belongs to the jack. A lever that is too short requires more force than is necessary. If the lever is too long there is a risk of the jack being overloaded.

• Support the truck: • as close to the part of the chassis that is lifted as possible to reduce the falling height if the truck tips over.

• so that the truck cannot roll.

• 1HYHU raise up the jack to lift higher • 1HYHU work under a lifted truck unless it is well supported. :$51,1*

5LVN RI FUXVKLQJ $ EDGO\ VXSSRUWHG WUXFN FDQ IDOO 1HYHU ZRUN XQGHU D WUXFN WKDW LV QRW VXSSRUWHG RQ WUHVWOH EORFNV DQG VHFXUHG E\ D OLIWLQJ GHYLFH

4 (4)

Service Manual

1998-10-28

English

F-code

Section

6/ IIssued by

66'

Approved by

Version no

)UHGULN :LJK

C-code

3 6HUYLFH VFKHGXOH T-code

6HUYLFH VFKHGXOH Valid from serial number: 7 FRGH

0RGHO

6HULDO 1R

378

SL 2.0

326301AA-

1RWHV

0DLQWHQDQFH FKDUW 3RV QR 0000 0000.1 0000.2 0000.3 0000.4 0380 0380.1 0380.2 0380.3 0380.4 0380.5 0380.6 1700 1700.1 1700.2 1700.3 1700.4 1700.5 2550 2550.1 2550.2 2550.3 2550.4 2550.5

:RUN WR FDUU\ RXW ,QWHUYDOV LQ KRXUV ,QWHUYDOV LQ 'D\V :HHNV 0RQWKV Chassis.

Check the door lock Check for wear to the battery rollers and the battery lock Check for damage and crack formation Check all links and locking pins Fork carriage Check for cracks and damage Check bushings for excess play Check carriage rollers for wear and play Check that push rods are not bent or damaged Check the lift limit switch Lubrication of rollers Motors Check for loose connections Clean the motor Check the mounting bolts Check for abnormal bearing noise Check the carbon brushes Drive unit Check for leakage Check the oil level Check for noises Check the mounting on the support arm Change the oil in the drive gear

© BT Industries AB

Service Manual

'

:

0

0

0

0

0

X X X X X X X X X X X X X X X X X X X Xa 1998-05-07

English

1 (6)

F-code

Section

Version no

T-code

6/ 3 6HUYLFH VFKHGXOH

3RV QR 3100 3100.1 3100.2 3100.3 3500 3500.1 3500.2 3500.3 3500.4 3500.5 5110 5110.1 5110.2 5110.3 5110.4 5300 5300.1 5300.2 5300.3 5300.4 5300.5 5300.6 5400 5400.1 5400.2 5400.3 5400.4 5400.5

2 (6)

C-code

:RUN WR FDUU\ RXW ,QWHUYDOV LQ KRXUV ,QWHUYDOV LQ 'D\V :HHNV 0RQWKV Brakes Clean Check the brake discs for wear Check the play in the released position Wheels Remove string and other rubbish Check for drive wheel wear and the bolts Check that the link wheel is rotating and can swing freely Check for wear and tear on the link wheel and the fork wheels Dismantle and grease the fork wheel´s bearings Battery Check the electrolyte level (10-15 mm above the cell plates) Check the connections on the battery, truck and charger Check the cell and pole guard Check the fluid density and temperature Control system driving Check the emergency switch off Check the ignition key Check the push buttons Check the microswitches and hydraulic functions Check the functioning of the safety pedal Check the operation of the left-foot pedal Power system driving Clean and check mountings Tighten cable connections Check the contactor points for the travel direction Check the contactor’s movement Check the transistor unit’s safety circuits Service Manual

'

:

0

0

0

0

0

X X X X X X X X

X X X X

X X X X X X

X X X X X

1998-05-07

English

F-code

Section

6/

3RV QR 5700 5700.1 5700.2 5700.3 6100 6100.1 6100.2 6100.3 6100.4 6100.5 6100.6 6200 6200.1 6600 6600.1 6600.2

C-code

3 6HUYLFH VFKHGXOH

Version no

T-code

:RUN WR FDUU\ RXW ,QWHUYDOV LQ KRXUV ,QWHUYDOV LQ 'D\V :HHNV 0RQWKV Electronic card Clean the electronic card: blow clean with air and dry with a cloth Check contacts and cables Check the LEDs Hydraulic system Check hoses and couplings for leakage Check pipes and hoses for wear Check the tank for leakage and its mountings Check the oil level Change filter/oil Check the oil quality Hydraulicl system Check valves for leakage Cylinders Check for leakage Check mountings

'

:

0

0

0

0

0

X X X X X X X X

b

X X X X X

a= Change Oil the first time after 80h/1month and then every 3000h/36moth. b= Change filter/Oil the first time after 80h/1month and then every 1000h/12months.

© BT Products AB

Service Manual

1998-05-07

English

3 (6)

F-code

Section

Version no

T-code

6/ 3 6HUYLFH VFKHGXOH

4 (6)

C-code

Service Manual

1998-05-07

English

F-code

Section

6/

C-code

3 6HUYLFH VFKHGXOH

Version no

T-code

/XEULFDWLRQ FKDUW 3RV QR

6HUYLFH SRLQW

,QWHUYDO 5XQQLQJ KRXUV K

3500 0380 6100 4100 2550

Wheel bearings Rollers in the fork carriage Hydraulic system Steering bearings Drive gear

K

9ROXPH

A A B D C

1.5 litre

K L

C

/XEULFDQW

L O1) L

C

O

L= Lubrication

C = Check

1.75 litre O = Oil change

3500 0380 3500

6100 4100 2550

© BT Products AB

Service Manual

1998-05-07

English

5 (6)

F-code

Section

Version no

T-code

6/ 3 6HUYLFH VFKHGXOH

6 (6)

C-code

Service Manual

1998-05-07

English

F-code

6/ IIssued by

66'

Approved by

)UHGULN :LJK

Section

C-code

3 2LO DQG JUHDVH VSHFLILFDWLRQ

Version no

T-code

2LO DQG JUHDVH VSHFLILFDWLRQ Valid from serial number: 7 FRGH

0RGHO

6HULDO 1R

378

SL 2.0

326301AA-

1RWHV

/XEULFDQW

6SHFLILFDWLRQ ! & &

$SSOLFDWLRQ DUHD

A

Grease

Bearings and bushings

B C

Hydraulic oil Transmission oil

D

Grease

BT 26777 (Spray) ISO-L-HM32 Hypoid oil SAE 80W/90 Staburags NBU 8EP

© BT Industries AB

Service Manual

BT 26777 (Spray) ISO-L-HV32 Hypoid oil SAE 75W Staburags NBU 8EP

1998-06-22

Hydraulic system Gears Steering bearings

English

1 (2)

F-code

Section

Version no

T-code

C-code

6/ 3 2LO DQG JUHDVH VSHFLILFDWLRQ

2 (2)

Service Manual

1998-06-22

English

F-code

Section

6/ IIssued by

66'

Approved by

6

Version no

C-code

&RQWHQW 6

T-code

&RQWHQW 6 6HUYLFH LQVWUXFWLRQV & FRGH

© BT Industries AB

S0

Chassis

0000

S1

Primary motor

1000

S2

Transmission/Drive gear

2000

S3

Brake/Wheel/Caterpillar system

3000

S4

Steering system

4000

S5

Electrical system

5000

S6

Hydraulic/pneumatic system

6000

S7

Working functions, lift mast/cylinders

7000

S8

Peripheral/installation equipment

8000

S9

Options, attatchments

9000

Service Manual

1998-11-04

English

1 (2)

F-code

Section

Version no

T-code

6/ 6 &RQWHQW 6

2 (2)

C-code

Service Manual

1998-11-04

English

F-code

Section

6/ IIssued by

Approved by

66'

Version no

)UHGULN :LJK

C-code

6

(OHFWUR PDJQHWLF EUDNH T-code

(OHFWUR PDJQHWLF EUDNH Valid from machine number: 7 FRGH

0RGHO

6HULDO 1R

378

SL 2.0

326301AA-

1RWHV

*HQHUDO GHVFULSWLRQ The brake is a two stage electro magnetic brake with separate coils for each of the stages. The stages are controlled individually by the logic card of the electrical system which controls the operation depending on the weight of the load on the forks.

