Download PDF: BT PPT 1400C/MX/MXC, PPT 1600MX, PPT 2000MX Master Service Manual

BT PPT 1400C

BT PPT 1400 MX

BT PPT 1400MXC

BT PPT 1600MX

BT PPT 2000MX

Master Service Manual

Product family PT

Part number: 147637-040 Issued: 1995-04-07 SSD

Contents Master Service Manual (MSM)

Part number:147637-040 Issued1999-06-23

Valid from serial number:

T-codeModelSerial NoNotes

200PPT 1400MX/MXC276898AA201PPT 2000MX276898AA202PPT 1600MX276898AA454PPL 2000MX305210AA-

1. Document list

SectionC-codeT-codeDocumentIssued Introduction1998-11-04

MContents, M1998-11-04

M1200, 201, 202, 454 Issued Operator’s manual1999-04-14

M2200, 201, 202General product information1999-06-02

454General product information1998-09-02

M4200, 201, 202Technical data1994-03-24

454Technical data1998-06-12

M6Ordering Spare Parts1998-11-04

M7200, 201, 202Quality Parts1999-06-21

M8200, 201, 202, 454 Recommended Spare Parts1999-06-21

PContents, P1998-11-04

P1Introduction, maintenance1998-11-04

P2200, 201, 202Preventive maintenance1994-01-21

454Preventive maintenance1998-01-09

001 200,201,202,454

SectionC-codeT-codeDocumentIssued

P3200, 201, 202Oil and grease specification1996-08-20 454Oil and grease specification1998-01-09

SContents, S1998-11-04

S11700200, 201, 202Electric drive motor1999-05-11 1700454Electric drive motor1999-02-03

S22550200, 201, 202, 454 Drive gear1998-01-09

S33360200, 201, 202, 454 Mechanical brakes1999-02-03

S55000.1200, 201, 202Electrical system, resistance regulator 1994-03-01

5000.2200, 201, 202Electrical system, transistor regulator 1994-03-12

5000454Electrical system, transistor regulator 1998-01-09

5230200, 201, 202, 454 Battery controller/hourmeter1999-01-02

5460.1200, 201, 202Transistor regulator1994-03-01

5460.2200, 201, 202Transistor regulator1997-03-19

5460.3200, 201, 202, 454 Transistor regulator1998-06-23

5710.1200, 201, 202Electronic card, resistence control 1994-03-03

5710.2200, 201, 202Transistor card, transistor control 1994-03-12

Introduction to BT’s Service Manual

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:

MMachine information

PPreventive maintenance

SService instructions

OOptions

At the top of each page you can find information on which section the page belongs: Section M4 means that it is Technical Data; F-code means it deals with this specific truck family; T-code means specific products; Date and Version number 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. 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:

XXXXXX-040=An English document on paper

XXXXXX-04C=The same document but on CD-ROM

IIssued byApproved byVersion noT-code

Contents, M

1 Truck information

M 1 Operator’s Manual

M 2General product information

M 3Product sheet

M 4Technical data

M 5Product improvements

M 6Spare Part ordering

M 7Quality Parts

M 8Recommended Spare Parts

Operator’s manual

Valid from serial number:

T-codeModelSerial NoNotes 200PPT 1400MX/MXC276898AA201PPT 2000MX276898AA202PPT 1600MX276898AA454PPL 2000MX305210AA-

1 General

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.

1.1 Issued operator’s manuals

T-codeModelSerial numberOrder number Issued

200/201/202PPT 1400/1600/2000MX1353291996-12-21

200PPT 1400MX/MXC276898AA-293314AA1473341996-04-10

200/201/202PPT 1400/1600/2000MX293315AA-298799AA1560671996-10-15

202PPT 1600MX276898AA-293314AA1473771996-04-11

201PPT 2000MX276898AA-293314AA1473361996-04-18

200/201/202PPT 1400/1600/2000MX298800AA-306954AA1570891997-04-02

200/201/202PPT 1400/1600/2000MX306955AA-1610431997-09-22

200/201/202PPT 1400/1600/2000MX306955AA-316911AA1612801998-02-06

200/201/202PPT 1400/1600/2000MX316912AA-324213AA1635791998-04-01

200/201/202PPT 1400/1600/2000MX324214AA-335438AA1661521998-08-12

200/201/202PPT 1400/1600/2000MX335439AA-1699831999-02-03

454PPL 2000MX305210AA-329899AA1602791998-02-10

454PPL 2000MX329900AA-1669041998-11-23

One of these Operator’s Manuals is supplied with the Manual as general information.

001200,201,202,454

General product information

Valid from serial number:

T-codeModelSerial NoNotes

200PPT 1400MX/MXC307085AA201PPT 2000MX307085AA202PPT 1600MX307085AA-

1 Presentation of the truck

The truck is a battery-powered support arm truck. In its standard design the truck is equipped with a tiller arm for control while walking.

PPT 1400C is a battery-powered support-arm truck for loading and leaving loads in confined areas. Thanks to its small format it is also suitable to carry on lorries.

The trucks PPT 1400MX and PPT 1400C have a maximum lifting capacity of 1400 kg.

PPT 1600MX has a maximum lifting capacity of 1600 kg.

PPT 2000MX has a maximum lifting capacity of 2000 kg.

The truck has a 24 V electrical system with two speed control options: A stepless transistor controlled system that gives smooth control of the speed while driving or a resistor controlled system with three speed steps.

The truck can be equipped with different accessories such as integrated charger, load support and running meter/battery status. The truck can also be fitted with stainless steel axles and low temperature oil if it is to be used in cool and humid conditions.

The forks are lifted by using a powerful and compact hydraulic unit that is automatically shut-off when the forks reach their highest lifting position. The automatic shut-off is used to increase the service life of the hydraulic components and reduce the power consumption from the battery.

Note that some of the truck models described in the Operator’s Manual may not be marketed in your country.

1.1 Intended application of the truck

The truck is solely designed and manufactured for indoor transportation, collecting and leaving of loads. The truck should be fitted with the appropriate accessories relevant to the application.

1.2 Forbidden application of the truck

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.

Lifting capacity with rated load, kg*

2 Truck data

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

Lift height, mm205205205205

Operating speed without load, m/s

Operating speed with rated load, m/s1.41.41.31.3

Max. operating gradient with rated load, %1111108 Weight

Weight with battery, kg (Ah)505 (240) 565(320) 455(160)535(240) 585(320) 535(240) 585(320)

Turning radius (Wa), mm (Ah)

(240) 1511 (320)

Continuous noise level according to CE prEN 12053, dB (A)< 70<70<70<70

Continuous noise level according to ASME B56, 11, 5_1992, db (A)71717171

Permitted drive wheel, material Vulkollan siped Vulkollan

Tractothan Elastomer Vulkollan siped Vulkollan

Tractothan Elastomer Vulkollan siped Vulkollan

Tractothan Elastomer Vulkollan siped Vulkollan

Tractothan Elastomer

* Deviations may occur on trucks adapted to specific application; the correct value can be found on the truck’s identification plate. In such cases the truck is also fitted with a modification plate.

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

3 Truck dimensions

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

PPT 1400, 1600 & 2000MX

4 Identification plate

The illustration shows the identification plate used on the truck.

DWEIGHT WITHOUT BATTERYkg

EBATTERY WEIGHTMAX MIN kg kg

FBATTERY VOLTAGEV

GBATTERY TYPE ACCORDING TO ASME-NORM UL583 (ONLY ASME)

5 Modification plate

The illustration shows the modification plate which is found on the truck if it is supplied as non-standard or if it has been modified after leaving the manufacturer. The plate includes information according to the table below.

ItemText

AModification plate

BType

CSerial number

DPlace of manufacture

EPlace of manufacture

FModification number

GDate

6 Main components

1.Tiller arm:

The truck is manoeuvred by the driver while walking. 208 degree steering area. The brakes are applied in the tiller arm’s upper and lower positions.

2.Covers:

Removable which provides good accessibility when servicing.

3.Emergency disconnector and battery connector:

The battery is charged via the permanently fitted charging connector.

4.Hydraulic unit:

Pump motor and pump are integrated in a compact unit.

5.Drive unit with brake:

Fixed drive unit with spring-loaded mechanical brake, travel motor, gears and drive wheel combined into a compact unit. Steering bearings between motor and gears.

6.Serial number:

The serial number plate fitted to the chassis.

7.Support castor wheels:

Two support castor wheels to ensure stability.

8.Electric panel:

Removable, which provides good access when servicing. 24 volt electrical supply. The speed is controlled by resistor or transistor (variable) systems.

9.Fork carriage:

The forks are held horizontal by a link system. The fork carriage requires no lubrication.

10.Battery:

24 V with different Ah values.

11.Instrument:

Combined hour meter/battery controller or hour meter only.

12.Identification plate:

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

2 3 4 5 6 7 8 9 10 11 12

7 Warning and information plates and symbols

The figure shows the position and significance of the plates and symbols located on the truck.

1.Signal/Horn

2.Hydraulic control: Lower

3.Hydraulic control: Lift

4.Travel direction

5.Hydraulic oil filling

6.Serial number

7.Lifting points

8.Identification plate

9.Modification plate

10.Passengers prohibited

General product information

Valid from serial number:

T-codeModelSerial

454PPL 2000MX305210AA-

1 Presentation of the truck

The truck is a battery powered support arm truck. In its basic design the truck is equipped with a tiller arm for alternative control: standing on the ride-on platform or walking. The truck has a maximum lifting capacity of 2000 kg.

The truck has a 24 V electrical system with variable transistor control that gives smooth control of the speed while driving. The truck can be equipped with different accessories including an integrated charger, load support and running meter/battery guard. The truck can also be fitted with stainless steel axles and low temperature oil with use in cold and damp environments.

The forks are lifted by a powerful and compact hydraulic unit, which is shut off automatically when the forks reach the highest lifting height. The automatic shut off is employed to increase the longevity of the hydraulic components and to reduce the energy drain on the battery.

2 Intended use of the truck

The truck is designed and manufactured solely for indoor transportation, loading and unloading of goods. The truck should be equipped with the appropriate accessories relevant to its working situation.

3 Forbidden use of the truck

As the truck is designed for indoor handling of goods it is forbidden, among others, to use the truck for the following:

-For driving in areas containing gases that can cause fire or explosions.

-As a tow truck for trailers

-For towing other trucks

-For the transport/lift of passengers

-For driving on surfaces other than hard surfaces, e.g. grass or gravel surfaces.

4 Truck data

The table provides information on specific technical data, which is of value with the daily use of the truck.

Truck typePPL 2000MX

Lifting capacity, classified load, kg2000

Lifting height, mm205

Ride-on platform height (collapsed) , mm150

Operating speed without load, m/s1.65

Operating speed with classified load, m/s1.4

Max. gradient with classified load, %8

Weight without battery, kg (240 Ah) (320 Ah) 375 390

Weight with battery, kg (240 Ah) (320 Ah) 575 640

Turning radius with raised forks and raised platform (medium battery compartment) (Wa), mm (depending of fork length) 1570-2300

Continuous sound pressure level value according to CE prEN12053, dB A< 70

Permitted drive wheel, materialvulkollan vulkollan siped tractothane elastomer rubber

The lifting capacity, lifting height and weight of the truck can be found on the truck’s type plates.

5 Truck dimensions

The diagram shows the outside dimensions of the truck in its standard design. PPL 2000MX

6 Type plate

The diagram shows the truck’s type plate.

CRATED

DWEIGHT WITHOUT BATTERYkg

EBATTERY WEIGHTMAX MIN kg kg

FBATTERY VOLTAGEV

GBATTERY TYPE ACCORDING TO ASME-NORM UL583 (ONLY ASME)

7 Modification plate

The diagram shows the modification plate that should be fitted to the truck if supplied as non-standard or if it has been modified after delivery by the manufacturer. The sign gives information as set out in the table below. ItemTextUnit

CharacterText

AModification plate

BType

CSerial number

DPlace of manufacture

EPlace of manufacture

FModification number

GDate

8 Main components

1.Tiller arm:

The truck is operated by the driver when walking. Steering range 208 degrees. The brakes are applied in the tiller’s upper and lower positions.

2.Hoods:

Easily removable, providing good accessibility when servicing.

3.Battery switch and Charging plug:

The battery is charged via the fixed charging plug.

4.Hydraulic unit:

Pump motor and pump are integrated into a compact unit.

5.Drive unit with brakes:

Fixed drive unit with spring loaded mechanical brakes, travel motor, drive gear, and drive wheel integrated into a compact unit. Steering bearing between the motor and drive gear. The pressure on the drive wheel is automatically adjusted to the weight of the load.

6.Machine number:

Punched plate on the chassis.

7.Support castor wheel:

2 support castors to ensure stability.

8.Electrical panel:

Removable, providing good accessibility for servicing. 24volt electrical system. The speed is regulated variably by means of a transistor regulator.

9.Fork carriage:

The forks are kept parallel by a link system. The fork carriage is lubrication free.

10.Battery:

24 V with different Ah-rates.

11.Instruments:

Combined running meter/battery guard or just a running meter.

12.Type plate:

Indicating the type designation, machine number, year of manufacture, weight without battery, battery weight, classified lifting capacity, battery voltage, type of battery and manufacturer.

13.Platform:

Collapsible ride-on platform, which is automatically raised when it is not loaded.

9 Warning and information plates

The diagram shows the placement and significance of the plates on the truck.

1.Horn

2.Hydraulic control: Lower

3.Hydraulic control: Lift

4.Direction of travel

5.Hydraulic oil filling point

6.Machine number

7.Lifting points

8.Type plate

9.Modification plate

Technical data

Transmission/gear

Type2-step angular2-step angular2-step angular

Gear ratio19,14:119,14:119.14:1

Normal temperatureSAE 80W/90SAE 80W/90SAE 80W/90 < -15oCSAE 75WSAE 75W SAE 75W Wheels

Torque wheel bolts65 Nm65 Nm65 Nm

Normal temperature ISO-L-HM32ISO-L-HM32ISO-L-HM32 < -15oCISO-L-HV32ISO-L-HV32 ISO-L-HV32 Fuses

Motor circuits, A292282922829228

Ampere, A100100100

Control circuit, A122308-075122308-075122308-075

Ampere, A7,57,57,5 ModelPPT

Version noT-code

001 200,201,202

Technical data

Valid from serial number:

T-codeModelSerial No.Notes

454PPL 2000MX305210AA-

MODELPPL 2000MX

Drive motor

TypeTTL 140S-M2

Power, kW1,2

Intermittens, %60

Min. carbon brush length, mm12

Min. commutator diameter, mm47

Transmission/drive gear

Type2-step angular

Gear ratio19,14:1

Oil volume, litre1,0

OilHypoid oil

Normal temperatureSAE 80W/90 < -15oCSAE 75W

Wheels

Drive wheel, mmDia 215x70

Axle pressure without load, kg325

Axle pressure at rated load, kg475

Tightening torque for wheel bolts, Nm65

Fork wheels, mmDia 80x75

Axle pressure without load, kg115

Axle pressure at rated load, kg1675

Tightening torque for axle bolts------------Support wheels, mmDia 125x40

Axle pressure without load, kg140

Axle pressure at rated load, kg430

Hydraulic unit

Output, kW1,2

Speed/min. at working pressure5500

Operating conditions, %10

Min. carbon brush length, mm7,5

Min. commutator thickness/diameter, mm 4,75

Pressure at rated load, bar110

Relief pressure, bar130

Pump flow, litre/min.4,7

Tank volume, litre0,5

Oil typeHydraulic oil

Normal temperatureISO-L-HM32

< -15oCISO-L-HV32

Fuses

Motor circuits100 A

Control circuits7,5 A

Batteries

Dimensions W x L x H, mm196x645x570/ 245x645x570

Capacity, Ah240/320

Weight, kg200/250

Driving speeds

Lifting and lowering times

Lift without load, s1,7

Lift with rated load, s2,6

Lowering without load, s2,2

Lowering with rated load, s1,9

Power consumption

Driving without load29 A

Driving with rated load50 A

Lifting without load60 A

Lifting with rated load150 A

Ordering Spare Parts

•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.