The first stage is in operation at all times. The second stage becomes operative at loads of 800-900 kg or more supervised by a pressure sensor in the hydraulic system.

3 4

5

6

7

2 1

8

12 11

© BT Industries AB

9 10

Service Manual

1998-08-20

English

1 (6)

F-code

Section

Version no

T-code

C-code

6/ 6

(OHFWUR PDJQHWLF EUDNH

0DLQ FRPSRQHQWV RI WKH EUDNH 3RV QR

'HVFULSWLRQ

1

Electrical wire, first stage

2

Coil winding, first stage

3

Electrical wire, second stage

4

Coil winding, second stage

5

Pressure spring, second stage

6

Pressure springs, first stage

7

Mounting bolts

8

Adjustment locking nut

9

Hub

10

Friction plate

11

Brake disc

12

Pressure plate

0DLQWHQDQFH Basically the brake is maintenance free in normal work environments. However it is recommended according to the preventive maintenance schedule to check the brake disc for wear and the gap between the magnetic coil housing and the pressure plate on a regular basis.

2 (6)

Service Manual

1998-08-20

English

F-code

6/

Section

C-code

6

(OHFWUR PDJQHWLF EUDNH

Version no

T-code

$GMXVWPHQW RI JDS 3

1

2

The nominal gap between the coil housing and the pressure plate, in applied position, shall be 0.3 mm. The maximum gap before readjustment is necessary is 0.8 mm. $GMXVWPHQW SURFHGXUH 1. Loosen the tension of the three mounting bolts (1).

2. Turn the lock nuts (2) anti-clockwise and tighten the bolts slightly while checking the gap LQ WKUHH SODFHV with a 0.3 mm feeler gauge (3).

3. Tighten the mounting bolts 25 Nm and recheck the gap with the feeler gauge.

© BT Products AB

Service Manual

1998-08-20

English

3 (6)

F-code

Section

Version no

T-code

C-code

6/ 6

(OHFWUR PDJQHWLF EUDNH

2SWLPLVLQJ WKH EUDNH V\VWHP To be able to obtain optimal brake effect on the truck and above all to avoid locking up the drive wheel during braking, some adjustment can be made. The brake force for the two brake stages can be individualy adjusted as well as the point where the second brake stage activate.

The factors to be considered when adjusting the brake are: - Avoiding lock up of the drive wheel. (The biggest risk for that is when the minimum of load is lifted for respective brake stage.)

- To meet the brake norm. (This is always hardest with maximum of load and speed).

$GMXVWLQJ WKH FKDQJH EHWZHHQ WKH EUDNH VWDJHV When the first brake stage is active the LED 305 comes on and when the second brake stage is active the LED 305 goes out. Switching usually takes place at a load of approx. 800900 kg. If switching at a higher load is required proceed as follows: - Lift a load at a weight for which the change is desired.

- Adjust the pressure switch so that LED 305 goes out.

- Lower the load and reduce it with approx. 50-100 kg.

- Lift the new weight and check that LED 305 is ON. If switching at a lower load is required proceed as follows: - Lift a load at a weight for which the change is desired.

- Adjust the pressure switch so that LED 305 goes on.

- Lower the load and reduce it with approx. 50-100 kg.

- Lift the new weight and check that LED 305 is out.

4 (6)

Service Manual

1998-08-20

English

F-code

6/

Section

C-code

6

(OHFWUR PDJQHWLF EUDNH

Version no

T-code

$GMXVWLQJ RI WKH ILUVW EUDNH VWDJH To reduce the braking force for the first brake stage turn the screws (6) counterclockwise on the brake. To increase the braking force, turn the screws clockwise.

3 4

5

6

7

2 1

8

12 11

9 10

To avoid locking up the drive wheel while braking, proceed as follows: - Turn screw counter clockwise, so that braking without load and with max speed is done without the drive wheel locking up.

- Check that the brake norm is met, for the first brake stage. This is done with max load for the first brake stage (check that input 305 is ON), drive at full speed and apply brake. Measure the stoptime, it must under all conditions be below 1.5 sec.

$GMXVWLQJ RI WKH VHFRQG EUDNH VWDJH To reduce the braking force for the second brakestage, turn the screw in the middle (5) counterclockwise. To increase the braking force, turn it clockwise.

To avoid locking up the drive wheel while braking, proceed as follows: - Turn screw counterclockwise, so that braking with the minimum of load that activates the second brake stage and max speed does not lock up the drive wheel.

- Check that the brake standard is obtained, for the second brake stage. This is done with max load, (input 305 OFF), drive at full speed and apply brake. Measure the stoptime, it must under all conditions be below 1.5 sec.

If the max. load never amounts to 2000 kg it can be limited by adjusting the pressure limiting valve. This means that the force required for the second brake stage can be reduced while the braking standard is still maintained. This gives the possibility of smoother braking during the second stage.

© BT Products AB

Service Manual

1998-08-20

English

5 (6)

F-code

Section

Version no

T-code

C-code

6/ 6

(OHFWUR PDJQHWLF EUDNH

([FKDQJH RI EUDNH GLVF The brake disc shall be exchanged when its total thickness has been reduced to 6 mm.

([FKDQJH SURFHGXUH 1. Disconnect the electrical wires of the brake.

2. Loosen and remove the three mounting bolts and remove the brake coil.

3. Replace the brake disc on the hub and make a visual inspection of the wear of the friction plate. Replace the friction plate if the surface is worn uneven.

4. Unwind the lock nuts on the coil at least 6 mm to make sure there is a gap between the coil and the pressure plate when the coil is refitted.

5. Mount the coil on the motor end and carry out adjustment of the gap according to section 4.

6. Reconnect the electrical wiring.

6 (6)

Service Manual

1998-08-20

English

F code

Section

6/ Issued by

66'

Approved by

Version No.

)UHGULN :LJK

C code

6

(OHFWULFDO V\VWHPV

T code

(OHFWULFDO V\VWHPV Vaild from serial number :

7 FRGH

0RGHO

6HULDO 1R

378

SL 2.0

326301AA-

1RWHV

(OHFWULFDO SDUWV

© BT Industries AB

Service Manual

1998-06-24

English

1 (16)

F code

Section

Version No.

T code

6/ 6 (OHFWULFDO V\VWHPV

C code

/LVW RI V\PEROV DQG HOHFWULFDO ZLU LQJ GLDJUDP 6\PERO

2 (16)

'HVFULSWLRQ

)XQFWLRQ

1RWHV

A1

Transistor regulator

A5

Electronic card

A6

Display

F1

Fuse

Drive motor circuit

160 A

F3

Fuse

Pump motor circuit

200 A

F 50

Fuse

Operating circuit

10 A

F 51

Fuse

Electric control motor

20 A

F 52

Fuse

Optional equipment

10 A

G1

Battery

24 V

H1

Horn

K9

Contactor

Main contactor

K10

Contactor

Main contactor

K30

Contactor

Pump motor

M1

Motor

Drive motor

M3

Motor

Pump motor

M6

Motor

Steering motor

R1

Potentiometer

Speed

5 - 0 kohms

S10

Switch

Travel brakes

Brake lever

S17

Switch

Key

S18

Switch

Horn button Service Manual

1998-06-24

Transistor regulator

English

F code

Section

6/

6\PERO

Version No.

T code

'HVFULSWLRQ

)XQFWLRQ

1RWHV

S19

Switch

Brake

Right foot switch

S23

Switch

Motor brake

Left foot switch

S31

Switch

Lift height limiter

S41

Switch

Fork lowering

S51

Switch

Fork lifting

S61

Switch

Pressure guard

S66

Inductive sensor

Steering end position

S67

Inductive sensor

Steering end position

U1

Tachometer

Steering wheel

Y1

Brake

Stage 1

Y2

Brake

Stage 2

Y41

Magnetic valve

Fork lowering

© BT Products AB

Service Manual

1998-06-24

C code

6

(OHFWULFDO V\VWHPV

Braking power

English

3 (16)

F code

Section

Version No.

T code

6/ 6 (OHFWULFDO V\VWHPV

C code

(OHFWULFDO ZLULQJ GLDJUDP

4 (16)

Service Manual

1998-06-24

English

F code

Section

6/

C code

6

(OHFWULFDO V\VWHPV

Version No.

T code

(OHFWULFDO ZLULQJ GLDJUDP

© BT Products AB

Service Manual

1998-06-24

English

5 (16)

F code

Section

Version No.

T code

6/ 6 (OHFWULFDO V\VWHPV

C code

(OHFWULFDO ZLULQJ GLDJUDP

6 (16)

Service Manual

1998-06-24

English

F code

Section

6/

C code

6

(OHFWULFDO V\VWHPV

Version No.

T code

(OHFWULFDO ZLULQJ GLDJUDP

© BT Products AB

Service Manual

1998-06-24

English

7 (16)

F code

Section

Version No.

T code

6/ 6 (OHFWULFDO V\VWHPV

C code

(OHFWULFDO ZLULQJ GLDJUDP

8 (16)

Service Manual

1998-06-24

English

F code

Section

6/

C code

6

(OHFWULFDO V\VWHPV

Version No.

T code

)XQFWLRQDO GHVFULSWLRQ *HQHUDO

VOLTAGE

CURRENT

STATUS

MODEL

SERIAL

The electrical system of the truck is built around two core components, consisting of the electronic card (A5) and the transistor regulator (A1). The electronic card receives input signals from the sensors, switches, pressure guards, speed potentiometers and the steering tachometer. The card processes these signals and outputs signals to the valves, contactors and the electric control motor. Some of the signals are also sent to the transistor regulator which, with the help of these signals, adjusts the speed, travel direction and reversing current. The electronic card further communicates with the display (A6) where information such as the operating time, error codes, etc. is shown. The card is equipped with LEDs that indicate input and output status as well as three switches used, e.g., to set the various parameters. For more information on the electronic card, see section 5710.

The truck speed is controlled by the stepless transistor regulator (A1), which basically is a transistor for independent excitations motors. The regulator has a four-quadrant transistor bridge for the field winding, and a one-quadrant transistor bridge for the armature winding. At start-up, the regulator checks whether the main contactor (K10) is "welded". When this is the case, the regulator turns off and an error code is generated.

The regulator is equipped with an LED (67$786), which lights whenever something is wrong.

When troubleshooting the transistor regulator, use of the 1307 handheld terminal is recommended. For more information on the transistor regulator and how to use the hand terminal, see section 5460.

This functional description is divided into three sections, coinciding with the functional processes of the electrical system.

The correct LED light-up pattern is presented in tables for each of the functional processes. .

© BT Products AB

'HVLJQDWLRQ

/(' QXPEHU

Designation of the input/output according to the electrical wiring diagram.

The LED number showing the active input/output on the card.

Service Manual

1998-06-24

English

9 (16)

F code

Section

Version No.

T code

6/ 6 (OHFWULFDO V\VWHPV

C code

.H\ LQ SRVLWLRQ When the battery is connected via the battery connector, the electronic card (A5) receives a voltage of +24 V over the F50 fuse on input 401 and also on input 701 via the F51 fuse.

The LEDs 307 and 308 light up depending on whether the sensors are being operated.

'HVLJQDWLRQ

/(' QXPEHU

INP. +24 VDC

401

+24 VDC STEER

701

INP. END POSITION STEER WHEEL

307, 308 STEER PWR

.H\ LQ SRVLWLRQ , When the driver turns the key (S17), the truck receives operating voltage. Current travels through the operating fuse (F50) to input 401 and then on through the card (A5) to output 211.

The current continues to the emergency stop switch (S21) through the start switch (S17) to input 210. From input 210, the voltage is fed internally to output 402, cable number 22 and the main contactor (K9) starts to operate. When input 210 receives +24 V the electronic card is operative and the 3RZHU2.

LED lights. The card outputs +7.35 V to the speed potentiometer (R1) and regulates the voltage on input 204 (,13 :,3(5) to 3.67 +0.44 V. If the voltage is outside this range, error code C016 is generated.

The regulator of the electrical steering wheel system makes a self-check of the built-in circuits. If everything is alright, the regulator closes the safety relay, thus supplying operating power to the control motor via 703 and 704. The electronic card (A5) now starts generating test pulses to the tachometer (U1) and the control motor (M6).

When cable number 22 receives power from output 402, voltage is fed onto the transistor regulator (A1), pin 16 (,13 .(< 6:,7&+ and to input 404 on (A5), causing LED 404 to light.

When the start switch (S17) is turned on while the right foot switch (S19) is activated, voltage is fed onto input 304 on (A5) and pin 15 (,13 ,17(5/2&. 6:,7&+ of the transistor regulator (A1). The transistor regulator then does a self-test of its 10 (16)

Service Manual

1998-06-24

English

F code

Section

6/

C code

6

(OHFWULFDO V\VWHPV

Version No.

T code

circuits. If everything is alright, the main contactor (K10) is powered up via pin 4 (287 0$,1 &217$&725 DQG LQSXW 404 on A5 goes low. LED 404 on A5 goes out. The transistor regulator status LED now starts to blink.

The display (A6) is turned on and first displays the programme version of the electronic card (A5) software, and then it shows the work hour meter for several seconds. After this the battery status is displayed and kept.

LED 304 lights if switch S19 is operated. LED 404 lights if switch S19 is not operated. LED 306 lights if S23 is operated and LED 209 lights if S19 is operated.

'HVLJQDWLRQ

/(' QXPEHU

INP. KEY

210

INP. DRIVE SHOPPER OK

404

INP. RIGHT FOOT SWITCH

304

INP. HYD. PRES

305

INP. LEFT FOOT SWITCH

306

INP. BRAKE

209 PowerOK

'ULYLQJ LQ WKH GULYH ZKHHO GLUHFWLRQ To allow truck movement, the right foot switch (S19) and the left foot pedal (S23) must be operated, and LEDs 304 and 306 on A5 should light.

When the speed lever (R1) is operated for driving in the drive wheel direction, the voltage on pin 204 increases from around +3.67 V to around 6.6 V (at max speed). Output 501 (287 '5,9( 67((5 :+((/ ',5 ) on A5 then goes high and sends a signal to the transistor regulator A1 informing that the drive wheel direction has been selected. Depending on the position of the speed lever (R1), A5 generates a voltage of 0-5 V on output 509 (287 63((' 5() 9$/8() informing the transistor regulator how fast the truck should travel. When the speed lever (R1) is operated, the brakes (Y1, Y2) are released by outputs 503 and 504 going high.

The transistor regulator now starts to operate. Armature power is fed from the battery through the K10 terminals over the armatures (A1-A2) to M- on the regulator. The current then trav© BT Products AB

Service Manual

1998-06-24

English

11 (16)

F code

Section

Version No.

T code

C code

6/ 6 (OHFWULFDO V\VWHPV

els inside the regulator to a switch transistor onto B- and back to the battery (see picture 1).

At the same time, the shunt field current is regulated via S1 and S2 on the transistor regulator.

If the driver removes the foot from the right foot pedal while the truck is travelling, the electromechanical brake is applied. If the driver removes the foot from the left foot pedal, the motor brake is engaged.

'HVLJQDWLRQ

/(' QXPEHU

INP. RIGHT FOOT SWITCH 304 INP. LEFT FOOT SWITCH

306

OUT. DRIVE STEER WHEEL DIR.

501

OUT. BRAKE 1

503

OUT. BRAKE 2

504

3LFWXUH Schematic diagram of driving in the drive wheel direction.

A1

A5

BS1 T1

Ish

Ia

OUT DRIVE FORK DIR.

501

OUT DRIVE STEER WHEEL DIR.