Ordering Spare Parts

Parts

T-codeModelSerial NoNotes

200PPT 1400MX/MXC239400AA201PPT 2000MX239400AA202PPT 1600MX239400AA454PPL 2000MX305210AA-

1 Issued Quality Parts

200/201/202PPT 1400/1600/2000MX239400AA-243536AA289951992-12-01

200PPT 1400/1600/2000MX243537AA-246663AA295371993-05-01

200PPT 1400/1600/2000MX246664AA-247613AA1396961993-09-01

200PPT 1400/1600/2000MX247614AA-268676AA1405761994-03-01

200PPT 1400/1600/2000MX268677AA-284058AA1481851995-10-01

200PPT 1400/1600/2000MX284059AA-293314AA1523801996-05-01

200PPT 1400/1600/2000MX293315AA-1547101996-11-01

200/201/202PPT 1400/1600/2000MX306955AA-316739AA1606701997-10-29

201/201/202PPT 1400/1600/2000MX316740AA-324213AA1635261998-03-27

200/201/202PPT 1400/1600/2000MX324214AA-329899AA1661021998-09-04

200/201/202PPT 1400/1600/2000MX329900AA-335438AA1690111998-11-22

200/201/202PPT 1400/1600/2000MX335439AA-340959AA1699911999-03-14

201PPT 2000MX335439AA-1685261999-03-24

200/201/202PPT 1400/1600/2000MX340960AA-1723861999-06-10

454PPL 2000MX305210AA-316739AA1602751997-11-27

454PPL 2000MX316740AA-329899AA1643051998-03-30

454PPL 2000MX329900AA-1669061998-11-24

001200,201,202,454

T-codeModelSerial NoNotes 200PPT 1400MX/MXC239400AA201PPT 2000MX239400AA202PPT 1600MX239400AA454PPL 2000MX305210AA-

1 Issued RSP

200/201/20207PPT

Introduction, maintenance

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 service interval may be shortened if the truck is used more frequently or in more demanding situations, e.g cold store, dusty or corrosive situations. 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 every 500 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.

1. Safety regulations with maintenance work

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

WARNING!

Short-circuiting/Burns.

When working with the truck’s electrical system, shortcircuiting/burns can occur if a metal object comes into contact with live electrical connections. Remove watches, rings or other types of metal jewellery.

•Always disconnect the battery by pulling out the battery isolator 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

WARNING!

Risk of burns.

Hot transmission and hydraulic oil. Let the truck cool before changing the oil.

•Only fill the hydraulic system with new and clean oil

WARNING!

The hydraulic system can be damaged. If the oil is contaminated hydraulic components can be damaged. Always use new and clean oil in the hydraulic system.

•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

NOTE!

The battery can be damaged. When welding using an electric power source the welding current can enter the battery. The battery should therefore be disconnected.

•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

CAUTION!

Harmful gases.

Paint that is heated gives off harmful gases. Remove 100 mm of paint from the work area.

2. Cleaning and washing

Cleaning and washing of the truck is important to ensure the truck’s reliability.

•Carry out general cleaning and washing weekly NOTE!

Risk of short-circuiting. The electrical system can be damaged Disconnect the battery before washing by pulling out the battery connector.

2.1. External cleaning

•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

NOTE!

Jamming, corrosion.

Mechanical components can be damaged. After washing, the truck should be lubricated as set out in the chapter Maintenance and lubrication chart.

2.2. Cleaning the motor compartment

•Cover the electric motors, connections and valves before washing NOTE!

Risk of short-circuiting. The electrical system can be damaged. Electrical components must not be cleaned with a high pressure washing unit.

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

•Rinse off loose grime using tepid water

2.3. Electrical components

•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

NOTE!

Risk of short-circuiting. Electrical components can be damaged. Do not break the guarantee seal on the electronic board.

3. Safe lifting

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.

•Activate the parking brake to prevent the truck from moving during the lift. If the lift applies to the brake 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 as possible to the part of the chassis that is to be lifted. This reduces the risk of the truck tipping over -so that the truck cannot roll

• Never lift up the jack in order to lift higher

• Never work under a lifted truck unless it is well supported

WARNING!

Risk of crushing.

A badly supported truck can fall. Never work under a truck that is not supported on trestleblocks and secured by a lifting device.

Preventive maintenance

1 Service schedule

0000.1Check that the truck identification plate is legible X

0000.2Check all links and roll pinsX

0000.3Check the battery securing blocks for wear X

0000.4Check for cracks and damageX

0000.5Check the lift cylinder brackets for wear or damage X

0000.6Check the cover lockingsX 0380 Fork Carriage

0380.1Check for cracks and damageX

0380.2Check bushings for excess playX 0640 Operator Controls

0640.1Check that the travel direction/speed selector is not binding X

0640.2Check that the horn button is operational X

0640.3Check that the lift/lower button is operational X 0840 Drivers Protection

0840.1Check that the red safety switch button is not binding X

Interval in hours520801602505001000

Interval in Days/Weeks/Months1d1v1m2m3m6m1m

1700 Drive Motor

1700.1Check for arcing due to poor connections X

1700.2All connections tightX

1700.3Check of carbon brushesX

1700.4Clean motor of dirt and dustX

1700.5Check tightening of motor boltsX

1700.6Check for abnormal noise in motor bearings X 2550 Drive Gear

2550.1Check for oil leakageX

2550.2Check oil levelX

2550.3Check for abnormal noise X 3100 Brake

3100.1Cleaning from dust and debrisX

3100.2Check brake disc for wearX

3100.3Check correct clearence of brake discX 3500 Wheels

3500.1Remove string and other rubbishX

3500.2Check drive wheel for wear and bolt torque X

3500.3Check castor wheel free to rotate and swivel X

3500.4Dismount and grease fork wheel bearings X 4100 Tiller Arm

4100.1Check fasteningX

4100.2Check steering forceX

4100.3Check the force of the gas suspensionX Pos. n° Work to carry out

Pos. n° Work to carry out

Interval in hours520801602505001000 Interval in Days/Weeks/Months1d1v1m2m3m6m1m

5110 Battery

5110.1Electrolyte level, 10 - 15 mm above cell plates X

5110.2All connections: battery, battery and charger plugs X

5110.3 All cell and link covers intactX

5110.4Check of battery specific gravity and battery temperature X

5200 Instrument Panel

5200.1Check battery indicator and hour meter for correct operation X

5300 Electrical Control System

5300.1Check Ignition key switch operationalX

5300.2 Check ”brake micro switch” (S10) operational X

5300.3Check the function of direction/speed micro switches X

5300.4Check control wiring harness for wearX

5400 Electrical Panel

5400.1Cleaning and fixation to chassisX

5400.2Tightening of connectionsX

5400.3Check contactor pointsX

5400.4Check contactor contacts for free movements X

5400.5Check all cable insulations for damage X

5710 Electronic Card

5710.1Cleaning of electronic card, blow with air and whipe off X

5710.2Check for play on cable connectorsX

5710.3Check of LED indicationsX

6000.1Check

Preventive maintenance

Valid from serial number:

1 Service schedule T-codeModelSerial

Pos. No. Work to carry out

Interval in hours520801602505001000

Interval in days/weeks/months1d1w1m2m3m6m12m

0000 Chassis

0000.1 Check that the truck’s rating plate is readable X

0000.2Check all links and pinsX

0000.3Check whether the battery’s locks are worn X

0000.4Check for crack formation and damageX

0000.5Check the lift cylinder mountings for wear or damage X

0000.6Check the hood locksX

0380 Fork carriage

0380.1Check for crack formation and damageX

0380.2Check whether there is too much play on the bushings X

0380.3Check that the pressure rods are not bent or damaged X

0560 Platform and brackets

0560.1Check for crack formation and damageX

0560.2Check whether there is too much play on the bushings X

0560.3Check the axles, washers and pinsX

0560.4Check whether the mat is wornX

0560.5Check the operation of the gas suspension X

Pos. No.

Work to carry out

Interval in hours520801602505001000

Interval in days/weeks/months1d1w1m2m3m6m12m

0640 Control devices

0640.1Check that the selector for the travel direction/speed does not jam X

0640.2Check the horn buttonX

0640.3Check that the lift/lower buttons workX

0840 Driver protection

0840.1Check that the red button for emergency revers does not jam X

1700 Drive motor

1700.1Check that there is no arcing due to bad connections X

1700.2All connections are tightened correctlyX

1700.3Check the carbon brushesX

1700.4Clean off dust and dirt from the motorX

1700.5Check that the motor mountings are tightened correctly X

1700.6Check that no abnormal sounds comingfrom the motor bearings X 2550 Drive shaft

2550.1Check for oil leakageX

2550.2Check the oil levelX

2550.3Check for abnormal sounds X 3100 Brakes

3100.1Remove dirt and dustX

3100.2Check whether the brake discs are worn X

3100.3 Check the brake discs’ playX

Pos. No. Work to carry out

Interval in hours520801602505001000

Interval in days/weeks/months1d1w1m2m3m6m12m

3500 Wheels

3500.1Remove string and other rubbishX

3500.2Check the drive wheel with regard to wear and the tightening torque of the bolts X

3500.3Check that the castors turn and rotate freely X

3500.4Dismantle and grease the fork wheel bearings X

4100 Tiller arm

4100.1Check the mountingsX

4100.2Check the steering forceX

4100.3Check that the steering frame returns to its original position X

5110 Battery

5110.1Electrolyte level: 10 - 15 mm above the top edge of the cellplates X

5110.2All connections: battery, battery and charger connections X

5110.3 Check that the cell and terminal protection are undamaged X

5110.4 Check the battery’s electrolyte concentration and temperature X

5200 Control panel

5200.1Check that the battery indicator and hour meter work correctly X

5300 Control system

5300.1Check that the ignition worksX

5300.2Check that the “brake microswitch”, S10, works X

5300.3Check the operation of the microswitch for direction/speed X

Pos. No.

Work to carry out

Interval in hours520801602505001000

Interval in days/weeks/months1d1w1m2m3m6m12m

5300.4Check the control cable harness for wear X

5400 Electrical panel

5400.1Clean and inspect the chassisX

5400.2Tighten all connectionsX

5400.3Check the contacts on the contactors, they must not be dirty or burnt X

5400.4Check the movement of the contactorsX

5400.5Check the cable insulationX

5710 Electronic card

5710.1Clean the electronic card using compressed air, then wipe X

5710.2Check that the cable connections are tight X

5710.3Check the LED indicatorsX

6000 Hydraulic system

6000.1Check the hoses and couplings for leakage X

6000.2Check the hoses for wear and damage X

6000.3Check the oil tank for cracks, leakage and damaged mountings X

6000.4Check that the oil level is correctX

6000.5Change the oilX 7310 Lift cylinder

7310.1Check for leakageX

7310.2Check the mountingsX

Oil and grease specification

Valid from serial number: T-codeModelSerial NoNotes 200PPT 1400MXMXC237000AA201PPT 2000MX237000AA202PPT 1600 MX237000AA-

LubricantType of lubricantSpecificationTo be used for > -15° C< -15o C

AGrease26777 (Spray) 26777 (Spray) Bearings and bushings

BHydraulic OilISO-L-HM32ISO-L-VG 32Hydraulic systems

CTransmission OilHypoid Oil SAE 80W/90 Hypoid Oil SAE 75W Gears

DGrease26778 (Spray) 26778 (Spray) Chains and wires

001200,201,202

IIssued byApproved byVersion noT-code

SSDL-G Andersson 001454 F-codeSectionC-code

Oil and grease specification

Valid from serial number:

T-codeModelSerial No.Notes 454PPL 2000MX305210AA-

Lubricant Type of lubricant

SpecificationUse

> -15° C< -15o C AGrease26777 (Spray)26777 (Spray)Bearings and bushings

BHydraulic oilISO-L-HM32ISO-L-VG 32Hydraulic system

CTransmission oilHypoid oil SAE 80W/90 Hypoid oil SAE 75W Gears

DGreaseStaburags NBU 8EP Staburags NBU 8EP Guide bearings

1 Service instructions

S 0Chassis0000

S 1Primary motor1000

S 2Transmission/Drive gear2000

S 3Brake/Wheel/Caterpillar system3000

S 4Steering system4000

S 5Electrical system5000

S 6Hydraulic/pneumatic system6000

S 7Working functions, lift mast/cylinders7000

S 8Peripheral/installation equipment8000

S 9Options, attatchments9000

Electric drive motor

Valid from serial number:

T-codeModelSerial numberNotes

200PPT 1400MX237000AA201PPT 2000MX237000AA202PPT 1600MX237000AA-

1 General

The drive motor, drive gearbox and brake are combined as a complete drive unit.

The drive motor is a compound type direct current motor, i.e. it is comprised of an stator winding connected in series with the armature and a stator winding, called a shunt field, which is connected in parallel with the armature.

The armature current is fed by four traditional type carbon brushes which lie against the armature commutator.

The rotation direction of the motor is changed by changing the armature current flow direction with relation to the stator windings.

In the illustration below, A1 and A2 are the armature connections, D1 and D2 are the series field connections and E1and E2 are the shunt field connections. The motor rotation direction is changed by reversing armature connections A1 and A2.

1.1 Mechanical construction

The motor is comprised of a yoke into which the stator windings are mounted. At each end of the casing there is a bearing end bracket in which the armature bearings are mounted.

A brush bridge assembly with four spring loaded carbon brushes is mounted on the bearing box at the motor commutator end. The carbon brushes sit against the armature commutator and transfer the armature current to armature windings.

Each of the motor windings is accessible via external connections.

1.2 Special tools

Tool

Torque wrench>30Nm

Undercut cleaner 60°, R=0.2 mm, D=0.6 mm

Cradle for drive unitPart number: 08-12432

2 Dismantling/Refitting

2.1 Dismantling the motor from the truck

•Open the motor compartment covers and remove the battery cable shoe.

•Remove the motor cables (armature winding, series field winding and shunt field winding) and the tiller arm cable from the electrical panel. Remove any cable ties.

•Remove the cover over the tiller arm. Disconnect the tiller arm cable from the tiller arm and remove the tiller arm from the bracket.

•Lift the truck and place the drive wheel in the cradle (see chapter ”Special tools”).

•Remove the motor attachment bracket from the chassis (four bolts).

•Lift the truck straight up with the drive wheel resting in the cradle. Check carefully that the drive unit does not follow up with the truck or fall to the side.

WARNING!

Pinch risk!

A lifted truck that is not secured can overturn. The truck may only be lifted from the lifting eyes intended for this purpose using a lifting device that is undamaged and dimensioned for the weight of the truck. Work must not be carried out under the truck when lifted.

•Remove the brake unit from the motor commutator end.

•Remove the tiller arm bracket from the motor by removing the four bracket bolts.

•Remove the four nuts for motor attachment to the drive gearbox and lift the motor carefully straight up, without damaging the sealing surfaces to the drive gearbox.

•Protect the drive gearbox from contamination by placing a suitable cover over the opening, for example, a piece of plastic.

The necessary service and repairs can now be carried out on the motor.

2.2 Re-assembling

•Lift the motor carefully down into the drive gearbox. The four studs on the motor must fit into the corresponding holes on the drive gearbox. In order for the motor to fit fully into the drive gearbox upper surface, the drive gearbox must sometimes be rotated by hand so that the motor shaft gear engages with the drive gearbox gear. Care must be taken that the motor O ring seal is not damaged.

•Tighten the nuts on the studs to the prescribed torque, 26.6Nm.

•Install the brake unit and adjust as per the instructions.

•Replace the drive assembly in the truck and re-connect the motor cables. Check that the polarity is correct.

•After the completed re-assembly, the brake function must be tested before the truck is moved.

3 Service/Repairs

3.1 Cleaning

For correct functioning, it is important that the motor is kept as clean as possible. The motor and motor compartment must be regularly checked for dust, oil and other contamination.

If the motor windings and interior are dry, use a vacuum cleaner with suitable mouthpiece to clean the motor. Compressed air can be used in combination with a vacuum cleaner. In this case the compressed air must be clean and dry.

If the windings have a coating, use a lint-free cloth, damped if necessary with an organic and volatile cleaning agent that can dissolve grease and which will not damage the windings. The cleaning agent must not be used in such quantity that it can enter the motor.

Remains of cleaning agent must be removed with a suitable solvent if an oily surface is left.

If the motor parts are badly dirtied it can be necessary to spray them with a solvent. It is especially important for the armature that the solvent is applied in such a way that dissolved dirt etc. does not enter into the motor section.

One method of cleaning the armature is to dip it in solvent. If this is done the armature must always be heat dried. Good ventilation is necessary during drying which must continue until a number of insulation measurements give consistent and acceptable results.

3.2 Dismantling the motor

•Remove the four plugs that cover the carbon brushes, lift the springs to one side and lift up the carbon brushes.

•Remove the brake disk collar by first removing the circlip and washer at the end of the armature shaft. The collar can then be lifted off, if necessary, with the aid of a suitable puller tool.

•Remove the commutator end bearing shield (11) together with brush holder (03) and carbon brushes (02) by removing the six hexagon socket bolts. Then lay the motor with a fixed stop against edge of the bearing shield and carefully striking the armature shaft with a rubber mallet.

•Remove the bearing shield (25) on the drive end together with the armature (09). Be careful not to damage the motor windings when the armature is removed from the motor yoke.

•After removing the motor bearing shield and removing the armature from the motor yoke, the gear wheel on the armature drive end must be removed. This is done by removing the gear wheel nut and then pulling the gear wheel off with a puller. Note that the gear wheel is locked with Loctite onto the armature shaft.

•Remove next the inner circlip and washer under it. Pull the armature shaft out of the bearing (24).

•Remove the outer circlip and washer and remove the bearing from the bearing shield.

•Remove the bearing shield seal (26) and clean the bearing shield carefully.

•Install a new seal in the bearing bracket.

3.3 Re-assembling the motor

•Reassembling of the motor is carried out in the reverse order to dismantling. Check carefully that the armature can move freely in the rotation direction and that the carbon brushes are lying against the commutator.

•Check the insulation resistance of the motor (between respective windings and the motor yoke). For a new motor this must be between 2 –3 Mohm. A used motor has been subjected to contamination and in this case a resistance of down to approx. 1 Mohm can be acceptable.

•Install a new O ring in the drive shaft end bearing shield and a new seal in the bearing shield collar.

3.4 Armature bearings

The armature bearings are comprised of a permanently lubricated and double sealed type 6204-2Z/C3 bearing in the armature commutator end and a single sealed type 6205/2ZC3 bearing in the armature drive end.

The grease used in both bearings is high temperature type HT24.

The bearing open spaces are partially filled with Texaco SRi2 grease from the factory to protect the inside of the bearing against the penetration of dust and contamination.

The life of the bearing is between 5 000 and 20 000 hours, depending upon the speeds and other stresses it has been subjected to.

During heavy loading the bearing temperature can rise to 180°. An abnormal temperature increase, or excessive noise, indicates insufficient lubrication or bearing wear.

3.4.1 Changing the drive end bearing

Clean the new bearing and fill to max. 50% with grease, type HT24. Install the bearing in the bearing shield with the unsealed side in toward the shield. Put the washer between the circlip and bearing in place and lock the bearing with the outer circlip.

Install the armature in the bearing shield and lock it in place with the washer and circlip.

Remove all grease and other contamination from the armature shaft gear wheel taper. The same applies for the gear wheel inner surface.

Apply a film of Loctite 603 onto the armature shaft taper and install the gear wheel onto the shaft. Put the washer in place, apply a film of Loctite 243 onto the shaft threads and screw on the nut. The nut must be tightened to the prescribed torque, 30 Nm, and then locked with a centre punch.

Care must be taken not to damage the field and armature windings during refitting of the armature and bearing shield.

3.4.2 Changing the commutator end bearing

After the commutator end bearing shield has been removed, the bearings can be removed from the armature shaft with a suitable extractor.

The new bearing is installed onto the armature shaft with the aid of a brass drift.

3.5 Carbon brushes and brush holder

The following checks must be carried out during the service and repair of the motor:

•The brush bridge and brush holder must be firmly attached.

•The carbon brushes must move freely in their holders.

•The brush holders must be free from contamination.

•Worn brushes must be replaced. The minimum permissible length of the carbon brushes is 11 mm.

The carbon brushes are normally supplied with a preformed radius that corresponds to the commutator radius.

3.5.1 Changing carbon brushes

Carbon brushes can be replaced without the drive unit needing to be removed from the truck.

To change the four carbon brushes, the plastic plugs that cover the brushes in the motor yoke must be removed. Then remove the screw that holds the cable for the brush in question. When the cable has been disconnected, lift the spring to one side so that the carbon brush can be withdrawn from the holder.

Refitting is carried out by installing a new carbon brush into the holder, lifting back the spring and then reconnecting the carbon brush connection cable.

After fitting, check carefully that the carbon brush can move freely in the holder and that it is lying correctly against the commutator.

3.6 Commutator

The commutator should normally have an even colour over the whole surface. The appearance of the commutator can, however, vary quite considerably, depending on how it has been used. If the commutator shows burn marks or uneven black coloured areas, it must be cleaned with fine glass paper. Emery cloth must never be used.

3.6.1 Machining the commutator

If it should become necessary to machine the commutator on a lathe, this must be done accurately and carefully.

To achieve an acceptable result the cutting speed must be at least 200 m/min if a hard metal tool is used. If a diamond cutting tool is used, which will produce the best results, the cutting speed must be considerably higher.

Feed must be between 0.08 and 0.1 mm and cutting depth must not exceed 0.05 mm.

After machining, the commutator eccentricity must not exceed 0.02 mm and surface unevenness must be less than 4 µm. An eccentricity of max. 0.04 mm can be accepted in use.

The commutator design allows machining a number of times. The diameter must not, however, be less than 60 mm.

It is normal for machining to be carried out for each third carbon brush replacement.

After each machining, the Micanite between the segments must be undercut down to a depth of 0.6 mm with a special tool. Micanite remains must not be left on the sides of the segments. After machining and undercutting of the Micanite, the segment edges must be chamfered. When this work has been completed, the space between the segments and the segment sides must be as shown in the illustration below.

4 Storage/Transport

If a motor is to be stored for a longer period, for example, more than a month, it must be packed so that it will not be damaged during storage.

The motor components that can be damaged if the motor is not stored correctly are the carbon brushes, commutator and bearings. The motor can be damaged by:

•Dust and other contamination.

•Moisture and condensation if the motor is stored in a location with large temperature variations.

•Rust, especially if the motor is stored in a location with corrosive gases.

•Mechanical influences such as vibration.

4.1 Storage

The following actions are recommended for storage:

•Lift all four carbon brushes.

•Wrap the armature in paper or other protective material.

•Store the motor as an assembled unit.

•Wrap the motor in dust and moisture protective material.

•Avoid placing the motor where it can be subjected to vibration.

The motor must be stored in a room with even temperature.

Condensation in the windings can be avoided by keeping the winding temperature a few degrees higher than the surrounding temperature.

Oxidation, especially on the commutator, can appear even under normal storage conditions. These problems are worsened if the air contains corrosive gases. These problems are especially prevalent if sulphur dioxide (SO2), chlorine (Cl2) and ammoniac (NH3) exists.

Vibration causes damage to the motor bearings. This can be avoided if the armature is rotated a few turns each month.

Check that the motor shaft ends and other clean metal surfaces are covered with a film of rust protective oil.

001200,201,202

Nut for drive end gear wheel30 + locking with centre punch

Nuts for motor attachment to drive gearbox26.6

Grease specification Armature bearingsHT24

ComponentItemMin.Max.Unit

Insulation resistance New motor2Mohm

Insulation resistance Used motor1Mohm

Carbon brushesLength11mm CommutatorDiameter60mm

Machining the commutator Cutting speed, hard metal cutting tool 200m/min

Machining the commutator Cutting speed, diamond cutting tool >>200m/min

Machining the commutator Cutting depth 0,05mm

Machining the commutator Feed0,080,1mm

CommutatorEccentricity0,02mm

CommutatorSurface unevenness 4 µm

Commutator segment Height difference 0,02mm

Electric drive motor

Valid from serial number:

T-codeModelSerial

454PPL 2000MX335887AA-

1 General

The drive motor, drive gearbox and brake are combined as a complete drive assembly.

The drive motor is a compound type direct current motor, i.e. it is comprised of an stator winding connected in series with the armature and an stator winding, called a shunt field, which is connected in parallel with the armature.

The armature current is fed by four traditional type carbon brushes which lie against the armature commutator.

The rotation direction of the motor is changed by changing the armature current flow direction with relation to the stator windings.

In the illustration below, A1 and A2 are the armature connections, D1 and D2 are the series field connections and E1and E2 are the shunt field connections. The motor rotation direction is changed by reversing armature connections A1 and A2.

1.1 Mechanical construction

The motor is comprised of a yoke into which the field windings are mounted. At each end of the yoke there is a bearing end bracket in which the armature bearings are mounted.

A brush bridge assembly with four spring loaded carbon brushes is mounted on the bearing box at the motor commutator end. The carbon brushes sit against the armature commutator and transfer the armature current to armature windings.

Each of the motor windings is accessible via external connections.

02)Carbon brush15)Ball Bearing 03)Brush bridge24)Ball Bearing 09)Armature25)Bearing shield 10)Yoke with stator26)Sealing 11)Bearing shield

1.2 Special tools

Tool

Torque wrench>30Nm

Undercut cleaner 60°, R=0,2 mm, D=0,6 mm

2 Removal/Refitting

2.1 Removing the motor from the truck

•Open the motor compartment covers and remove the battery cable shoe.

•Remove the motor cables (armature winding, series field winding and shunt field winding), tiller arm cable from the electrical panel, the blue cable in the battery cable shoe and the hydraulic pump cables. Remove any cable ties.

•Remove the four nuts for the motor attachment to the drive gearbox.

•Remove the cover over the tiller arm. Disconnect the tiller arm cable from the tiller arm and remove the tiller arm from the bracket.

•Remove the cables for the battery indicator and ignition switch. Pull all cables out of the cable ducting in the cover.

•Remove the tiller arm bracket and the brake unit from the motor. Remove the cover over the motor compartment together with the tiller arm bracket.

•Lift the motor carefully straight up, without damaging the sealing surfaces to the drive gearbox.

•Protect the drive gearbox from contamination by placing a suitable cover over the opening, for example, a piece of plastic.

The necessary service and repairs can now be carried out on the motor.

2.2 Re-assembly

•Lift the motor carefully down into the drive gearbox. The four studs on the motor must fit into the corresponding holes on the drive gearbox. In order for the motor to fit fully into the drive gearbox upper surface, the drive gearbox must sometimes be rotated by hand so that the motor shaft gear engages with the drive gearbox gear. Care must be taken that the motor O ring seal is not damaged.

•Tighten the nuts on the studs to the prescribed torque, 26.6Nm.

•Replace the tiller arm bracket and brake unit. Adjust the brake as per instructions. Screw down the cover and connect the cables previously disconnected. Check that the polarity is correct.

•After the completed re-assembly, the brake function must be tested before the truck is moved.

3 Service/Repairs

3.1 Cleaning

For correct functioning, it is important that the motor is kept as clean as possible. The motor and motor compartment must be regularly checked for dust, oil and other contamination.

If the motor windings and interior is dry, use a vacuum cleaner with suitable mouthpiece to clean the motor. Compressed air can be used in combination with a vacuum cleaner. In this case the compressed air must be clean and dry.

If the windings have a coating, use a lint-free cloth. The cloth can be dampened with an organic and volatile cleaning agent if necessary, that can dissolve grease and which will not damage the windings. The cleaning agent must not be used in such quantity that it can enter the motor.

Remains of cleaning agent must be removed with a suitable solvent if an oily surface is left.

If the motor parts are badly dirtied it can be necessary to spray them with a solvent. It is especially important for the armature that the solvent is applied in such a way that dissolved dirt etc. does not enter into the motor section.

One method of cleaning the armature is to dip it in solvent. If this is done the armature must always be heat dried. Good ventilation is necessary during drying and it must continue until a number of insulation measurements give similar and approved results.

3.2 Dismantling the motor

•Remove the brake disk collar by first removing the circlip and washer at the end of the armature shaft. The collar can then be lifted off. It may need to be pulled off with a suitable tool.

•Remove the four plugs that cover the carbon brushes, lift the springs to one side and lift up the carbon brushes.

•Dismantle the bearing bracket (11) at the commutator end together with the brush holder (03) and carbon brushes (02) by removing the six hexagon socket bolts. Lay the motor down with a fixed stop against the edge of the bearing shield and then strike the armature shaft carefully with a rubber mallet.

•Remove the bearing shield (25) on the drive end together with the armature (09). Be careful not to damage the motor windings when the armature is removed from the motor yoke.

•After removing the motor bearing shield and removing the armature from the motor yoke, the gear wheel on the armature drive end must be removed. This is done by removing the gear wheel nut and then pulling the gear wheel off with a puller. Note that the gear wheel is locked with Loctite onto the armature shaft.

•Remove next the inner circlip and washer under it. Pull the armature shaft out of the bearing (24).

•Remove the outer circlip and washer and remove the bearing from the bearing shield.

•Remove the bearing shield seal (26) and clean the bearing shield carefully.

•Install a new seal in the bearing bracket.

3.3 Refitting of motor

•Reassemble the motor in the reverse order to dismantling. Check carefully that the armature can move freely in the rotation direction and that the carbon brushes are lying against the commutator.

•Check the insulation resistance of the motor (between respective windings and the motor yoke). For a new motor this must be between 2 and –3 Mohm. A used motor has been subjected to contamination and in this case a resistance of down to approx. 1 Mohm can be acceptable.

•Install a new O ring in the drive shaft end bearing shield and a new seal in the bearing shield collar.

3.4 Armature bearings

The armature bearings are comprised of a permanently lubricated and double sealed bearing, type 6204-2Z/C3 in the armature commutator end and a single sealed 6205/2Z-C3 bearing in the armature drive end.

The grease used in both bearings is high temperature type HT24.

The bearing open spaces are partially filled with Texaco SRi2 grease from the factory to protect the inside of the bearing against the penetration of dust and contamination.

The life of the bearing is between 5000 and 20 000 hours, depending upon the speeds and other stresses it has been subjected to.

During heavy loading the bearing temperature can rise to 180°. An abnormal temperature increase, or excessive noise, indicates insufficient lubrication or bearing wear.

3.4.1 Changing the drive end bearing

Clean the new bearing and fill to max. 50% with grease, type HT24. Install the bearing in the bearing shield with the unsealed side in toward the shield. Put the washer between the circlip and bearing in place and lock the bearing with the outer circlip.

Install the armature in the bearing shield and lock it in place with the washer and circlip.

Remove all grease and other contamination from the armature shaft gear wheel cone. The same applies for the gear wheel inner surface.

Apply a film of Loctite 603 onto the armature shaft cone and install the gear wheel onto the shaft. Put the washer in place, apply a film of Loctite 243 onto the shaft threads and screw on the nut. The nut must be tightened to the prescribed torque, 30 Nm, and then locked with a centre punch.

During refitting of the armature and bearing shield, care must be taken not to damage the field and armature windings.

3.4.2 Changing the commutator end bearing

After the commutator end bearing shield has been removed, the bearings can be removed from the armature shaft with a suitable extractor.

The new bearing is installed onto the armature shaft with the aid of a brass drift.

3.5 Carbon brushes and brush holder

The following checks must be carried out during the service and repair of the motor:

•The brush bridge and brush holder must be firmly attached.

•The carbon brushes must move freely in their holders.

•The brush holders must be free from contamination.

•Worn brushes must be replaced. The minimum permissible length of the carbon brushes is 11 mm.

The carbon brushes are normally supplied with a preformed radius that corresponds to the commutator radius.

3.5.1

Changing carbon brushes

Carbon brushes can be replaced without the drive unit needing to be removed from the truck.

To change the four carbon brushes, the plastic plugs that cover the brushes in the motor yoke must be removed. Then remove the screw that holds the cable for the brush in question. When the cable has been disconnected, lift the spring to one side so that the carbon brush can be withdrawn from the holder.

Refitting is carried out by installing a new carbon brush into the holder, lifting back the spring and then reconnecting the carbon brush connection cable.

After fitting, check carefully that the carbon brush can move freely in the holder and that it is lying correctly against the commutator.