509

OUT SPEED REF. VALUE

MShunt

+

502

S2 A2

A A1

T2

K10

B+ 0-5 V

'ULYLQJ LQ WKH IRUN GLUHFWLRQ To allow truck movement, the right foot switch (S19) must be operated, and LED 304 on A5 should light.

When the speed lever (R1) is operated to drive the truck in the fork direction, the voltage on pin 204 falls from around +3.67 V to around 0.7 V (at max speed). Output 502 (287 '5,9( )25. ',5 ) on A5 then goes high and sends a signal to the transistor regulator A1 that the drive wheel direction has been 12 (16)

Service Manual

1998-06-24

English

F code

Section

6/

C code

6

(OHFWULFDO V\VWHPV

Version No.

T code

selected. Depending on the position of the speed lever (R1), A5 outputs a voltage of 0-5 V on output 509 (287 63((' 5() 9$/8() informing the transistor regulator how fast the truck should travel. When the speed lever (R1) is operated, the brakes (Y1, Y2) are released by outputs 503 and 504 going high.

The transistor regulator now starts to operate. Armature power is fed from the battery through the K10 terminals over the armatures (A1-A2) to M- on the regulator. The current then travels inside the regulator to a switch transistor onto B- and back to the battery (see picture 2).

At the same time, the shunt field current is regulated via S1 and S2 on the transistor regulator. When driving in the fork direction, the shunt field current travels in the opposite direction compared to driving in the drive wheel direction.

If the driver removes the foot from the right foot pedal while the truck is travelling, the electromechanical brake is applied. If the driver removes the foot from the left foot pedal, the motor brake is engaged.

'HVLJQDWLRQ

/(' QXPEHU

INP. RIGHT FOOT SWITCH 304 INP. LEFT FOOT SWITCH

306

OUT. DRIVE FORK DIR.

502

OUT. BRAKE 1

503

OUT. BRAKE 2

504

3LFWXUH Schematic diagram of driving in the fork direction.

A1

A5

BS1 T1

Ish

Ia

OUT DRIVE FORK DIR.

501

OUT DRIVE STEER WHEEL DIR.

509

OUT SPEED REF. VALUE

MShunt

+

502

S2 A2

A A1

T2

K10

B+ 0-5 V

© BT Products AB

Service Manual

1998-06-24

English

13 (16)

F code

Section

Version No.

T code

6/ 6 (OHFWULFDO V\VWHPV

C code

0RWRU EUDNLQJ DQG UHYHUVLQJ When the speed lever (R1) is released to the neutral position or moved in the opposite direction, an alteration in the voltage on output 509 287 63((' 5() 9$/8( on the electronic card takes place. At the same time the status on outputs 501 and 502 changes. The transistor regulator senses these changes and applies the motor brake.

This is achieved by completely disengaging the switch regulators used while driving, and instead using other transistors (T2) to regulate the generated current from the motor.

These transistors that regulate the brake current are switched on/off rapidly. While the transistors are not live, the generated current needs to pass through the battery over K10 and to B-on the transistor regulator. Inside the regulator, the brake current passes through the brake diodes and onto the motor through M- (see picture 3).

When the transistors go live, the brake current passes through the transistors (T2) to the armature via M- (see picture 4).

Throughout this entire process and until the truck comes to a complete stop, the shunt field is engaged achieving current generation inside the armature circuit.

3LFWXUH The transistors (T2) for the generated brake current are not live.

A1 BS1

T1 Ish

Ia

MShunt

+

S2 A2

A A1

T2 K10

14 (16)

Service Manual

1998-06-24

B+

English

F code

Section

6/

C code

6

(OHFWULFDO V\VWHPV

Version No.

T code

3LFWXUH The transistors (T2) for the generated brake current are live.

A1 BS1 T1

Ish

Ia

MShunt

+

S2 A2

A A1

T2

K10

B+

%UDNLQJ The brake is always applied when the truck is started. The brake is released when the right and left foot pedals are operated and a drive direction has been selected.

While travelling, the truck can be braked by operating the brake lever (S10). Current on input 209 (,13 %5$.() is then interrupted and the truck brakes. Depending on the current load on the forks, this is achieved by either output 503 (287 %5$ .( going low or both 503 and 504 (287 %5$.( going low. The brakes operate in a two-step action depending on the pressure in the hydraulic system, i.e. the lifted load on the forks. At a pressure corresponding to a lifted weight of 800 kg, only the first stage operates and the pressure guard (S61) remains closed. This is indicated by LED 305. When braking within this load range, the second stage will be engaged within a few seconds.

For lifted weights exceeding approx. 850 kg, both stages are engaged simultaneously and the pressure guard (S61) opens while LED 305 goes out.

The brake is also applied if the right foot pedal (S19) is released.

LED 209 goes out when the brake lever is operated. LEDs 503 and 504 go out when the brake lever is operated or the right foot pedal is released. © BT Products AB

Service Manual

1998-06-24

English

15 (16)

F code

Section

Version No.

T code

6/ 6 (OHFWULFDO V\VWHPV

C code

/LIWLQJ WKH IRUNV In order to lift the forks, the left foot pedal must be operated.

When the fork lift switch (S51) is operated, input 201 (,13 )25. 83) receives voltage and the LED lights. The pump contactor (K30) then is fed from output 505 (287 3803 &217$& 725) and turns on. The pump motor (M3) starts operating and the forks are lifted.

The pump contactor (K30) is also engaged for as long as the switch (S51) is kept depressed or until the lift height limiter (S31) is activated. The lift height limiter (S31) is triggered by the fork cage and interrupts the current received on input 301 (,13 )25. 723), thus causing the pump contactor (K30) to release.

'HVLJQDWLRQ

/(' QXPEHU

INP. LEFT FOOT SWITCH

306

INP. FORK UP

201

OUT. PUMP CONTACTOR

505

INP. FORK TOP

301

/RZHULQJ WKH IRUNV In order to lower the forks, the left foot pedal must be operated.

When the fork lowering switch (S41) is operated, input 202 (,13 )25. '2:1) receives voltage and the LED lights. The lowering valve (Y41) then is fed from output 506 (287 /2:( 5,1* 9$/9() and the forks are lowered.

'HVLJQDWLRQ

/(' QXPEHU

INP. LEFT FOOT SWITCH

306

INP. FORK DOWN

202

OUT. LOWERING VALVE

506

+RUQ The horn is sounded by pressing switch S18. Voltage is then applied on input 104 (,13 +251) and the LED lights. The horn is powered by output 508 (287 +251) and sounds for as long as the switch (S18) is kept pressed.

16 (16)

Service Manual

1998-06-24

English

F code

Section

6/ Issued by

66'

Approved by

Version No.

)UHGULN :LJK

C code

6

7UDQVLVWRU SDQHO

T code

7UDQVLVWRU SDQHO Valid from serial number: 7 FRGH

0RGHO

6HULDO 1R

378

SL 2.0

326301AA-

1RWHV

STATUS MODEL

VOLTAGE

SERIAL

CURRENT

*HQHUDO B+

A1

M-

M

A2

Curtis 1243 is a regulator for controlling shunt motors, also known as independent excitation motors. Varying the voltage applied through the armature primarily controls the speed. The voltage is varied through use of pulse-width modulation (PWM). This involves varying the “on” time of the MOS-FET transistors regulating the armature current.

Switching of the rotational direction is achieved by switching the polarity on the field winding (S1-S2). The regulator is fitted with a four-quadrant transistor bridge for the field winding and a single-quadrant transistor bridge for the armature winding.

S1

S2

The regulator is a multi-mode type, which means that two separate and selectable parameter settings for driving characteristics can be set. For more information, see the section PARAMETERS. The regulator is fitted with an error indication LED, placed on top of the regulator and marked STATUS. On the side of the regulator, there is also a connector for the 1307 handheld terminal.

© BT Industries AB

Service Manual

1998-07-27

English

1 (18)

F code

Section

Version No.

T code

6/ 6 7UDQVLVWRU SDQHO

C code

&RQQHFWRUV C2

C1

S1 B-

S2 M-

B+

The table below explains the various connectors on the regulator.

&RQQHFWRU

)XQFWLRQ

B+

Positive battery, Motor+

M-

Motor-

B-

Negative battery

S1

Field winding

S2

Field winding

C1

Logic

C2

Hand terminal

The regulator has three connectors for the motor and battery.

The connected cables are held in position by M8 screws, which should be tightened to a torque of max 16.3 Nm.

2 (18)

Service Manual

1998-07-27

English

F code

Section

6/

C code

6

7UDQVLVWRU SDQHO

Version No.

T code

/RJLF FRQQHFWRU

The transistor regulator has a built-in 16-pin connector for connection of logic operating current. See the table below for correct pin designation.

3LQ 1R

&RQQHFWLRQ &RQWDFWRU GULYHUV

P1

Not connected

P2

Not connected

P3

Not connected

P4

Main contactor 6SHHG VLJQDOV

P5

Pot High, Bias resistor

P6

Reference voltage 0-5 V

P7

Pot Low, Bias resistor &RQWURO VLJQDOV

© BT Products AB

P8

Not connected

P9

Not connected

P 10

Not connected

P 11

Travel in drive wheel direction, input

P 12

Travel in fork direction, input

P 13

Not connected

P 14

Parameter selection, input (Mode 1 Select)

P 15

Right foot switch, input

P 16

Start switch, input (KSI)

Service Manual

1998-07-27

English

3 (18)

F code

Section

Version No.

T code

6/ 6 7UDQVLVWRU SDQHO

C code

3DUDPHWHUV Curtis 1243 features a large selection of parameters for optimising the behaviour of the truck. Most of these parameters are set at the factory and cannot be changed in the field. The table below shows the parameters that may be changed by a service engineer using the 1307 handheld terminal. See section “Using the handheld terminal” for instructions on how to check and change the parameters.

4 (18)

3DUDPHWHU

$UHD

6WDQGDUG 8QLW YDOXH

([SODQDWLRQ

M1 ACCEL RATE

0,1-3

0.8

Sec

Time to reach full feeding to the motor from standstill in Mode 1

M2 ACCEL RATE

0,1-3

0.8

Sec

Time to reach full feeding to the motor from standstill in Mode 2

*M3 ACCEL RATE

0,1-3

0.5

Sec

Time to reach full feeding to the motor from standstill in Mode 3

*M4 ACCEL RATE

0,1-3

0.5

Sec

Time to reach full feeding to the motor from standstill in Mode 4

M1 DRIVE C/L

50-190

270

Amp

Current limit for travelling in Mode 1

M2 DRIVE C/L

50-270

270

Amp

Current limit for travelling in Mode 2

*M3 DRIVE C/L

50-190

270

Amp

Current limit for travelling in Mode 3

*M4 DRIVE C/L

50-190

270

Amp

Current limit for travelling in Mode 4

M1 BRAKE C/L

50-160

160

Amp

Current limit value for brake current in Mode 1

M2 BRAKE C/L

50-230

230

Amp

Current limit value for brake current in Mode 2

*M3 BRAKE C/L

50-160

160

Amp

Current limit value for brake current in Mode 3

Service Manual

1998-07-27

English

F code

Section

6/

C code

6

7UDQVLVWRU SDQHO

Version No.

T code

3DUDPHWHU

$UHD

6WDQGDUG 8QLW YDOXH

([SODQDWLRQ

*M4 BRAKE C/L

50-160

160

Amp

Current limit value for brake current in Mode 4

M1 DECEL RATE

0,1-10

4

Sec

Time for truck to completely stop from the speed lever being released in Mode 1

M2 DECEL RATE

0,1-10

3

Sec

Time for truck to completely stop from the speed lever being released in Mode 2

*M3 DECEL RATE

0,1-10

5

Sec

Time for truck to completely stop from the speed lever being released in Mode 3

*M4 DECEL RATE

0,1-10

5

Sec

Time for truck to completely stop from the speed lever being released in Mode 4

M1 MAX SPEED

50-100

100

%

Max. speed in Mode 1

M2 MAX SPEED

50-92

100

%

Max. speed in Mode 2

*M3 MAX SPEED

50-100

100

%

Max. speed in Mode 3

*M4 MAX SPEED

50-100

100

%

Max. speed in Mode 4

THROTTLE MAP

20-80

40

%

Degree of feeding to the motor at 50% reference voltage ( 63((' 5()(5(1&( 9$/8()

*Not used.

© BT Products AB

Service Manual

1998-07-27

English

5 (18)

F code

Section

Version No.

T code

6/ 6 7UDQVLVWRU SDQHO

C code

0RGH DQG Curtis 1243 is a Multi-mode regulator, which means it is possible to select different parameter settings. This allows selection of optimum truck behaviour in unloaded and loaded condition. Switching between Mode 1 and Mode 2 is enabled through pin 14 in the logic connector.

• Mode 1: These parameters are active when pin 14 is low.

• Mode 2: These parameters are active when pin 14 is high.

'LDJQRVLQJ DQG WURXEOHVKRRWLQJ 'LVSOD\ RI HUURU FRGHV DQG HUURU ORJJLQJ A built-in microprocessor continuously monitors regulator operation. When a fault is detected an error code is generated.

The error code can be checked with the 1307 handheld terminal or through the blinking pattern of the STATUS LED on top of the regulator. Normally, when no fault is present, the LED blinks about once every second.

STATUS MODEL

VOLTAGE

SERIAL

CURRENT

The regulator logs all faults in its internal memory. If a fault appears repeatedly, this is logged only once. Using the 1307 handheld terminal, it is possible to check which faults are still present and it is also possible to obtain a historical listing of faults. The STATUS LED only shows one fault at a time and faults cannot be queued.

See section “Using the handheld terminal” for instructions on how to read the error codes using the handheld terminal.

6 (18)

Service Manual

1998-07-27

English

F code

Section

6/

C code

6

7UDQVLVWRU SDQHO

Version No.

T code

(UURU FRGHV DQG WURXEOHVKRRWLQJ The table below depicts the error codes that may be shown by the STATUS LED or read using the handheld terminal. The table also presents suggestions to possible causes for each error.

67$786 /(' +DQGKHOG WHU PLQDO GLVSOD\

([SODQDWLRQ

3RVVLEOH FDXVH

LED off

-

No voltage or defective regulator

Burnt fuse, bad contact, not connected, defective regulator

LED on

-

Defective regulator

Defective regulator

1,1

¤¤

CURRENT SHUNT FAULT

Built-in current shunt defective

Defective regulator

1,2

¤ ¤¤

HW FAILSAFE

Safety error

Defective regulator

1,3

¤ ¤¤¤

M- SHORTED

M- shorted

Defective regulator

1,4

¤ ¤¤¤¤

SRO

Sequence error

This parameter has been set to OFF at the factory. This fault should not happen

2,1

¤¤ ¤

THROTTLE FAULT 1

Reference current 0-5 volt error

1. Ref. voltage signal interrupted 2. Input signal cable shorted to B+ or B3. Broken potentiometer 4. Wrong potentiometer type selection

2,3

¤¤ ¤¤¤

HPD

Sequence error

1. Wrong sequence of input signal for KSI and speed lever 2. Incorrectly set speed lever

2,4

¤¤ ¤¤¤¤

THROTTLE FAULT 2

Pot Low interrupted or shorted

1. Pot Low input open 2. Pot Low input shorted 3. Wrong potentiometer selection

3,1

¤¤¤ ¤

CONT COIL/FLD SHORT

Too high current for contactor feeding or shorted field winding

1. Coil, main contactor shorted 2. Field winding shorted

3,2

¤¤¤ ¤¤

MAIN CONT WELDED

Welded main contactor

1. Main contactor stuck in closed position 2. Contactor output shorted

© BT Products AB

Service Manual

1998-07-27

English

7 (18)

F code

Section

Version No.