3.6 Commutator

The commutator should normally have an even colour over the whole surface. The appearance of the commutator can, however, vary quite considerably, depending on how it has been used. If the commutator shows burn marks or uneven black coloured areas, it must be cleaned with fine glass paper. Emery cloth must never be used.

3.6.1 Turning the commutator

If it should become necessary to machine the commutator on a lathe, this must be done accurately and carefully.

To achieve an acceptable result the cutting speed must be at least 200 m/min if a hard metal tool is used. If a diamond cutting tool is used, which will produce the best results, the cutting speed must be considerably higher.

Feed must be between 0.08 - 0.1 mm and cutting depth must not exceed 0.05 mm.

After machining, the commutator eccentricity must not exceed 0.02 mm and surface unevenness must be less than 4 µm. An eccentricity of max. 0.04 mm can be accepted in use.

The commutator design allows for machining a number of times. The diameter must not, however, be less than 60 mm.

It is normal for machining to be carried out for each third carbon brush replacement.

After each machining, the Micanite between the segments must be undercut down to a depth of 0.6 mm with a special tool. Micanite remains must not be left on the sides of the segments. After machining and undercutting of the Micanite, the segment edges must be chamfered. When this work has been completed, the space between the segments and the segment sides must be as shown in the illustration below.

4 Storage/Transport

If a motor is to be stored for a longer period, for example, more than a month, it must be packed so that it will not be damaged during storage.

The motor components that can be damaged if the motor is not stored correctly are the carbon brushes, commutator and bearings. The motor can be damaged by:

•Dust and other contamination.

•Moisture and condensation if the motor is stored in a location with large temperature variations.

•Rust, especially if the motor is stored in a location with corrosive gases.

•Mechanical influences such as vibration.

4.1 Storage

The following actions are recommended for storage:

•Lift all four carbon brushes.

•Wrap the armature in paper or other protective material.

•Store the motor as an assembled unit.

•Wrap the motor in dust and moisture protective material.

•Avoid placing the motor where it can be subjected to vibration.

The motor must be stored in a room with even temperature.

Condensation in the windings can be avoided by keeping the winding temperature a few degrees higher than the surrounding temperature.

Oxidation, especially on the commutator, can appear even under normal storage conditions. These problems increase if the air contains corrosive gases. These problems are especially prevalent if sulphur dioxide (SO2), chlorine (Cl2) and ammoniac (NH3) exists.

Vibration causes damage to the motor bearings. This can be avoided if the armature is rotated a few turns each month.

Check that the motor shaft ends and other clean metal surfaces are covered with a film of rust protective oil.

5 Data TorqueNm

Nut for drive end gear wheel30 + locking with centre punch

Nuts for motor attachment to drive gearbox26,6

Grease specification

Armature bearingsHT24 ComponentItemMin.Max.Unit

Insulation resistance New motor2Mohm

Insulation resistance Used motor1Mohm

Carbon brushesLength11mm

CommutatorDiameter60mm

Turning the commutator

Turning the commutator

Turning the commutator

Cutting speed, hard metal cutting tool 200m/min

Cutting speed, diamond cutting tool >>200m/min

Cutting depth 0.05mm

Turning the commutator Feed0.080.1mm

CommutatorEccentricity0.02mm

CommutatorSurface unevenness 4 µm

IIssued byApproved byVersion noT-code

Drive gear

Valid from serial number:

T-codeModelSerial NoNotes 200PPT 1400MX246664AA201PPT 2000MX246664AA202PPT 1600MX246664AA454PPL 2000MX305210AA-

1 General technical description

001200,201,202,454

1.1 Technical data

DataDescription

Type2-step angular

Upper gear wheelsCylindrical with helical gear

Lower gear wheelsAngle gear 90 degrees

Gear ratio, overall

PPT1400/1600, PPL2000 19,14:1

Gear ratio, upper gear

PPT1400/1600, PPL2000 4:1

Gear ratio, lower gear

PPT1400/1600, PPL2000 4,86:1

Oil volume1,0 litre

Oil type, normal temperatureHypoid oil SAE 80W/90

Oil type, < -15oCHypoid oil SAE 75

Oil changeFirst time: 250 hours

Regular change: 3000 hours

001200,201,202,454

Pos NoComponent

11Drive shaft

12Drive shaft seal

ABuilt-in measure, pinion height65 mm

1.3

Special tools

Pos NoTool

1Bearing withdrawer: part no = 08-13022

2Dial indicator with magnetic bracket

3Thickness gauge

4Micrometer 0-25 mm (0-1 inch)

5Spring balance 0-10 kg (0-22 lb)

6Measuring gauge: part no = 08-13020

7Assembly axle: part no 08-13021

2 Removing the gear from the truck

•Lift the machine so the bolts for the driving gear are easily accessible from beneath. The truck can also be laid on the side after removal of the battery and sealing off the hydraulic system.

•Remove the drive wheel (17 mm spanner)

•Drain the gear oil by removing the lower gear cover (6mm allen key).

•Remove the nuts (13 mm spanner) holding the gear and motor together.

•Take the driving gear out of the machine.

•Reassemblying the driving gear into the truck is made in the reversed order.

3 Change of seal on the drive shaft

•Remove the gear from the truck as shown in chapter ”Removing the gear from the truck”.

•Remove the upper gear cover (6 mm allen key).

•Knock out the locking on the drive shaft nut.

•Remove the drive shaft nut (36 mm spanner).

•Knock the drive shaft out with a plastic club or press it out.

•Remove the crown wheel and bearing L3.

•Remove the old seal ring and re-fit with a new part.

•Put the drive shaft in position and place the inner ring of the bearing L3 in the gear housing.

•Put the crown wheel onto the splines of the drive shaft and fit a new washer and nut. Tighten the drive shaft nut 300Nm (217 ft-lb) with a torque wrench.

•Lock the shaft nut with a punch into the groove in the shaft.

•Fit the covers to the gear with new gaskets. Tightening torque: 26,6Nm (19,5 ft-lb).

•Fit the driving gear into the truck. Tightening torque: 26,6Nm (19,5 ft-lb). Fill up with new oil.

•Fit the drive wheel. Tightening torque: 65Nm (47,7 ft-lb).

4

Reconditioning of the gear

•Remove the gear from the truck as shown in chapter ”Removing the gear from the truck”.

•Remove the gear covers (6 mm allen key).

•Knock out the locking on the drive shaft nut.

•Remove the drive shaft nut (36 mm spanner).

•Knock the drive shaft out with a plastic club or press it out.

•Remove the crown wheel and bearing L3.

•Remove the old seal ring.

•Press or knock out the bearing cups for bearing L3 and L4 and remove the shim-pack S3 from the gear housing.

•Remove the bearing L4 from the drive shaft by using the withdrawer, part no 08-13022. Remove the shim S4 from the shaft.

•Knock out the locking on the pinion nut. Remove the nut (22 mm spanner) and the primary gear wheel.

•Knock out the pinion with a plastic club or press it out. Remove the bearing L2 and shim S2.

•Remove the bearing L1 from the pinion with the withdrawer, part no 08-13022.

•Press or knock the cups for the bearings L1 and L2 out and remove the shim-pack S1 from the housing.

•Clean the covers, gear housing and drive shaft with a suitable dissolvent.

•Fit new races for the bearings L1 and L2 into the gear housing with 0,5mm shim S1.

•Fit the new bearing L1 on the new pinion.

•Assemble the pinion, bearing L2 and primary gear wheel. Assemble with enough thickness of shim S2 so that there is no axial play. Tighten the nut 30Nm (22,5 ft-lb), using the old nut.

•Fit the new races for the bearings L3 and L4 into the gear housing without shim S3.

•Fit the assembly axle 08-13021 with the bearing L4 into the gear housing. Place the bearing L3 and the crown wheel onto the axle. Make sure that there is enough shim S4 for the bearing L4 so there is no axial play on tool 08-13021. Tighten the axle nut 100Nm (72 ft-lb), using the old nut.

•Measure the pinion height with the measuring gauge, part no 08-13020, between the surface of bearing L1 and the pin on tool 08-13021. Use shims or feeler gauge together with the measuring gauge to get the correct thickness of shim S1. Built-in measure pinion height = 65 mm, measuring gauge length 59 mm + the radius of the pin 5 mm + 1mm shim or feeler gauge thickness. The difference from 65 mm gives you the thickness of shim S1.

•Fit the measured shim thickness under bearing L1.

•Assemble the pinion, bearings and primary gear wheel with shim thickness S2 so that there is no axial play on the pinion, Zero-play, when having tightened the pinion nut 70Nm (50,5 ft-lb). When needed adjust S2 so that the play is zero.

•Fit the assembly axle 08-13021 with bearings, crown wheel and shim as previously. Tighten the nut 300Nm (217 ft-lb)

•Measure the flank clearence with the crown wheel in three different positions. Carefully point the dial indicator 90degrees to the gear tooth surface.

•Shim (S3) bearing L3 so that a flank clearence of 0,10–0,15mm is attained. Remove the same shim thickness from S4 that is fitted on S3, before the tool with bearings and crown wheel is reassembled.

•Check the flank clearence and measure the axial play on the tool 08-13021.

•Adjust the axial play to Zero-play by adjusting shim S4.

•Check the gear tooth impression with engineer’s blue. Adjust shim S1 when needed. After adjusting S1, S2 will need to be set. S2 needs to be reduced if S1 thickness is increased. But if the thickness of S1 is reduced, then S2 is increased. Check the axial play on the pinion.

•Fit the tool 08-13021 with bearings and crown wheel. Check the flank clearence. Adjust shim S3 when needed. S4 is to be adjusted, reduced if S3 is increased and increased if S3 is reduced, correspondingly to the change on S3. Check the axial play on tool 08-13021.

•Check the gear tooth impression. When the impression is correct fit a new washer and pinion nut. Tighten the nut 70Nm (50,5 ft-lb) and lock it with a punch in the keygroove.

•When the gear tooth impression and the axial play is correctly adjusted, remove tool 08-13021. Shim-pack S4 is shifted over to the drive shaft and bearing L4 is placed on the shaft.

•Fit the new seal ring in the gear housing.

•Put the drive shaft into the housing and put bearing L3 in place.

•Put the crown wheel onto the splines of the drive shaft and fit a new washer and nut. Tighten the drive shaft nut 300Nm (217 ft-lb) with a torque wrench. Check the axial play on the drive shaft, shall be Zero. Lock the nut with a punch in the groove on the shaft.

•Check the force needed to rotate the gear with the spring balance. Maximum value: 6-6,5 kg.

•Fit the covers onto the gear with new gaskets. Tightening torque: 26,6Nm (19,5 ft-lb).

•Fit the driving gear into the truck. Tightening torque: 26,6Nm (19,5 ft-lb). Fill up with new oil.

•Fit the drive wheel. Tightening torque: 65Nm (47,7 ft-lb)

IIssued byApproved byVersion noT-code

Mechanical brakes

Valid from serial number:

T-codeModelSerial NoNotes

200PPT 1400MX335887AT201PPT 2000MX335887AA202PPT 1600MX335887AT454PPL 2000MX335887AT-

1 General

The brake is a mechanical spring-loaded brake. The brake construction is as shown in the component list below.

PositionDescription

1Brake disk

2Adjustment screws for braking force

3Collar

4Adjustment screws for clearance in off position

5Pressure plate

2 Function

The mechanical brake provides both the driving and parking brakes for the truck.

2.1 Releasing the brakes

The brakes are released when the tiller arm is in the driving position.

2.2 Braking

The truck is braked when the tiller arm is moved into one of the two braking positions.

3 Maintenance

The brakes require virtually no maintenance in normal working environments. It is, however, recommended that regular cleaning, inspection of wear in brake disk and pressure plate plus the clearance between these is carried out in accordance with the schedule for preventative maintenance. Check also the brake force adjustment.

PositionAdjustment measurement

1Clearance in un-braked position

2Adjustment of brake force. Clearance in braked position

001 200,201,202,454

Electrical System Resistance Control

Valid from serial number:

1 Electrical panel, components T-codeModelSerial NoNotes 200PPT 1400MX237000AA200PPT 1400MXC237000AA201PPT 2000MX237000AA202PPT 1600MX237000AA-

001 200,201,202

2 List of symbols

SymbolDescriptionFunctionRemark

A1Electronic card

BTBattery

F10FuseMotor circuit100 A

F50FuseControl circuit7,5 A

H1Horn

K11ContactorDrive direction

K13ContactorDrive direction

K17Contactor2:nd speed

K18Contactor3:rd speed

K30ContactorPump motor

M1MotorDriving

M3MotorPump

P1IndicatorHour meter

P3IndicatorBattery indicator/Hour meter

R11ResistorSpeed control

R12ResistorSpeed control

S10Micro switch

S12Micro switchSpeed step2

S13Micro switchSpeed step3

SymbolDescriptionFunctionRemark

S15Micro switchDrive direction

S16Micro switchDrive direction

S17SwitchKey

S18Micro switchHorn

S20Micro switchEmergency switch off

S41Micro switchFork lowering

S52Micro switchFork lifting

Y41Magnetic valveFork lowering

2.1 Circuit diagram 1(3)

2.2 Circuit diagram 2(3)

200,201,202

2.3 Circuit diagram 3(3)

3 Description of function

3.1 General

The BT PPT 1400MX/1600MX/2000MX controller contains a logic-unit (micro processor) which detects signals from microswitches, armature voltage, etc. The controller’s inputs and outputs are equiped with connectors for connection/disconnection of cables.

The controller is equipped with a green LED (labelled PWR/ ERROR), which indicates correct main voltage. The LED for PWR/ERROR also indicates faults in the emergency stop circuit or in the contactor circuits.

The inputs are suited for the 24 V voltage level and will draw a certain current in order to clean the opening contacts and, also, to indicate input signals with green LED’s.

The contactor outputs are electronically short circuit proof and indicate output signals with red LED’s. The drive contactor outputs are controlled by transistors and will receive the full main voltage when the current is turned on, i.e. 24 V and after the contactors have closed, the voltage will drop to half this value, i.e. 12 V.

In addition to signals from switches, the drive motor’s armature voltage is monitored, so that speed step 3 will be engaged at a pre-determined voltage level or, alternatively, after a fixed time lapse.

The description is divided into the different phases which correspond to the operational sequense steps. For each sequense step the correct LED-pattern is shown below. A filled circle denotes a LED emitting light.

3.2 Ignition lock S17 in the ON position

When S17 closes, the micro-processor will check that S10 is not closed. If this is the case, operation is not permitted.

Battery voltage via F50, terminals 407 and 205 to S17 and terminal 202 for the controller’s internal voltage. The controller gets (-) return through cable 40 and terminal 207, the PWR/ERROR-diode lights up. Controller terminal 108 distributes the battery voltage to S10, S52, S41 and S18.

3.3 The operating arm in drive position, S10

When the operating arm is pushed down to the driving position, S10 is activated and closes and at the same time the brake is mechanically released. LED 109 lights up when the voltage is fed via terminal 109 to the run-time totalizer’s terminal 206 and to the shunt field’s terminal 301.

The controller sends a fixed current through the shunt field, 1,2 A and (-) return is provided via terminals 302 ans 207.

3.4 Driving in the fork direction, 1:st speed

When the butterfly is activated for driving forward, S15 will close. Battery voltage is fed to terminal 101 and LED 101 lights up. The micro-processor now feeds 24 V closing voltage to terminal 401, red LED 401 lights up and K11 closes, (-)return is provided via terminals 409 and 207. After K11 has closed, the micro-processor reduces the contactor’s holding voltage to 12 V.

The transistor regulator checks that S10 is closed before S15 is made, for driving to be permitted.

The motor current now passes F10, R11, R12, K11, the armature A2-A1, K11 and the series field D2-40 to the battery’s negative pole.

3.5 Driving in the fork direction, 2:nd speed

When S12 is activated by the butterfly, battery voltage is fed to terminal 103 and LED 103 lights up. The micro-processor now feeds 24 V voltage to terminal 403, red LED 403 lights up and K17 closes, (-) return is provided via terminals 409 and 207. After K17 has closed, the micro-processor reduces the contactor’s holding voltage to 12 V.