T code

6/ 6 7UDQVLVWRU SDQHO

C code

67$786 /(' +DQGKHOG WHU PLQDO GLVSOD\ 3,3

¤¤¤ ¤¤¤

3,4

¤¤¤ ¤¤¤¤ MISSING

FIELD OPEN

([SODQDWLRQ

3RVVLEOH FDXVH

Open field winding

1. Field winding not connected 2. Interruption in field winding

Missing contactor

1. Main contactor, coil interruption 2. Missing main contactor 3. Main contactor not connected

CONTACTOR

4,1

¤¤¤¤ ¤

LOW BATTERY VOLTAGE

Low battery voltage

1. Battery voltage <16 volts 2. Corroded battery terminals 3. Loose battery or regulator connections

4,2

¤¤¤¤ ¤¤

OVERVOLTAGE

Overvoltage

1. Battery voltage > 33 volts 2. Truck operating with connected charger

4,3

¤¤¤¤ ¤¤¤ THERMAL

Over-/under-temperature reduction

1. Temp. >85oC or < - 25oC 2. Truck overloaded 3. Wrong installation of transistor regulator 4. Operation under extreme conditions

CUTBACK

+3' HUURU This is a sequence error. This error is detected if the reference voltage (0-5 V) exceeds 25% of the maximum value when the KSI input is high (pin 16).

8 (18)

Service Manual

1998-07-27

English

F code

Section

6/

C code

6

7UDQVLVWRU SDQHO

Version No.

T code

5HVHWWLQJ HUURUV To reset an error and remove the error code indication, apart from remedying the fault itself, the start switch (S17) or the right foot switch (S19) also needs to be turned on and off.

Some exceptions exist as follows:

(UURU

5HVHW ZKHQ

HPD

Reference voltage is less than 25% of max value

OVERVOLTAGE

Battery voltage falls below 33 V

THERMAL CUTBACK

The temperature is within allowed range

THROTTLE FAULT 1, 2

Error has been fixed

LOW BATTERY VOLTAGE

When battery voltage exceeds 16 V

0DLQWHQDQFH The transistor regulator contains no user-repairable parts. 'R QRW DWWHPSW WR RSHQ WKH WUDQVLVWRU UHJXODWRU 23(1,1* 7+( 5(*8/$725 :,// &$86( 7+( :$55$17< 72 %( &20( 92,' It is recommended that the regulator be cleaned on the outside at regular intervals. When the regulator is cleaned this is also a good opportunity to check the diagnostics file of the regulator using the handheld terminal (if available).

6DIHW\ The regulator is a high-power component. When working on a battery operated vehicle, necessary precautions should be taken. This includes, but is not limited to, correct training, use of eye protectors, avoiding use of lose-fitting clothes, removal of watches and jewellery, and use of insulated tools only. :$51,1* 5LVN RI VKRUW FLUFXLWLQJ 5HPRYH DOO ZDWFKHV MHZHOOHU\ DQG DOZD\V XVH LQVXODWHG WRROV RQO\

© BT Products AB

Service Manual

1998-07-27

English

9 (18)

F code

Section

Version No.

T code

6/ 6 7UDQVLVWRU SDQHO

C code

&OHDQLQJ Although the transistor regulator does not require any maintenance as such, the following minimum maintenance regiment is recommended every 250 working hours.

1. Disconnect the regulator from the battery.

2. Prior to performing any work on the transistor regulator, discharge the capacitors inside the transistor regulator by connecting a load (e.g. a contactor coil or the horn) across the regulator’s B+ and B- terminals.

3. Remove all dirt and traces of corrosion from the power terminals. Wipe the regulator clean using a moistened rag, and let it dry before reconnecting it to the battery.

Check that the regulator’s power terminals are properly tightened. Use two insulated wrenches for this purpose in order to avoid unbalanced loads on the power terminals.

10 (18)

Service Manual

1998-07-27

English

F code

Section

6/

C code

6

7UDQVLVWRU SDQHO

Version No.

T code

7HFKQLFDO VSHFLILFDWLRQV ± &XUWLV 9DOXH

8QLW

Rated operating voltage

24

Volts

Overvoltage limit

33

Volts

Undervoltage limit

16

Volts

Minimum operating voltage

Electrical insulation towards cold body

500

V AC

Minimum

PWM frequency

15

kHz

Max. current of armature winding *

300

Amps

for 2 minutes

100

Amps

for 1 hour

35

Amps

for 2 minutes

Max. current of field winding

20

([SODQDWLRQ

for 1 hour

Contactor voltage

24

Volts

Same as battery voltage

Contactor current

2

Amps

Max (current limit at 2.5 amps)

KSI input voltage, Min.

16.8

Volts

KSI input current

50

mA

Logic input voltage

>7.5; High <1; Low

Volts

Logic input current

15

mA

Operating temperature

-40 to +50

°C

Overtemperature, reduction

85

°C

Undertemperature, reduction

-25

°C

* During specific test conditions.

© BT Products AB

Service Manual

1998-07-27

English

11 (18)

F code

Section

Version No.

T code

6/ 6 7UDQVLVWRU SDQHO

C code

+DQGKHOG WHUPLQDO The 1307 handheld terminal is used to programme, test and troubleshoot the 1243 transistor regulator. The handheld terminal is powered through the 4-pin Molex connector on the side of the regulator.

S1 B-

12 (18)

Service Manual

1998-07-27

S2 M-

B+

English

F code

Section

6/

C code

6

7UDQVLVWRU SDQHO

Version No.

T code

)XQFWLRQ

([SODQDWLRQ

LCD display

4-line LCD Display

PROGRAM MODE button

Select this mode to display (and change) regulator parameters

TEST MODE button

Select to display input/output status, etc.

DIAGNOSTICS MODE

Select to display current, active faults detected by the regulator

SCROLL DISPLAY buttons

Scroll the display text lines (up and down)

MORE INFO button

Press to display more precise information regarding the selected mode

Button LEDs

Indicate whether the relevant CHANGE VALUE button is active. Adjustment is not possible when the LED goes out

CHANGE VALUE buttons

Increase/decrease the value of the selected item

Operating mode LEDs

Indicate the active function mode

© BT Products AB

Service Manual

1998-07-27

English

13 (18)

F code

Section

Version No.

T code

6/ 6 7UDQVLVWRU SDQHO

C code

8VLQJ WKH KDQGKHOG WHUPLQDO

S1 B-

S2 M-

B+

• Connect the handheld terminal to the programming connector on the regulator.

• Make sure the truck is powered.

The terminal will now display the regulator control number, the manufacturing date and the software version. Then the terminal displays prompts for further instructions.

The terminal has three main functions: PROGRAM, TEST and DIAGNOSTICS. • The PROGRAM mode is used to display the terminal parameters. In this mode, the displayed parameters can be changed.

• The TEST mode displays real-time information on input/ output signal statuses and the regulator temperature. In the TEST mode, the selected item need not be the first in the displayed list; it may be among any of the four items shown. The TEST mode is useful, e.g., to check the regulator operating conditions during installation and to troubleshoot errors.

• The DIAGNOSTICS mode displays current errors detected by the regulator.

Further, with the handheld terminal two other functions are accessible: SPECIAL PROGRAM MODE and SPECIAL DIAGNOSTIC MODE.

14 (18)

Service Manual

1998-07-27

English

F code

Section

6/

C code

6

7UDQVLVWRU SDQHO

Version No.

T code

• The SPECIAL PROGRAM MODE is used for various functions, such as language selection, saving edited parameters, adjustment of the contrast in the LCD window and to clear the DIAGNOSTIC HISTORY FILE. • The SPECIAL DIAGNOSTIC MODE is used to review the errors saved by the regulator in the DIAGNOSTIC HISTORY FILE and not yet cleared.

&KHFNLQJ DQG DGMXVWLQJ SDUDPHWHUV • Press the PROGRAM mode button. The Program mode LED lights.

PROGRAM

The terminal displays the first four parameters.

See the picture below.

The display shows four parameters at a time. Each line represents one parameter. (A) is the name of the parameter. The arrow (B) shows the selected parameter, which can be edited, and (C) shows the current setting of the parameter.

Press one of the SCROLL DISPLAY buttons to see other parameters.

To adjust a parameter, scroll the display up or down until the arrow (B) points towards the desired one.

• Increase the value by pressing the CHANGE VALUE - ”up” button or decrease it by pressing the CHANGE VALUE ”down” button.