The motor current now passes through F10, K17, R12, K11, the armature A2-A1, K11 and the seriesfield D2-40 to the battery’s negative pole.

3.6 Driving in the fork direction, 3:rd speed

When S13 is activated by the butterfly, battery voltage is fed to terminal 104 and LED 104 lights up.

The micro-processor now measures the armature voltage over terminal 408 in order to determine the delay for the 3:rd speed.

The delay of the 3:rd speed is determined either by the armature voltage reaching 13 V when a light load or no load is on the forks, or alternatively, after a one second delay via a timer circuit for heavier loads.

The micro-processor now sends 24 V voltage to terminal 404, red LED 404 lights up and K18 closes and (-) return is provided via terminal 409 and 207.

After K18 has closed, the micro-processor will interrupt the holding voltage to K17, which now opens.

The motor current now passes through F10, K18, K11, the armature A2-A1, K11 and the series field D2-40 to the battery’s negative pole.

3.7 Driving in the steering wheel direction, 1:st speed

When the butterfly is activated for driving in the steering wheel direction, S16 will close. Battery voltage is fed to terminal 102 and LED 102 lights up. The micro-processor now feeds 24 V voltage to terminal 402, red LED 402 lights up and K13 closes, (-) return is provided via terminals 409 and 207. After K13 has closed, the micro-processor reduces the contactor’s holding voltage to 12V.

The controller checks if S10 is closed before S16 is made, for driving to be permitted.

The motor current now passes F10, R11, R12, K13, the armature A1-A2, K13 and the series field D2-40 to the battery’s negative pole.

3.8 Driving in the steering wheel direction, 2:nd speed

When S12 is activated by the butterfly, battery voltage is fed to terminal 103 and LED 103 lights up. The micro-processor now feeds 24 V voltage to terminal 403, red LED 403 lights up and K17 closes, (-) return is provided via terminals 409 and 207. After K17 has closed, the micro-processor reduces the contactor’s holding voltage to 12 V.

The motor current now passes through F10, K17, R12, K13, the armature A1-A2, K13 and the seriesfield D2-40 to the battery’s negative pole.

3.9

Driving in the steering wheel direction, 3:rd speed

When S13 is activated by the butterfly, battery voltage is fed to terminal 104 and LED 104 lights up.

The micro-processor now measures the armature voltage over terminal 408 in order to determine the delay for the 3:rd speed.

The delay of the 3:rd speed is determined either by the armature voltage reaching 13 V when a light load or no load is on the forks, or alternatively, after a one second delay via a timer circuit for heavier loads.

The micro-processor now feeds 24 V voltage to terminal 404, red LED 404 lights up and K18 closes and (-) return is provided via terminal 409 and 207.

After K18 has closed, the micro-processor will interrupt the holding voltage to K17, which now opens.

The motor current now passes through F10, K18, K13, the armature A1-A2, K13 and the series field D2-40 to the battery’s negative pole.

3.10 Reversing/ motor brake fork direction to steering wheel direction

When reversing, the speed control is moved from fork direction to steering wheel direction. S15 returns to the neutral position when S16 closes. The current in the series field causes the motor to work as a generator since the drive wheel rotates in the "wrong direction". The micro-processor detects the negative potential over terminal 408 and interrupts the holding voltage to K17 and K18, causing these to open.

The motor is now braking in the 1:st speed. When the drive wheel rotates in the "right direction" and the potential over terminal 408 becomes positive, acceleration is done in the usual way.

During the braking sequence, the motor current passes F10, R11, R12, K13, A1-A2, K13 and the series field D2-40 to the negative pole.

3.11 Reversing/ motor brake steering wheel direction to fork direction

When reversing, the butterfly is moved from the steering wheel direction to fork direction. S16 returns to the neutral position when S15 closes. The current in the series field causes the motor to work as a generator since the drive wheel rotates in the "wrong direction". The micro-processor detects the negative potential over terminal 408 and interrupts the holding voltage to K17 and K18, causing these to open.

The motor is now braking in the 1:st speed. When the drive wheel rotates in the "right direction" and the potential over terminal 408 becomes positive, acceleration is done in the usual way.

During the braking sequense, the motor current passes F10, R11, R12, K11, A2-A1, K11 and the series field D2-40 to the battery negative pole.

3.12 Safety reversing

Possible breakages in the cables for safety reversing are always checked by the micro-processor, which sends a small current through the circuit comprising terminal 110, cable 32, S20, cable 32 and terminal 111.

S20 is activated causing terminal 110 to become positive and the micro-processor now interrupts the holding voltage to K13 and K18, which opens. At the same time the processor provides voltage to terminal 401 to K11 and terminal 403 to K17.

The motor is now in the motor braking stage and will subsequently accelerate in the fork direction until S20 returns to the neutral position. Safety reversing is done using the 2:nd speed.

When S20 returns to neutral position, (+) voltage will be interrupted to terminal 110, the micro-processor will interrupt the holding voltage to terminals 401 and 403 to K11 and K17 and the truck will stop.

In order to be able to start again if S16 still is activated, the micro-processor must be returned to the inactive position by letting the speed-control return to the neutral position, after which a new direction of travel can be chosen.

3.13 Lifting of the forks

The micro-switch S52 closes. K30 receives (+) voltage via terminal 105, terminal 203, by use of a jumper or via the battery indicator, terminal 201 and terminal 405 and LED’s 105 and 405 lights up. (-) return via terminal 409 and 207. K30 closes and pump motor M3 starts.

3.14 Driving in fork direction in 3:rd speed and simultaneously lifting the forks

In order to reduce the load on the motor fuse when driving in 3:rd speed in fork direction and simultaneously lifting the forks, the micro-processor interrupts the holding voltage to K18 during the time S52 is activated.

When lifting is completed and S52 is not activated, the microprocessor will activate the 3:rd speed, K18, with a normal delay time.

3.15 Driving in steering wheel direction in 3:rd speed and simultaneously lifting the forks

In order to reduce the load on the motor fuse when driving in 3:rd speed in steering wheel direction and simultaneously lifting the forks, the micro-processor interrupts the holding voltage to K18 during the time S52 is activated.

When lifting is completed and S52 is not activated, the microprocessor will activate the 3:rd speed, K18, with a normal delay time.

3.16 Lowering the forks

When the forks are lowered, S41 is activated. The magnetic valve, Y41, is provided with (+) voltage from terminal 106, LED 106 lights up, and terminal 204. (-) return through terminal 409 and 207.

3.17 Horn

Micro-switch S18 is activated. The horn, H1, receives (+) voltage from terminal 107, LED 107 lights up, and terminal 406. (-) return through cabel 40.

3.18 Fault indication

During operation, the cables to S20 are checked. If breakage is detected, the LED labelled PWR/ERROR will flash. The truck is fully manouverable as long as S10 is closed. When the operating arm is released, or the brake is activated in the lower position, and S10 interrupts the voltage, the micro-processor will not permit further operation of the truck by interrupting the output signal to all drive contactors.

PLEASE NOTE! The interruption can be deactivated for temporarily driving to a service area (key off and then on). If the brake is activated, deactivation of the interruption must be done again.

The LED labelled PWR/ERROR also flashes when a short circuit occurs at the contactor outputs 401-404. After the fault is repaired, the LED will cease to flash.

Electrical System

Transistor Control

Valid from serial number:

1 Electrical panel, components T-codeModelSerial NoNotes 200PPT 1400 MX243537AA200PPT 1400MXC243537AA201PPT 2000MX243537AA202PPT 1600MX243537AA-

002200,201,202

1.1 List of symbols

SymbolDescriptionFunctionRemark

A1Transistor controller

A2Electronic card

BTBattery

F10FuseMotor circuit100 A

F50FuseControl circuit7,5 A

H1Horn

K11ContactorDrive directionFork direction

K13ContactorDrive directionSteer wheel direction

K30ContactorPump motor

M1MotorDrive

M3MotorPump

P1IndicatorHour meter

P3IndicatorBatteryindicator/Hour meter

R1PotentiometerSpeed5 - 0 kOhm

RV1PotentiometerSpeed reduction

S10Switch ”Brake”

S15SwitchDrive directionFork direction

S16SwitchDrive directionSteer wheel direction

S17SwitchKey

S18SwitchHorn

S41SwitchFork

002200,201,202

1.2 Electrical diagram 1(3)

1.3 Electrical diagram 2(3)

002200,201,202

1.4 Electrical diagram 3(3)

2 Description of function

2.1 General

The Transistor controller (A1) regulates the speed step less up to maximum speed. When starting the truck, does the controller check the closing sequency of the micro switches in the circuit. The controller is equipped with a lightdiode (LED) showing system status and potentiometers for adjusting the current limit and acceleration, placed under a sliding cover.

The electrical system have a electronic card (A2) to group all connections of the control circuits for input respectively output signals to the transistor controller. The electronic card is equipped with LED’s for indication of incomming or outgoing signals and a potentiometer for adjustment of the maximum speed.

2.2 Adjustable settings

SettingStd. valueMin. valueMax. value

Current limit150 A100 A150 A

Acceleration0,8 s0,1 s3 s

Maximum speed, without load

REFERENCES:

For more information about adjustment of the transistor controller and the electronic card, see C-code 5460 resp. 5710.

The description is devided into different phases which correspond to the operational sequense steps. For each sequense step the correct LED-pattern is shown below. A filled circle denotes a LED emitting light.

2.3 Ignition lock S17 in the ON position

When S17 closes, the transistor controller will check that S10 is not closed. If this is the case, operation is not permitted.

Battery voltage on A2-terminal 202, LED 202 lights up. A2 (-) return terminal 409.

Battery voltage to A1.16 via A2-terminal 410, LED-status starts to flash.

2.4 The operating arm in drive position, S10

When the opersting arm is pushed down to the driving position, S10 is activated and closes and at the same time the brake is mechanically released. Voltage obtained via terminal 109 and 408 to A1.15, LED 109 lights up, on the hour meter terminal 206 and the shunt field terminal 301.

The transistor controller now regulates the current through the shunt field, 1,2 A, (-) return via terminal 302, 417 and A1.1.

2.5 Driving, fork direction

When the butterfly is activated for driving in the fork direction, S15 will close. The transistor controller checks that S10 is closed before S15 closes, if not, driving is not permitted.

Battery voltage obtained via terminal 101 and 411 to A1.11, LED 101 lights up.

Battery voltage to K11 via terminal 403. A1.2 now gives (-)return to K11, (-)input on terminal 401, LED 401 lights up.

Depending on the position of the speed control (R1) and adjustment of potentiometer RV1 will A1.8 obtaine a voltage between 4.8-0.25 V.

The motor current now passes through F10, the series field D2-D1, K11, the armature A2-A1 and K11 to battery negative via A1.

2.6 Driving, steer wheel direction

When the butterfly is activated for driving in the steer wheel direction, S16 will close. The transistor controller checks that S10 is closed before S16 closes, if not, driving is not permitted.

Battery voltage obtained via terminal 102 and 412 to A1.12, LED 102 lights up.

Battery voltage to K13 via terminal 403. A1.3 now gives (-)- return to K13, (-)input on terminal 402, LED 402 lights up. Depending on the position of the speed control (R1) and adjustment of potentiometer RV1 will A1.8 obtaine a voltage between 4,8-0,25 V.

The motor current now passes through F10, the series field D2-D1, K13, the armature A1-A2 and K13 to battery negative via A1.

2.7 Reversing/motor brake fork direction to steer wheel direction

S15 returns to neutral position while S16 closes. The current in the series fiels causes the motor to work as a generator since the drive wheel rotates in the ”wrong direction”. The transistor controller detects the generated current at connection A2, and reduces the series field current to 60 A.

When the drive wheel rotates in the ”right direction” and the potential at connection A2 becomes positive, acceleration is done according to adjusted values of current limit and acceleration.

During braking sequence, the armature current passes in the circuit A1-A2, K13, A2, the brake diode of the transistor controller, M- and K13.

2.8 Reversing/motor brake steer wheel direction to fork direction

S16 returns to neutral position while S15 closes. The current in the series fiels causes the motor to work as a generator since the drive wheel rotates in the ”wrong direction”. The transistor controller detects the generated current at connection A2, and reduces the series field current to 60 A.

When the drive wheel rotates in the ”right direction” and the potential at connection A2 becomes positive, acceleration is done according to adjusted values of current limit and acceleration.

During braking sequence, the armature current passes in the circuit A2-A1, K11, A2, the brake diode of the transistor controller, M- and K11.

2.9 Switch for safety reversing

Possible breakages in the wiring for safety reversing is continously checked by the transistor controller, who sends a small pulsed current through the circuit A1.10, terminal 416, 111, wire 32, S20, wire 32, terminal 110, 415 and A1.13.

S20 is activated causing terminal 110, 415 and A1.13 to become positive, A1 now interrupts the (-)return to K13 which opens. At the same time will A1 provide (-) at A1.3 to K11, LED 401 lights up.

The motor will now be connected for motor braking at maximum current limit 150 A, and subsequently accelerate in the fork direction until S20 returns to its neutral position.

When S20 returns to neutral position, (+) disappears from terminal 110, A1 will interrupt the (-)return at A1.3 to K11 and the truck will stop.

In order to be able to start again if S16 still is activated, the transistor controller must be returned to the inactive position by letting the speed control return to the neutral position, after which a new drive direction can be chosen.

2.10 Lifting the forks

The micro switch S52 closes. K30 receives (+)voltage via terminal 105, 203, battery controller or the jumper, terminal 201 and 405, LED 105 and 405 lights up. (-)return via wire 40. K30 closes and the pump motor M3 starts.

2.11 Driving and simultaneously lifting the forks

A1 detects the activation of K30, (+) at terminal 404 and A1.14. A1 then reduces the speed to 70% and the motor current to 100 A.

2.12 Lowering the forks

When lowering the forks S41 is activated. The magnetic valve, Y41, receives (+)voltage via terminal 106 and 204, LED 106 lights up. (-)return via wire 40.

2.13 Horn

Micro switch S18 is activated. The horn, H1, receives (+)voltage via terminal 107 and 406, LED 107 lights up. (-)return via wire 40.

IIssued byApproved byVersion noT-code

Electrical system

Transistor regulator

Valid from serial number:

1 Electrical panel, components T-codeModelSerial no.Notes 454PPL 2000MX305210AA-

1.1 List of Symbols

SymbolDescriptionFunctionNotes

A1Transistor regulator

A5Electronic card

E8HeaterHandle heaterOnly freezer trucks

F1FuseMotor circuit100 A

F50FuseControl circuit7.5 A

F51FuseExtra equipmentOption

G1Battery

H1Horn

K11ContactorDrive directionDirection of forks

K13ContactorDrive directionDirection of steer wheel

K30ContactorPump motor

M1MotorDriving

M3MotorPump

P3InstrumentBattery indicator/running meter

R1PotentiometerSpeed5 - 0 kOhm

RV1PotentiometerSpeed reduction

S10Switch ”Brakes”

S15SwitchDrive directionDirection of forks

SymbolDescriptionFunctionNotes

S16SwitchDrive directionDirection of steer wheel

S17SwitchIgnition key

S18SwitchHorn

S20SwitchSafety reversing

S31SwitchLifting limit

S40SwitchLowering forks

S52SwitchLifting forks

Y41Magnetic valveLowering forks

Y52Magnetic valveLifting forks

1.2 Electrical diagram 1/6

1.3 Electrical diagram 2/6

1.4 Electrical diagram 3/6

1.5 Electrical diagram 4/6

1.6 Electrical diagram 5/6

1.7 Electrical diagram 6/6

2 Operating description

2.1 General

The transistor regulator A1 regulates the speed variably up to maximum speed. When the truck is started the regulator checks the closing sequence for the microswitches in the circuit. The regulator is equipped with a LED that displays the system status.

The electrical system has a connection card A5 to group all the connections to the control card for input and output signals to the transistor regulator. The connection card is equipped with LEDs to indicate incoming and outgoing signals and a potentiometer to adjust the maximum speed.

REFERENCES

For further information on transistor regulation and the electronic card, see C-code 5460 and 5710.

2.2 Description

The description is divided into different phases that correspond to the operating sequence stages. The correct LED patterns are shown below for each sequence stage. A filled circle represents the LED when on.

2.3 Ignition switch S17 in the ON position

•When S17 makes, the transistor regulator checks that S10 is not made. If this is the case, driving is not permitted.

•The battery voltage on A5-connection pin 202, LED 202 comes on. A5 (-) return connection pin 207. Battery voltage to A1.16 via A5-connection pin 410, LED-status starts to flash.

2.4 Tiller arm in driving position, S10

•When the tiller arm is pushed down to the driving position, S10 makes and the mechanical brake releases at the same time. The voltage goes via connection pins 109 and 408 to A1.15. LED 109 lights on the running meter’s connection pin 206 and the shunt field’s connection pin 301.

•The transistor regulator now regulates the current through the shunt field, 1.2 A, (-)-return via connection pin 302, 417 and A1.1.

2.5 Driving, direction of the forks

•When the throttle is activated for driving in the direction of the forks,S15 makes. Battery voltage goes via connection pins 101 and 411 to A1.11, LED 101 comes on.

•Battery voltage to K11 via connection pin 403. A1.2 now gives (-) return to K11, (-) input on connection pin 401, LED 401 comes on.

•Depending on throttle’s, R1’s, position and the position of potentiometer RV1, A1.8 will receive a voltage between 4.8–0.25 V.

•The motor current now passes through F1, the series field D2-D1, K11, the rotor A2-A1 and K11 to the battery’s negative pole via A1.

2.6 Driving, direction of the steering wheel

•When the throttle is activated for driving in the direction of the steer wheel, S16 makes. The transistor regulator checks that S10 is made before S16 makes, if not, driving is not permitted.

•Battery voltage flows via connection pins 102 and 412 to A1.12, LED 102 comes on. Battery voltage to K13 via connection pin 403. A1.3 now gives (-) return to K13, (-) input on connection pin 402, LED 402 comes on.

•Depending on the throttle’s, R1’s, position and the position of potentiometer RV1, A1.8 will receive a voltage between 4.8 - 0.25 V.

•The motor current now passes through F1, the series field D2-D1, K13, the rotor A1-A2 and K13 to the battery’s negative pole via A1.

2.7 Reversing/speed reduction, direction of forks to direction of steer wheel

•S15 returns to the neutral position and S16 makes. The current in the series field makes the motor act as a generator as the drive wheel is rotating in the “wrong direction”.

•The transistor regulator senses the generated current on connection A2, and reduces the series field current to 60A. When the drive wheel rotates in the “right direction” and the potential on connection A2 is positive, acceleration occurs according to the adjusted values for the current limit and acceleration.

•The rotor current in the circuit passes A1-A2, K13, A2, transistor regulator’s brake diode, M- and K13 during the braking sequence.

2.8 Reversing/speed reduction, direction of steer wheel to direction of forks

•S16 returns to the neutral position and S15 makes. The current in the series field makes the motor act as a generator as the drive wheel is rotating in the “wrong direction”. The transistor regulator senses the generated current on connection A2, and reduces the series field current to 60A.

•When the drive wheel rotates in the “right direction” and the potential on connection A2 is positive, acceleration occurs according to the adjusted values for the current limit and acceleration.

•The rotor current in the circuit passes A2-A1, K11, A2, transistor regulator’s brake diode, M- and K11 during the braking sequence.

2.9 Switch for safety reversing

•The transistor regulator continuously monitors the safety reversing circuit for a possible broken line, by sending a small pulsed current through A1.10, connection pin 416, 111, line 32, S20, line 32, connection pin 110, 415 and A1.13.

•S20 is activated and makes connections 110, 415 and A1.13 positive, A1 now cuts the (-) return to K13, which breaks. At the same time A1 will deliver (-) at A1.3 to K11, LED 401 comes on.

•The motor will now be connected for speed reduction with a maximum current of 150 A. The truck will then accelerate in the direction of the forks until S20 returns to its neutral position.

•When S20 returns to its neutral position, the (+) disappears from connection pin 110, A1 cuts the (-) return on A1.3 to K11 and the truck stops.

•In order to start again while S16 is still active, the transistor regulator must be reset to the inactive mode by allowing the throttle to return to the neutral position whereafter a new driving direction is selected.

2.10 Lifting the forks

•The microswitch S52 makes. K30 receives (+) voltage via connection pins 105, 203, battery regulator or strapping, connection pins 201 and 405. LEDs 105, 405 come on. (-) return via line 40. K30 makes and the pump motor M3 starts.

2.11 Driving and lifting the forks at the same time

•A1 sense the activation of K30, (+) on connection pin 404 and A1.14. A1 then reduces the speed to 70% and the motor current to 100 A.

2.12 Lowering the forks

•S40 is activated when the forks are lowered S40. The magnetic valve, Y41, receives (+) voltage via connection pins 106 and 204, LED 106 comes on. (-)-return via line 40.

2.13 Horn

•Microswitch S18 is activated. The horn, H1, receives (+) voltage via connection pins 107 and 406, LED 107 comes on. (-) return via line 40.

Battery controller/hourmeter

Valid from serial number:

T-codeModelSerial

200PPT 1400MX/MXC330613AA201PPT 2000MX330613AA202PPT 1600MX330613AA454PPL 2000MX330613AA-

1 General

This instrument consists of a single, quartz, hourmeter, H, a 10bar multi color battery discharge controller (BC), and a lockout relay. The lift lockout relay is operating in such a way that if there is a current passing through the relay contacts when the instrument registers empty battery, the contacts stay closed until the current ceases. Meaning that there will be no lockout of the lift during the lift operation. The hourmeter features a liguid crystal dispay (LCD) which has six segment digits with a decimal point on last digit. This provoides a reading of 0.1 hours or 6 minutes.

Battery controller/hourmeter

2 Electrical

2.1 Voltage

The instrument is supplied as a pin selectable dual voltage unit with the voltage of 24/48 VDC.

2.1.1 The contact voltage and current ratings for switch- ing resistive loads.

Open Contact Voltage200VDCMax

Closed Contact Current3ADCMax

Volt Ampere Product50WMax

2.1.2 Memory Retention

The instrument contains an internal battery which allows (BC) memory retention when external power is remowed. Typical battery life is 10 years. The hourmeter has a solid state non volatile memory which does not require battery backup.

3 Battery Controller

3.1 General

The (BC) measures the state of the battery. The charge is indicated on a column of ten LEDs.

Right: 1 – fully-charged battery. Left: 0 – empty battery.

When the battery is fully charged, the LED to the right will be lit. As the battery discharges, LEDs further and further to the left will stop glowing, to show the current discharge level. When the battery is 70% discharged, the two LEDs from the left will flash alternately to warn the driver that he should recharge the battery. When the battery is 80% discharged, the last LED is lit and the relay is opening.

3.1.1 Discharge Adjustment

The BC features an adjustable discharge setting. The setting designators K-U appear at the rear of the gage at the periphery of the adjusting screw. The inital factory setting is N, but will depend on the battery and machine type.

The given settings are approximate and might need to be fine tuned to get a 100% correct lockout for a specific application.

A hydrometer must be used for exact adjustment. When the two lower LEDs flash, the density of the battery fluid should not fall below 1.14. If the LEDs start to flash at a higher density the discharge potentiometer U must be turned anticlockwise (towards K). If both diodes flash at a density lower than 1.14, turn the potentiometer clockwise (towards P).

If necessary, adjust one step at a time. Charge the battery and drive the truck until the instrument starts to flash again. Measure once again using the hydrometer to ensure the adjustment is correct. If not, the procedure must be repeated until the setting is correct.

The letter designation in the table below shows the voltage value per cell (VPC) with a discharged battery.

Battery controller/hourmeter

Pin No.Function

1Hour meter (-)

2Keyswitch (+)

3Relay arm (+)

4Relay NC (-)

5Battery (-)

6Hour meter (+)

724 Volt (+)

848 Volt (+)

NOTE:

The instrument can be connected differently in different trucks, please see diagrams in the electrical descriptions C-code 5000.

NOTE:

The discharge adjustments can be made at any time during a working cycle before lift lockout. However, discharge pot. adjustments made late in a working cycle have little or no effect in delaying the lift lockout in that particular working cycle. Normally discharge pot. adjustments are made before or at the beginning of a working cycle to effectively change the discharge profile of that working cycle. Once lift lockout does occur, the gauge must be reset before discharge pot. adjustments can have an effect.

3.2 Reset

The instrument is supplied with a fixed reset voltage setting. This factory set, reset voltage brings the BC to full regardless of its previous level. The reset will be done when the battery has been charged and connected to the machine.

3.3 Keyswitch

The electronics of the BC and the LCD of the hourmeter are energized as long as the machine battery remains connected to the gauge. The display of the BC is turned on and off by the keyswitch.

The keyswitch also enables timing function of the hourmeter. With the keyswitch ”on”, the hourmeter can be activated by the connection No 1 at the rear of the BC. With the keyswitch ”off” the hourmeter will not respond to the connection No1 and the LCD of the hourmeter will be off.

3.4 Hourmeter

Hourmeter operation is indicated by flashing of the hourglass icon on the face of the LCD. The flash rate is 15 times a minute with a duty cycle of 3 seconds on and 1 second off. When the hourmeter is not in operation the icon is visible but does not flash.

4 Trouble shooting

This section is separated into two parts: battery discharge indicator and hour meter.

4.1 Battery Discharge Indicator

4.1.1

No reset

There are two ways to reset the instrument.

Using the open circuit reset, the instrument must first have a break in the power and then measure a voltage greater than 2.09 volts per cell across its pin 7 or 8 and pin 5.

Verify that a leakage voltage is not present across these terminals by disconnecting one of the lines supplying battery voltage to the instrument.

Replace this connection and measure the voltage across the gauge at its pin 7 or 8 and pin 5. It must be above 2.09 volts per cell. If it is and the gauge does not reset to indicate full charge, the instrument is defective.

The second method of resetting the instrument is by using the high voltage reset. This reset function also has two requirements to reset the instrument. The voltage across pin 7 or 8 and pin 5 must be above 2.35 volts per cell and must remain above this level for six minutes continuously. Measure the voltage across these pins and verify that it is greater than 2.35 volts per cell. Also verify that it remains above this level for a minimum of six minutes. If these two conditions are met and the instrument does not reset it is defective.

4.1.2

Always resets after break in power

If the voltage of the batteries to which the instrument is connected is below 2.09 volts per cell and the gauge was not formerly indicating full, it should not reset to full after a break in power. If it does, its memory cell is depleted.

This will not affect the discharge function of the instrument if it is always connected to a fully charged battery and allowed to track its discharge without break in power.

NOTE:

New instruments are shipped from the factory with a full reading in their memory. The first time the instrument is connected to the truck’s battery it will always show a full charge. It is either resetting to full because the battery is fully charged, or if the battery is not fully charged it is repeating the information in its memory which is a full reading.

Vad är J ? SCR?

4.1.3

No discharge, gauge does not run down

The instrument monitors loaded battery voltages. If connected to a partially discharged battery, it will not run down until it observes the loaded voltages of that battery. A working time of at least 30 minutes is required for the gauge to run from full to empty.

To verify that the instrument will run down measure across pin7 or 8 and pin 5. A voltage less than 2.0 volts per cell is required to bring the gauge indication downwards from a full reading.

4.1.4 No lockout

The two far left red LEDs on the LED display must be fashing alternately for lockout to occur.

The J output functions like an SCR. At lockout pins 3 and 4 will open as long as lift is inactive. To test this output remove the wire leading to pin 3 when at lockout. Replace the wire and then try to lift. If the lift ceases to operate the instrument is good.

After replacing the wire if the lift operates, the instrument is defective, or there could be a leakage current somewhere in lift circuit. Check across the lift switch.

4.1.5

No lift

First verify that the gauge is not at lockout with its two red LEDs alternately flashing. The relay outputs should be closed above lockout and should read 0 ohms with an ohmmeter across pins 3 and 4. If not test the lift switch and contactor.

4.1.6 Early lockout

It is very important that the instrtument is installed so that its pins are reading the true battery voltage. Any voltage drops caused by long lines, switches, fuses or poor connections will be seen by the instrument as a deeper discharged battery.

To check for voltage drops use a voltmeter with its positive lead on the battery’s positive terminal and the meter’s negative lead on pin 7 or 8 (whichever pin B+ is connected to). Load the battery and record this measurement. Repeat this procedure with the voltmeter’s positive lead on pin 5 and its negative lead on the battery’s negative terminal and record the voltage measured. Add the two voltage readings. This total should be less than 1% of the nominal battery voltage. Voltages higher than this will cause the instrument to calculate battery state-of-charge from incorrect readings.

4.1.7 LEDs don’t light

The battery discharge indicator LEDs are illuminated by the keyswitch, pin 2. Verify that B+ is present across pin 2 and pin 5. If voltage is present and the LEDs do not light the instrument is defective.

4.2 Hour meter

4.2.1 No display

The LCD of the hour meter will illuminate when power is applied at pin 7 or 8 and pin 5. If voltage is measured across these pins and the LCD does not turn on the instrument is defective.

4.2.2 Hour glass icon does not flash

If the icon does not flash the hour meter is not accumulating time. The keyswitch pin 2 must be on (at B+), pin 7 or 8 must be connected to B+, and one or both of the hour meter lines must be active. If both the keyswitch is on and one or both inputs are correct and the hour meter icon does not flash the instrument is defective.

4.2.3 Hour meter glass icon always flashes

When the icon is flashing the hour meter is accumulating time. Turn the truck’s keyswitch off. This should remove voltage from pin 2 of the instrument. Should voltage be present at pin 2 and the hour meter’s icon is continues to flash the instrument is defective.

Transistor regulator

Version noT-code

001200,201,202

Transistor regulator

Valid from serial number:

T-codeModelSerial NoNotes

200PPT 1400MX243537AA-293314AA

200PPT 1400MXC243537AA-293314AA

201PPT 2000MX243537AA-293314AA

202PPT 1600MX243537AA-293314AA

1 Transistor controller, Curtis 1207

2 Motor circuit

The transistor controller have four terminals for the high current circuits according to the table below.

TerminalConnecting

M-Output to motor armature

B-Negative connection to battery

B+Positive connection to battery/series field

A2Plug diode to motor armature

Transistor regulator

3 Control circuit

The transistor controller have an integrated 16-pin connector to provide the low power logic control connections. The designation of the pins are according to table below.

Pin NoConnecting

Contactor drivers

P1Shunt field driver output

P2Fork direction contactor driver output

P3Steer wheel direction contactor driver output

P4Not connected

Throttle connections

P5Not connected

P6Not connected

P7Throttle: pot low

P8Throttle: 2-wire 5 kOhm-0 input

Basic control signals

P9Not connected

P10Safety reversing check output

P11Drive fork direction input

P12Drive steer wheel direction input

P13Safety reversing input

P14Speed range selection input

P15Brake switch input

P16Key switch input (KSI)

Transistor

Version noT-code

001200,201,202

4 Technical specification

The technical specification for the BT-version of the Curtis 1207 transistor controller is according to the table below.

ParameterRangeSTD settingUnitsDescription

Operating voltage2424Volt

Maximum voltage45VoltOvervoltage point

Minimum operating voltage 16VoltUndervoltage point

Electrical isolation to heatsink 500Volt acMinimum

Frequency15kHz

Contactor voltage24Volt

Contactor current1AmpMaximum(current limit at 2 amp)

Shunt driver current 21.2Amp

KSI input current80mA

Logic input current10mAAt 24 Volt

Logic input threshold8Volt

Plug BrakingVariableVariablePlug current dependant upon throttle position

Current Limit, Main100-150150Amp

Current Limit, Low Speed, Main 100AmpMaximum current in low speed mode

Current Limit, Plug60AmpMaximum plug current in the series field

001200,201,202

ParameterRangeSTD settingUnitsDescription

Current Limit, Low Speed, Plug

Current Limit, Safety reversing

Current Limit, Low speed, safety reversing

60AmpMaximum plug current in the series field in low speed mode

150AmpMaximum field current in safety reversing

150AmpMax. field current when in low speed for safety reversing

Throttle Type5k-0Ohm

Min. Duty Cycle0%Speed (duty factor) at minimum throttle setting

Low Speed70%Maximum speed (duty factor) in low speed mode

Speed, safety reversing

50%Speed during safety reversing

Acceleration Rate0.1 - 30.8SecTime to reach full output from zero output

5 Adjustment panel

The adjustment panel is located on top of the controller, under a sliding protective cover. The panel provides access to a set of adjustable potentiometers, a connector for a handheld terminal and the STATUS LED.