127(

:KHQ DQ\ RI WKH SDUDPHWHUV VKRZQ RQ WKH GLVSOD\ DUH FKDQJHG WKH QHZ YDOXH LV LPPHGLDWHO\ HQWHUHG LQWR WKH UH JXODWRU

8VLQJ 025( ,1)2 LQ WKH 352*5$0 02'( When the MORE INFO button is pressed in the PROGRAM MODE, details of the selected parameter are displayed. The parameter is shown using a horizontal bar graph together with the Min. and Max. values of the parameter. © BT Products AB

Service Manual

1998-07-27

English

15 (18)

F code

Section

Version No.

T code

C code

6/ 6 7UDQVLVWRU SDQHO

MODE 1 ACCELERATION RATE; SECS MIN 0.2

1.3

MAX 3.0

63(&,$/ 352*5$0 02'(

*

MORE INFO

PROGRAM

The SPECIAL PROGRAM MODE is used for a number of more or less self-explanatory functions. In the SPECIAL PROGRAM MODE it is possible to select the language, save settings, return to previous settings, download settings to the regulator, adjust the contrast in the LCD display and to clear the DIAGNOSTIC HISTORY FILE. To access the SPECIAL PROGRAM MODE, keep the MORE INFO button depressed and simultaneously press the PROGRAM button. The LED in the PROGRAM button lights just like in the PROGRAM mode. Once in the SPECIAL PROGRAM MODE, the MORE INFO button is used to carry out the desired function.

Example: To adjust the contrast of the LCD display, select Contrast Adjustment by pressing the SCROLL buttons until “Contrast Adjustment” is displayed on the top line. Then press MORE INFO to adjust the contrast.

8VLQJ WKH 7(67 PRGH • Press the TEST mode button. The TEST mode LED lights.

The terminal now shows the real-time status of the various input/output values. See the picture below.

TEST

Four rows of values can be shown at any one time. Each row represents the value of an input/output signal. (A) is the name of the input/output signal, while (B) is the actual value.

Press one of the SCROLL DISPLAY buttons to show other values.

16 (18)

Service Manual

1998-07-27

English

F code

Section

6/

C code

6

7UDQVLVWRU SDQHO

Version No.

T code

([DPSOH The speed adjustment function of the truck can be verified by driving the truck forwards and backwards. The THROTTLE % value changes to display the percentage of full speed as requested. It should be possible to obtain a 100% value in both directions.

The table below explains the various TEST values.

7HVW YDOXH

([SODQDWLRQ

THROTTLE %

Speed lever input signal as a percentage

FIELD CURRENT

Actual current load in field winding

ARM CURRENT

Actual current load in armature winding

FIELD PWM

Modulation of field winding (%)

ARM PWM

Modulation of armature winding (%)

BATT VOLTAGE

Actual battery voltage

HEATSINK TEMP

Actual regulator temperature

FORWARD INPUT

Status of forward drive in aisle (on/off)

REVERSE INPUT

Status of reversing in aisle (on/off)

MODE INPUT A

Status of Mode 1 Select input (pin 14)

MODE INPUT B

Status of Mode 2 Select input (not used)

INTERLOCK

Status of Interlock input (pin 15, right foot switch)

EMR REV INPUT

Status of Emergency Reverse input (not used)

MAIN CONT

Status of Main contactor output (pin 4)

AUX DRIVER

Not used

8VLQJ WKH ',$*1267,&6 02'( • Press the DIAGNOSTICS mode button. The DIAGNOSTICS function mode LED lights.

DIAGNOSTICS

© BT Products AB

The terminal shows a list of current errors detected by the regulator. The picture below shows the display status when no errors have been detected.

Service Manual

1998-07-27

English

17 (18)

F code

Section

Version No.

T code

6/ 6 7UDQVLVWRU SDQHO

C code

63(&,$/ ',$*1267,&6 02'(

*

MORE INFO

DIAGNOSTICS

In the SPECIAL DIAGNOSTICS MODE, the DIAGNOSTIC HISTORY FILE of the regulator is displayed. This file contains all errors logged by the regulator since the file was last cleared. Each error is logged only once in disregard of how many times the error may have occurred.

To access the SPECIAL DIAGNOSTICS MODE, keep the MORE INFO button depressed and simultaneously press the DIAGNOSTICS button. The LED in the DIAGNOSTICS button lights.

To clear the DIAGNOSTICS HISTORY FILE, switch to the SPECIAL PROGRAM MODE, select “Clear Diag History" and press the MORE INFO button for further instructions.

18 (18)

Service Manual

1998-07-27

English

F-code

Section

6/ IIssued by

66'

Approved by

Version no

)UHGULN :LJK

C-code

6

(OHFWURQLF FDUG T-code

(OHFWURQLF FDUG Valid from machine number: 7 FRGH

0RGHO

7UXFN 1R

378

SL 2.0

326301AA-

1RWH

*HQHUDO GHVFULSWLRQ The electronic cards function is to supervise all the truck’s logic functions. The card also includes a steering servo section which drives a permanent magnet type steering motor.

The card is supplied with power from the truck’s 24 V battery.

Input signals are received from transmitters and steering devices and output signals are sent to valves, contacts and transistor controller. The signals are both analogue and digital. Some of these functions can be adjusted by parameter settings.

The electronic card is equipped with green LED’s on the inputs from micro switches and red LED’s on the outputs to the contactors.

© BT Industries AB

Service Manual

1998-07-31

English

1 (8)

F-code

Section

Version no

T-code

6/ 6 (OHFWURQLF FDUG

C-code

3DUDPHWHU VHWWLQJV The parameter setting mode is accessed by pressing SW1 (select) at the same time as the ignition key is switched on.

The truck cannot be driven in this mode. The parameter number is presented on the display and the parameter indicator comes on.

Press SW2 (UP) or SW3 (DOWN) to step up or down respectively in the parameter list. The parameter value is shown and is opened for modification by pressing SW1(SELECT). The parameter indicator starts to flash. The parameter value is increased or decreased by using SW2 (UP) or SW3 (DOWN) respectively. The parameter value is saved and acknowledged using SW1(SELECT).

3DUD PHWHU

1DPH

P01 P02

2 (8)

8QLW

0LQ 0D[

6WHS 6WG 'HVFULSWLRQ

SteerProgPar

1

5

1

2

Steering sensitivity

BatteryPar

1

20

1

10

Setting size/type of battery (see section 2.1)

Service Manual

1998-07-31

English

F-code

Section

6/

C-code

6

(OHFWURQLF FDUG

Version no

T-code

6HWWLQJ WKH EDWWHU\ VL]H W\SH The BatteryPar parameter must be set to the Ah-value of the battery in order for the charge status shown by the inbuilt battery meter to be as accurate as possible. The table below shows the available battery sizes that can be programmed.

3DUDPHWHU YDOXH

%DWWHU\ VL]H

1 2 3 4 5 6 7 8 9

600Ah

10 11

480Ah

12 13

400Ah

14 15

300Ah

16 17

200Ah

18 19 20 :$51,1* Do not set a higher value than that recommended as this will result in a deeper discharge, which can damage the battery.

© BT Products AB

Service Manual

1998-07-31

English

3 (8)

F-code

Section

Version no

T-code

C-code

6/ 6 (OHFWURQLF FDUG

&DUG SLQ FRQQHFWLRQV DQG OHG¶V

7HUPLQDO /(' QR QR

6LJQDO QDPH

)XQFWLRQ

Power Ok

Internal supply voltage OK

+24 V STEER

Supply to steering servo

SteerPwr

Supply to steering servo after the safety relay

%$77

Battery -

102

287 &$1 +

Communication to display

103

287 &$1 /

Communication to display

104

,13 +251

Switch for horn (S18)

101

101

201

201

,13 )25. 83

Lifting the forks (S51)

202

202

,13 )25. '2:1

Lowering the forks (S41)

203

287 :,3(5 )(('

Supply to accelerator (+7.35 V)

204

,13 :,3(5

Accelerator (0.7-6.6 V, 3.7 V in neutral position)

205

:,3(5 5(7851

Supply to accelerator 0 V

206

,13 67((5,1* :+((/ 7$&+2

Steering tacho voltage (+/-3 V. 0 V in neutral position

207

,13 67((5,1* :+((/ 7$&+2

Steering tacho voltage (+/-3 V. 0 V in neutral position

4 (8)

Service Manual

1998-07-31

English

F-code

Section

6/

Version no

T-code

7HUPLQDO /(' QR QR

6LJQDO QDPH

)XQFWLRQ

208

287 %5$.( 683 3/<

Supply brake micro switch

209

209

,13 %5$.(

Brake micro switch (S10)

210

210

,13 .(<

+24 V from key

287 .(<

+24 V to key out

211

C-code

6

(OHFWURQLF FDUG

301

301

,13 )25.723

Forks at top (S31)

304

304

,13 5,*+7 )227 6:,7&+

Right foot switch (S19)

305

305

,13 +<'35(6

Load >550 kg (S61)

306

306

,13 /()7 )227 6:,7&+

Left foot switch

307

307

,13 (1' 326, 7,21 67((5 :+((/

Inductive transmitter (S66), end position, steering

308

308

,13 (1' 326, 7,21 67((5 :+((/

Inductive transmitter (S67), end position, steering

401

401

,13 9 '&

+24 V from battery

402

287 9 '&

+24 V from key out

403

9

Battery -

404

404

,13 '5,9( &+233(5 2.

Transistor controller OK

409

409

,13 %$77 ,1',

Battery + for voltage main (+24 V)

410

,13 %$77 ,1', &855(17

+ side of battery shunt

411

,13 %$77 ,1', &855(17

Battery - and - side of battery shunt

© BT Products AB

Service Manual

1998-07-31

English

5 (8)

F-code

Section

Version no

T-code

C-code

6/ 6 (OHFWURQLF FDUG

7HUPLQDO /(' QR QR

6LJQDO QDPH

)XQFWLRQ

501

501

287 '5,9( 67((5 :+((/ ',5

Output to transistor controller for driving in steer wheel direction

502

502

287 '5,9( )25. Output to transistor controller for driving ',5 in fork direction

503

503

287 %5$.(

Mechanical brake (step1)

504

504

287 %5$.(

Mechanical brake (step2)

505

505

287 3803 &21 7$&725

Hydraulic pump (K30)

506

506

287 /2:(5,1* 9$/9(

Magnetic valve lower function (Y41)

508

287 +251

Horn (H1)

509

287 63((' 5() Reference voltage for speed to transistor 9$/8( controller 287 02'( 6(/(&7

Output to transistor controller for selection of parameter range

287 9 '&

+24 V out to pressure guard

9'& 67((5 6833/<

Supply to steering motor

702

2 9

Battery -

703

287 67((5 02725

Supply to steering motor

704

287 67((5 02725

Supply to steering motor

608

608

610

701

701

Signal names marked by inverted underlining have the following meaning: Signal INP.FRKTOP e.g. the system presupposes that the forks are at the top when the signal is LOW (0 V) LED out.

6 (8)

Service Manual

1998-07-31

English

F-code

Section

6/

C-code

6

(OHFWURQLF FDUG

Version no

T-code

(UURU FRGHV The logic card records all error codes (E101-E140) in an error code register together with the current hour meter setting.

The 80 most recent errors are stored. Press SW1 (SELECT) to see the error code register when the power is on. The most recent error is shown first. Step up by pressing SW2 (UP). By pressing SW3 (DOWN) you can work through the errors, error codes and hour meter settings in the order they were registered. If no button is pressed within 20 seconds the display will return to the battery status.

© BT Products AB

&RGH 1R

(UURU W\SH

'LVSOD\

(IIHFW RQ WKH WUXFN

11

Steering servo current limited due to high temperature

C011

Limited to 50%

16

Speed control’s potentiometer not in neutral position when current switched on

C016

If the potentiometer is moved to the neutral position the truck can then be driven

19

Error in parameter area, new standard values have been loaded

C019

Set applicable parameters before driving

27

Voltage supply not connected

C027

101

Program error

E101

Note 1

102

One of the outputs has short circuited to earth

E102

Note 2

103

One of the outputs has short circuited to +24 V

E103

Note 2

104

Fault on accelerator potentiometer or its connections

E104

Note1

107

The transistor chopper has broken the main contactor

E107

Note 1

Service Manual

1998-07-31

English

7 (8)

F-code

Section

Version no

T-code

C-code

6/ 6 (OHFWURQLF FDUG

&RGH 1R

(UURU W\SH

'LVSOD\

(IIHFW RQ WKH WUXFN

120

Memory cells that should hold steering commands have been corrupted

E120

Note 3

121

Steering servo reports an error on the output transistor

E121

Note 3

122

Steering servo is too hot

E122

Note 3

123

Control voltage does not match reference

E123

Note 3

125

Faulty steering tachometer or its connections

E125

Note 3

126

Faulty connections to steering motor

E126

Note 3

127

Communication error with steering control

E127

Note 3

128

The steering servo has switched the safety relays (check sum error or no communications)

E128

Note 3

131

Error in safety relay

E131

Note 3

140

Wrong check sum in program memory

E140

Note 4

Note 1: The fault cuts out the drive (the truck free wheels) Note 2: If the fault occurs on the outputs for driving/brakes the drive is cut.

If the fault occurs on the outputs for hydraulic pump the lift is blocked.

If the fault occurs on the outputs of other hydraulic functions lifting and lowering are blocked.

Note 3:The fault blocks the steering and the truck’s brakes are applied.

Note 4: The truck cannot be driven.

8 (8)

Service Manual

1998-07-31

English

F code

Section

C code

6/ 6

+\GUDXOLF SQHXPDWLF V\VWHP Issued by

66'

Approved by

Version No.

)UHGULN :LJK

T code

+\GUDXOLF SQHXPDWLF V\VWHP Valid from serial number: 7 FRGH

0RGHO

6HULDO 1R

378

SL 2.0

326301AA-

1RWHV

*HQHUDO The hydraulic system is comprised of a compact hydraulic unit, including a magnetic valve to lower the forks, a relief valve and a pressure guard as well as two telescopic cylinders to lift the forks.

© BT Industries AB

Service Manual

1998-08-19

English

1 (4)

F code

Section

Version No.

T code

C code

6/ 6

+\GUDXOLF SQHXPDWLF V\VWHP

+\GUDXOLF GLDJUDP

3

7

/LVW RI V\PEROV 6\PERO

'HVLJQDWLRQ

)XQFWLRQ

1

Lift cylinder

Lifting the forks

2

Valve

Pressure limiter valve

3

Valve

Flow valve

4

Valve

Nonreturn valve

M3

Motor

Pump motor

P

Pump

Pump

Pressure guard

Braking power

T

Tank

Tank

Y41

Valve

Lowering the forks

S61

2 (4)

Service Manual

1998-08-19

English

F code

Section

C code

6/ 6

+\GUDXOLF SQHXPDWLF V\VWHP Version No.

T code

)XQFWLRQDO GHVFULSWLRQ /LIWLQJ WKH IRUNV When the fork lifting lever is operated, the pump contactor closes and turns on the pump motor, which feeds oil through the nonreturn valve (4) and into both cylinders lifting the fork cage.

/RZHULQJ WKH IRUNV When the fork lowering lever is operated, the magnetic valve Y41 opens completely to allow the oil in the hydraulic pipes to rush back to the oil tank through the flow valve (3).

3UHVVXUH JXDUG 6 The purpose of the pressure guard is to adjust the electromagnetic braking power, depending on the load on the forks, and also to switch between the two different parameter modes of the transistor regulator.

The pressure guard opens when the hydraulic pressure reaches a pressure corresponding to a weight of around 800-900 kg on the forks.

© BT Products AB

Service Manual

1998-08-19

English

3 (4)

F code

Section

Version No.

T code

C code

6/ 6

+\GUDXOLF SQHXPDWLF V\VWHP

4 (4)

Service Manual

1998-08-19

English