5.1 Adjustable potentiometers

MAIN and ACCEL potentiometers can be adjusted with a screwdriver within the range given in the technical specification.

NOTE: In the BT-version of the Curtis 1207 are only two of the potentiometers in operation, MAIN and ACCEL. The other three potentiometers are disabled from factory.

5.2 Connection of handheld terminal

To adjust the parameters with the handheld terminal the corresponding potentiometer must be set to ”off”.

5.3 Status LED

The LED displays flashing codes to indicate controller status. The codes are listed with explanations in section “ Diagnostics and troubleshooting”.

6 Maintenance

There are no user-servicable parts inside the transistor controller.

NOTE:

No attempt should be made to open the controller. OPENING THE CONTROLLER WILL VOID THE WARRANTY!

It is however recommended that the controller exterior be cleaned periodically. When cleaning the controller gives a good opportunity to check the controller’s diagnostic history file with the handheld terminal, if available.

6.1 Safety

The controller is inherently a high power device. When working around any battery powered vehicle, proper safety precautions should be taken. These include, but are not limited to: proper training, wearing eye protection, avoiding loose clothing, removing watches and jewelry, and using insulated wrenches.

WARNING Risk of short circuits. Remove all watches and jewelry and always use insulated tools.

6.2 Cleaning

Although the controller requires virtually no maintenance if properly installed, the following minor maintenance is recommended on a regular 250 hours basis.

•Remove power by disconnecting the battery.

•Discharge the capacitors in the controller, by connecting a load (such as a contactor coil or the horn) across the controller’s B+ and B- terminals, before doing any work on the controller.

•Remove all dirt or corrosion from the bus bar area. The controller should be wiped clean with a moist rag. Allow it to dry before reconnecting the battery.

•Make sure the connections to the bus bars are tight. Use two well insulated wrenches for this task in order to avoid stressing the bus bars.

7 Diagnostics and troubleshooting

During normal operation, with no faults present, the Status LED flashes a single flash at approximately 1 flash/second. If the controller detects a fault, a 2-digit code is flashed continously until the fault is corrected, see the table below.

If using a handheld terninal for the diagnostics, switched over to diagnostic mode, the diagnostic information can be read in the terminal display, see the table below.

1,2 ¤ ¤¤ HW FAILSAFE hardware fail-safe error

1. Controller defective

1,3¤ ¤¤¤ M- FAULT M- output shorted1. M- output shorted to ground

2. Direction contactor not closing

3. Direction contactor not closing fast enough

4. Internal motor short to ground

1,4¤ ¤¤¤¤ SRO SRO fault1. Improper sequence of KSI, brake and direction inputs

2. Brake or direction switch circuit open

2,1¤¤ ¤ THROTTLE FAULT 1 5kOhm-0 or wiper fault

2,2¤¤ ¤¤ BB WIRING CHECK Safety reversing wiring fault

1. Throttle input wire open

2. Throttle input wire shorted to ground or B+

3. Throttle pot defective.

4. Wrong throttle type

1. Safety reversing wire open

2.Safety reversing check wire open

Led codeTerminal LCD Display ExplanationPossible cause

2,3 ¤¤ ¤¤¤ HPD

2,4¤¤ ¤¤¤¤ THROTTLE FAULT 2

HPD sequencing fault

Potentiometer Low broken or shorted

3,1¤¤¤ ¤ CONT DRVR OC driver output overcurrent

3,2¤¤¤ ¤¤ DIR CONT WELDED welded direction contactor

3,4¤¤¤ ¤¤¤¤ MISSING CONTACTOR missing contactor or shunt

1. Improper sequence of KSI, brake, throttle inputs

2. Misadjusted throttle

1. Potentiometer low wire open

2. Potentiometer low wire shorted

3. Wrong throttle type

1. Direction contactor coil shorted

2. Shunt field shorted

1. Direction contactor stuck closed

1. Direction contactor open coil

2. Direction contactor missing

3. Shunt field open

4. Wire to shunt or direction contactor open

4,1¤¤¤¤ ¤ LOW BATTERY VOLTAGE low battery voltage

1. Battery voltage <16 volts

2. Corroded battery terminal

3. Loose battery or controller terminal

4,2¤¤¤¤ ¤¤ OVERVOLTAGE overvoltage1. Battery voltage > 45 volts

2. Vehicle operating with charger attached

4,3¤¤¤¤ ¤¤¤ THERMAL CUTBACK over-/under-temperature cutback

1. Temperature >85oC or < 25 oC

2. Excessive load on vehicle.

3. Improper mounting of controller

4. Operation in extreme environments

Transistor regulator

Valid for serial number:

T-codeModelMachine No.Notes

200PPT 1400MX293315AA-319892AA

200PPT 1400MXC293315AA-319892AA

201PPT 2000MX293315AA-319892AA

202PPT 1600MX293315AA-319892AA

454PPL 2000MX305210AA-319892AA

1. General

This document describes the functions of Curtis 1207-1131 versions 137197-003 up to 137197-005. The functions are activated by setting the parameters on the hand terminal. See chapter “Curtis hand terminal”.

Version 137197-003 includes a new function called neutral braking. When the function is activated it allows the truck to work in the neutral braking mode, auto motor brake.

137194-004 contains an overhaul of parameters to obtain improved driving characteristics. Acceleration and Ramp shape have been changed. Quick start and Creep speed introduced.

137195-005 is a rebuild of the regulator to handle a “contact bounce” from the brake’s microswitch and avoid error code 1.4. Introduced from Serial number: 317085AA.

002 200,201,202,454 Transistor

1.1. Connections

The transistor regulator has four terminals for the heavy current circuits, one control current terminal and a connection for a hand terminal as set out in the table below.

ConnectionCircuit

1Connection for the hand terminal

2

16 way connection, logic’s control current

M-Output for motor armature

B-Negative connection to the battery

B+Positive connection for the battery/series field

A2Brake LED for motor armature

2. Control circuits

The transistor regulator has an integrated 16 way connector for the connection of the logic’s control current. The designation of the pins is set out in the table below.

Pin No.Connection

Contactor drive

P1Shunt field output

P2Fork direction, contactor output

P3Steering wheel direction, contactor output

P4Not connected

Speed control connection

P5Not connected

P6Not connected

P7Speed control, potentiometer low

P8Speed control, 2-wire 5 kOhm-0 input

Regulator signals

P9Not connected

P10Safety reversing, check, output

P11Driving, fork direction, input

P12Driving, steer wheel direction, input

P13Safety reversing, input

P14Speed range, selection, input-

P15Brake microswitch, input

P16Ignition, input (KSI)

Transistor regulator

002 200,201,202,454

3. Technical specification

The technical specification for the BT-version of the Curtis 1207-1131 transistor regulator is presented in the table below.

NOTE! Column T/M shows how the parameter can be adjusted.

T = Terminal, M = Manual adjustment possible, - = Not adjustable.

Parameter

(Terminal display)

value

Operating voltage24-3624Volt-

Maximum voltage45Volt-Overvoltage point

Minimum operating voltage 16Volt-Undervoltage point

Electrical insulation against heatsink 500Volt ac-Minimum

Frequency15kHz-

Contactor voltage24Volt-

Contactor current1Amp-Maximum, current limit at 2amp

Shunt field current21.2Amp-

KSI Input current80mA-

Logic Input current10mA-At 24 V

Logic minimal withstand voltage 8VoltAmbient temperature

temperature, reduction

Under temperature, reduction

Motor brakeVariableVariable-Motor brake current depending on position of accelerator pedal

Current limit, Main current, M1 MAIN C/L 100- 150150AmpP

Parameter (Terminal display)

Current limit, low speed, main current (M2 MAIN C/L)

Current limit, motor brake (M1 PLUG C/L)

Current limit, low speed, motor brake (M2 PLUG C/L)

Current limit, safety reversing (EMR REV C/L)

RangeSTD value UnitT/MDescription

60-100100AmpPMaximum current in low speed range

20-6060AmpPMaximum current in series field during motor braking

20-6060AmpPMaximum current in series field during motor braking low speed range

25- 250150Amp-Maximal field current, safety reversing

Accelerator type 15k-0Ohm-

Minimal pulse length 0%-Speed at minimum setting of accelerator

Low speed (M2 MAX SPEED)

Speed, safety reversing (EMR REV SPEED)

Acceleration

Acceleration ramp shape (RAMP SHAPE)

Neutral brake (NEUTRAL BRAKE)

Neutral brake current (NEUT BRAKE C/L)

40-100100%-Maximum speed in low speed range

25- 10070%-Speed during safety reversing

SecP,MTime to reach full output from zero output

137197-004 introduced from Serial No.: 309922AA

20- 7030 50 %POutput signal in% at 50% of speed’s input signal

137197-004 introduced from Serial No.: 309922AA

ON/OFFOFFPSelection, braking/freewheeling when the accelerator is in neutral position

10- 10010AmpPMaximum field current during neutral braking

Parameter (Terminal display)

RangeSTD value UnitT/MDescription

Quick Start0-40Defines how quickly the output signal changes when changing the position of the accelerator 137197-004

Introduced from Serial No.: 309922AA

Creep speed/Min. Duty Cycle

0-2510%The output signal jumps to this speed when you select the travel direction 137197-004 introduced from Serial No.: 309922AA

4. Adjustment panel

The adjustment panel is located on top of the regulator, under the sliding protective cover. The panel accommodates a set of adjustable potentiometers, a connection for a hand terminal and a STATUS LED.

4.1. Adjustable potentiometers

The parameter Acceleration Rate can be adjusted using a screwdriver via the potentiometer ACCEL within the range defined in the technical specification.

NOTE! Only the ACCEL potentiometer is functional in the BTversion of Curtis 1207. All other potentiometers are deactivated at the factory.

4.2. Connection for the hand terminal

For information on how to use the hand terminal, see chapter “Curtis hand terminal”

To change settings using the hand terminal the corresponding potentiometer must be set to “off”.

4.3. Status LED

The status LED shows flashing codes to indicate the status of the regulator. These codes are listed with an explanation in the chapter “Maintenance”.

5. Maintenance

There are no components in the transistor regulator that may be repaired by the user.

NOTE!

Do not attempt to open the transistor regulator. THE WARRANTY WILL CEASES TO BE VALID IF THE REGULATOR IS OPENED!

It is recommended to clean the outside of the transistor regulator regularly. When the regulator is cleaned this provides an excellent opportunity to check the regulator’s diagnosis file using the hand terminal, if available.

5.1. Safety

The regulator is a high power component. Requisite safety precautions should be observed when working on the battery powered vehicle. The safety instructions comprise, among others, suitable training, protective glasses, appropriate clothing that must not hang loosely. Remove your watch and any jewellery. Use insulated tools.

WARNING

Risk of short-circuiting.

Remove all watches and jewellery as well as always use insulated tools.

5.2. Cleaning

The following minimum maintenance is recommended at intervals of 250 hours, even though the transistor regulator dose not require any real maintenance if installed correctly.

•Switch off the voltage by disconnecting the battery.

•Discharge the capacitors in the regulator by connecting a load, for example, a contactor coil or horn across the regulator terminal connections B+ and B- before work on the regulator is carried out.

002 200,201,202,454

•Remove all dirt and corrosion from around the busbars. Wipe off the regulator with a damp cloth. Let it dry correctly before reconnecting the battery.

•Make sure the connections to the busbars are tightened correctly. Use two well insulated spanners to tighten the connections so as not to load the bars.

6. Diagnosis and trouble shooting

During normal operations, without error indications, the status LED flashes at a rate of approx. 1 flash/second. If the regulator discovers a fault, a two digit code flashes continuously until the fault has been rectified, see the table below.

If the hand terminal is used for diagnosis, set to the diagnosis mode, then diagnosis information can be read off of the display, see the table below.

LED codeHand terminal LCD Display ExplanationPossible cause

1,2¤ ¤¤ HW FAILSAFE Hardware, safety circuit fault

1,3¤ ¤¤¤ M- FAULT M output shortcircuited

1. Regulator faulty

1. M output short-circuited to earth.

2. Direction contactors do not make.

3. Direction contactors do not make quickly enough.

4. Internal motor short-circuiting to earth.

1,4¤ ¤¤¤¤ SRO Switch sequence error

2,1¤¤ ¤ THROTTLE FAULT 1

5 kOhm-0 or contact error

1. Wrong sequence of input signal for KSI, brakes and travel direction

2. Brake or travel direction switch’s circuit broken.

1. Potentiometer input signal cable broken.

2. Potentiometer input signal shortcircuited to earth or B+.

3. Potentiometer faulty

4. Wrong potentiometer type.

LED codeHand terminal LCD Display

2,2 ¤¤ ¤¤ BB WIRING CHECK

2,3¤¤ ¤¤¤ HPD

2,4¤¤ ¤¤¤¤ THROTTLE FAULT 2

ExplanationPossible cause

Safety reversing cable broken

HPD sequence error

Potentiometer low, broken or short-circuited.

3,1¤¤¤ ¤ CONT DRVR OC Contactor driving over current

3,2¤¤¤ ¤¤ DIR CONT WELDED

3,4¤¤¤ ¤¤¤¤ MISSING CONTACTOR

4,1¤¤¤¤ ¤ LOW BATTERY VOLTAGE

4,2¤¤¤¤ ¤¤ OVERVOLTAGE

4,3¤¤¤¤ ¤¤¤ THERMAL CUTBACK

Welded direction contactor

Missing contactor or shunt field

Low battery voltage

1. Safety reversing, cable broken.

2. Safety reversing, control cable broken.

1. Wrong sequence of input signals for KSI, brakes and accelerator.

2. Incorrectly adjusted accelerator

1. Potentiometer low cable broken.

2. Potentiometer low cable shortcircuited.

3. Wrong potentiometer type.

1. Coil, direction contactor shortcircuited.

2. Shunt field short-circuited.

1. Direction contactor lodged in made position.

1. Direction contactor, break in coil.

2. Direction contactor missing.

3. Shunt field broken.

4. Cable to shunt field or direction contactor, broken.

1. Battery voltage <16 volt.

2. Corroded battery connection.

3. Loose battery or regulator connection.

Overvoltage1. Battery voltage >45 volts

2. Vehicle operational with charger connected.

Over/under temperature falling

1. Temperature >85oC or < 25 oC

2. Vehicle overloaded.

3. Incorrect installation of the transistor regulator

4. Operations in extreme environments.

7. Curtis 1307 hand terminal

Using the Curtis 1307 hand terminal you can program, test and perform diagnostics on Curtis PMC 1207 regulators. It is the 1207 regulator that drives the hand terminal through an RJ11 modular connection located on the adjustment panel on the top of the regulator.

PosFunctionNotes

1LCD display4 row LCD Display

2PROGRAM MODE buttonSelect this function to show and change the regulator’s parameters.

3TEST MODE buttonSelect to show the status of the inputs/outputs, etc.

4DIAGNOSTICS MODESelect to show the current active fault that the regulator has discovered.

5SCROLL DISPLAY buttonsScroll the text rows up and down.

6MORE INFO buttonPress to access more relevant information for the current mode.

7Key active LED’sIndicates whether the relevant CHANGE VALUE button is active. When it dims no more adjustment can be made.

8CHANGE VALUE buttonsIncrease or decrease the value of the selected object.

9Operating mode LED’sIndicates which function mode is active.

8. Using the hand terminal

•Connect the hand terminal to the regulator’s programming output located on the top of the adjustment panel.

•Ensure the truck’s current is switched on.

When the hand terminal is connected for the first time the brakes’ microswitch should be open, the brakes applied, until the terminal has gathered all the regulator parameters. When this is complete the terminal will display the regulator’s control number, date of manufacture and the software’s revision code. After this display, the terminal will present a prompt for further instructions.

The terminal has three main functions: PROGRAM, TEST and DIAGNOSTICS.

•PROGRAM mode is used to show the terminals parameters. The presented parameters can also be replaced in this mode.

•TEST mode shows real time information about the status of the input/output signal and the regulator’s temperature. In the TEST mode the current point does not need to be the first on the list, it only needs to be among the first four displayed in the window. The test mode is usable when you test the function of the regulator during installation and for trouble shooting if problems occur.

•DIAGNOSTICS mode shows the current fault found by the regulator.

8.1. Test and adjust the parameters

•Press the PROGRAM mode button. The program mode LED comes on.

The terminal now displays the first, four parameters. See the diagram below.

The parameters are shown four at a time. Each row represents one parameter. A indicates the name of the parameter. The arrow B indicates the parameter that has been selected for modification. C indicates the value of the current parameter.

Press one of the SCROLL DISPLAY buttons to display more parameters.

To adjust a specific parameter scroll the display up or down so that the arrow B points at it.

•Increase the value by pressing the CHANGE VALUE - “up” button, or lower the value using the CHANGE VALUE“down” button.

NOTE!

As soon as any of the parameters on the display have been changed, the new value is transferred immediately to the regulator.

See the relevant Service Manual for the actual regulator with regard to information on standard parameter values and adjustments.

8.2. Using the TEST mode

•Press the TEST mode button TEST mode LED comes on.

The terminal now shows the real time status of the different input/output values. See the diagram below.

Values are shown on four rows at a time. Each row represents one input/output signal or value. A is the name and B is the actual value.

Press on any of the SCROLL DISPLAY buttons to show more values.

Example

The truck’s accelerator function can be tested by moving the butterfly disc forwards or backwards. The value THROTTLE% will automatically be changed to show the requested percentage value at full throttle. A value of 100% should be possible in both travel directions.

002 200,201,202,454

The table explains the TEST values.

Test valueDescription

THROTTLE%

BATT VOLTAGE

HEATSINK °C

BRAKE INPUT

SPEED IN

EMR REV INPUT

FORWARD INPUT

REVERSE INPUT

FWD CONTACT

REV CONTACT

MAX TEMP °C

MIN TEMP °C

Accelerator input signal in per cent.

Current battery voltage.

Current regulator temperature.

Status brake input signal, on/off.

Status pin 14 input to the regulator, on/off.

Status safety reversing input, on/off.

Status driving forward input, on/off.

Status driving reversing input, on/off.

Status - connection driving in forward direction output, on/off.

Status - connection driving in reversing direction output, on/off.

The regulator’s registered maximum temperature since DIAGNOSTIC HISTORY was last reset.

Registered minimum temperature since DIAGNOSTIC HISTORY was last reset.

8.3. Use of diagnostic mode

•Press the DIAGNOSTICS mode button. DIAGNOSTICS mode LED comes on.

The terminal now shows a list of the current faults discovered by the regulator. The diagram shows the display when no faults have been discovered.

NOTE!

Refer to therelevantservicemanualdocumentcovering the controller itself for information about possible fault codes displayed in DIAGNOSTICS mode.

Transistor regulator

Valid from serial number:

T-codeModelSerial No.Notes

200PPT 1400MX/MXC319893AA201PPT 2000MX319893AA202PPT 1600MX319893AA454PPL 2000MX319893AA-

1 General

Curtis 1207A-4110 version 137197-006 is similar to Curtis 1207-1137. The difference being the potentiometers and connections for the hand terminal under the sliding cover have been removed. You must have a hand terminal to make adjustments on 1207A. See the chapter “Curtis hand terminal”.

1.1 Characteristics and functions

The model 1207A gives the driver excellent control of the drive motor speed. The current fed to the motor is controlled by varying the pulse time, operating cycle, for the regulator’s power semiconductors, MOSFET-transistors. This technique is called pulse width modulation, PWM, and provides, silent, variable speed control. Pulse width modulation also known as “chopping”, is a technique that rapidly switches the battery voltage to the motor on and off very quickly, so that the motor speed can be controlled. Model 1207A uses high frequency PWM, 15 kHz.

During acceleration and operations at a reduced speed, the regulator permits more current to flow to the motor than what the battery delivers. The regulator then acts as a DC transformer, which takes in a low current at high voltage, full battery voltage, yet a high current strength and low voltage.

A microprocessor continuously monitors the regulator’s operation. If an error is detected a corresponding error code is displayed via LEDs, on top of the regulator. The diagnostic codes shown by the LEDs are listed in the chapter “Diagnostics and trouble shooting”. If the error is critical the regulator is deactivated. Normally the error can be rectified and is only temporary. A low voltage error e.g. disappears when the undervoltage no longer exists.

2 Connections

The transistor regulator has four connections for the high current circuits, one control circuit connection and a connection for a hand terminal as set out on the table below.

ConnectorConnection

1Hand terminal connection

2Low output logic connector with 16 pins

M-Output to the motor armature

B-Negative connection to the battery

B+Positive connection to the battery/series field

ABrake diode to the motor armature

Cables are secured on the busbar by M8 bolts. Two spanners should be used when tightening the bolts and thereby avoid the risk of bending the busbar and applying unnecessary strain on the connections.

2.1 Control circuit connections

The transistor regulator has an integrated connector with 16 pins for the low output connections. Pin configuration is as set out in the table below.

Pin No.Connection

Control circuit contactor

P1Shunt field output

P2Output to the contactor for direction of forks

P3Output to the contactor for direction of steering wheel

P4Not connected

Throttle connection

P5Not connected

P6Not connected

P7Throttle, potentiometer low

P8Throttle, 2-wire 5 kOhm-0-input

Basic control signals

P9Not connected

P10Output for check of safety reversing

P11Input for driving in fork direction

P12Input for driving in steering wheel direction

P13Input for safety reversing

P14Input for selection of mode 1 or 2, (PowerTrak)

P15Input for brake switch

P16Input for ignition switch, (KSI)

003200,201,202,454 Transistor regulator

3 Technical specification

The technical specification for the regulator is in accordance with the table below.

ParameterRangeUnitDescription

Nominal input voltage24Volt

Maximum operating voltage30Volt

Overvoltage point33Volt

Minimum operating voltage16VoltUndervoltage point

Electrical insulation for heatsink500V ACMinimum

PWM-operating frequency15kHz

Output current*250ADuring 1 minute

200ADuring 2 minutes

150ADuring 5 minutes

100ADuring 1 hour

Contactor voltage24Volt

Contactor current, maximum1ACurrent limit at 2 A

Shunt drive current2AStandard approx. 1 A

KSI-input voltage16-30Volt

KSI-input current80mA

Logic card, input current10mAat 24 V

Logic card, input threshold8Volt

Ambient operating temperature-25 to +50 °C

Reduction with over temperature85°C

Reduction with under temperature-25°C

*Output current measured under specific test conditions.

Parameter (1307 display)

Acceleration M1

(M1 ACCEL RATE)

Acceleration M2 (M2 ACCEL RATE)

Maximum speed M1 (M1 MAX SPEED)

Maximum speed M2 (M2 MAX SPEED)

Main current limit M1 (M1 MAIN C/L)

Main contact current limit M1

(M1 MAIN PLUG C/L)

Ramp start current limit M1

(M1 RAMP C/L)

Main current limit M2

M2 MAIN C/L)

Main contact current limit M2

(M2 PLUG C/L)

Ramp start current limit M2

(M2 RAMP C/L)

Neutral brake current limit

(NEUT BRAKE C/L)

4 Parameters

The table below describes the parameters that can be adjusted using the hand terminal. To set parameters using the hand terminal see the chapter “Using the hand terminal”.

RangeStd. valueUnitDescription

0-31.0sTime from zero to full throttle in operating mode 1

0-31.0sTime from zero to full throttle in operating mode 2

40-100100%Percentage of output signal at max. speed input signal in operating mode 1

40-10070%Percentage of output signal at max. speed input signal in operating mode 2

100-150150AMaximum current in operating mode 1

20-6060AMaximum contact current in operating mode 1

100-150100AMaximum contact current during ramp start in operating mode 1

100-150100AMaximum current in operating mode 2

20-6060AMaximum contact current in operating mode 1

60-100100AMaximum contact current during ramp start in operating mode 2

10-7010AMaximum contact current during neutral braking

Parameter (1307 display)

Neutral brake (NEUT BRAKE)

RangeStd.

ON/OFFOFFChoice of braking or freewheeling when the throttle returns to the neutral position

Quick start0-40Defines how quickly the output signal changes when changing the position of the throttle

Creep speed/min. operating cycle

0-2510%The control unit’s output signal jumps to this speed when you change driving direction

The parameters for operating mode 1 respective operating mode 2 are selected via the status on pin 14, Selection of operating mode 1 or 2 (PowerTrak).

•Operating mode 1: These parameters are active when the signal on pin 14 is low.

•Operating mode 2: These parameters are active when the signal on pin 14 is high.

5 Diagnostics and trouble shooting

5.1 Trouble shooting

A microprocessor continuously monitors the regulator’s operation. If an error is detected a corresponding error code is displayed via LEDs, on top of the regulator. The diagnostic codes shown by the LEDs are listed in the chapter “Error codes”. If the error is critical the regulator is deactivated. Normally the error can be rectified and is only temporary. A low voltage error e.g. disappears when the undervoltage no longer exists.

The automatic system for error detection includes:

•Contactor coils open/ short-circuited drive circuit.

•Overcurrent, contactor drive circuit/ contactor coil shortcircuited.

•Contactor welded together.

•Control of function for safety reversing.

•M-output error.

Version noT-code

•Memory controlled during start-up.

•Cut-out with overvoltage.

•Current supply outside permitted range (internal).

•Throttle error.

•Reduction with undervoltage.

•Watchdog.

5.2 Error codes

During normal operations without any errors the STATUS LEDs flashes approx. once per second. If the regulator detects an error, a two digit code flashes continuously until the error is rectified, see the table below.

If a hand terminal is used for error diagnostics, select the DIAGNOSTIC mode; diagnostic information can then be read-off on the display, see table below.

5.2.1 LED indications

Only one error at a time is shown. Errors are not queued.

LED

codeProgramming unit’s LCD display

ExplanationProbable cause

LED dimmedNo current or defective regulator

Fuse has tripped, bad connection, no connection

LED onDefective regulatorRegulator defective

1,2 ¤ ¤¤ HW FAILSAFE Failsafe function error 1. Regulator defective

1,3¤ ¤¤¤ M- SHORTED M- output shortcircuited 1. M-output short-circuited to earth

2. Direction contactor does not make

3. Direction contactor does not make quickly enough

4. Internally short-circuit to earth in motor

1,4¤ ¤¤¤¤ SRO SRO-error1. Incorrect sequence in KSI, braking and direction input

2. Switching circuit for braking or direction open

Transistor regulator

003200,201,202,454

LED codeProgramming unit’s LCD display

2,1 ¤¤ ¤ THROTTLE FAULT 1

ExplanationProbable cause

5 kOhm-0 or lever error

2,2¤¤ ¤¤ BB WIRING CHECK

2,3¤¤ ¤¤¤ HPD

2,4¤¤ ¤¤¤¤ THROTTLE FAULT 2

Function for safety reversing connection error

HPD-sequence error

Potentiometer low cut-off or shortcircuited

3,1¤¤¤ ¤ CONT DRVR OC Overcurrent in drive circuit output

3,2¤¤¤ ¤¤ DIR CONT WELDED

3,4¤¤¤ ¤¤¤¤ MISSING CONTACTOR

4,1¤¤¤¤ ¤ LOW BATTERY VOLTAGE

Welded direction contactors

Contactor or shunt missing

1. Throttle input cable open. 2. Cable for throttle input short-circuited to earth or B+

3. Throttle potentiometer defective

4. Wrong throttle type

1. Function for safety reversing-cable open

2. Function for safety reversing-Check open cable

1. Incorrect sequence on KSI, brake/throttle inputs

2. Incorrectly adjusted throttle

1. Potentiometer low, cable open

2. Potentiometer low, cable short-circuited

3. Wrong throttle type

1. Direction contactor’s coil short-circuited

2. Shunt field short-circuited

1. Direction contactor locked in made position

1. Direction contactor’s coil open

2. Direction contactor missing

3. Shunt field open

4. Cable to shunt or direction contactor open

Low battery voltage1. Battery voltage <16 volts

2. Corrosion on battery terminals

3. Loose connection on the battery or regulator

4,2¤¤¤¤ ¤¤ OVERVOLTAGE Overvoltage1. Battery voltage >33 V

2. Truck used with charger connected

LED codeProgramming unit’s LCD display

4,3¤¤¤¤ ¤¤¤ THERMAL CUTBACK

ExplanationProbable cause

Reduction with over-/under temperature

1. Temperature >85o C or <-25o C

2. Truck overloaded

3. Incorrect fitting of regulator

4. Extreme operating environment

The BT version of regulator 1207A has SRO-type “3”. This means that the regulator is made operational through all inputs for KSI, brakes and forward must be made in the mentioned order. However, operations are permitted if a reverse input precedes the brake input. This can be used with start of the truck on an incline. It is this that is called “Starting on incline”.

5.3 Testing the error detection circuits

Special materials handling directives such as nprEN1175, demand regular testing of the transistor regulator’s error detection function. It is therefore recommended that the detection circuits are checked each time the truck is serviced as follows:

•Support the truck so that the drive wheel is free from the ground, disconnect the battery and ensure that the ignition switch is Off.

•Use a suspended fuse holder with a 10 A-fuse and crocodile clips, connected to the regulator’s M- and B connections.

•Switch On the ignition switch, release the brake and press the throttle. The motor should not be running and the direction contactors should not be switched.

•Let the ignition switch remain On and disconnect the suspended fuse. The truck’s should still not start.

•Switch the ignition on and off a few times, release the brake and press the throttle. The truck should now work normally.

6 Maintenance

There are no parts inside of the transistor regulator that the user can service.

NOTE!

Do not attempt to open the transistor regulator. IF THE REGULATOR IS OPENED THE WARRANTY CAN CEASES TO BE VALID!

However, the outside of the transistor regulator should be cleaned regularly. Cleaning provides an excellent opportunity to check the regulator’s diagnostic history using the hand terminal.

6.1 Safety

High power components can be found in the regulator. Appropriate safety precautions must always be taken when working on a battery powered vehicle. Safety precautions include, but are not limited to, training, the use of protective glasses, not wearing loosely hanging clothes. Remove watches and jewellery and always use insulated tools.

WARNING

Risk of short-circuiting. Remove watches or jewellery and always use insulated tools.

6.2 Cleaning

Despite the regulator not requiring any maintenance if installed correctly, it is however recommended that the following minimum care should be carried out regularly after every 250 hours.

•Cut the voltage by disconnecting the battery.

•Discharge the capacitors in the transistor regulator by connecting a load for example, a contactor coil or the horn across the regulator’s B+ and B- connections before carrying out any work on the regulator.

•Remove all dirt and corrosion from around the busbars.The regulator should be wiped clean with a damp cloth. Allow it to dry before reconnecting the battery.

Cables are secured on the busbar by M8 bolts. Two spanners should be used when tightening the bolts and thereby avoid the risk of bending the busbar and applying unnecessary strain on the connections.

7 Hand terminal Curtis 1307

The hand terminal Curtis 1307 makes it possible to program, test and trouble shoot regulators of the type Curtis PMC 1207/1207A. The hand terminal is controlled by the host processor 1207/1207A via a modular connector RJ11 located on the adjustment panel above the regulator 1207, or a 4way Molex connector located on the front of regulator 1207A.

Curtis 1207 connection

Curtis 1207A connection

Pos.FunctionNotes

1Display4 row LCD-display.

2PROGRAM MODE keySelect this mode to show and change the regulator’s parameters.

3TEST MODE keySelect this mode to show the status of the inputs/ outputs, etc.

4DIAGNOSTICS MODE key Select this mode to show the current error condition detected by the regulator.

5SCROLL DISPLAY keysScroll the displayed rows of text up and down.

6MORE INFO keysPress this key to receive more information about the current status.

7LED for active keysIndicates whether the relevant CHANGE VALUE key is active. When the LED is dimmed no further adjustment can be made.

8CHANGE VALUE keysIncrease or decrease the value of the selected parameter

9LED for operating modeStates which operating mode is currently active.

8 Using the hand terminal

•Connect the hand terminal to the regulator’s programmer socket located above the adjustment panel.

•Make sure the current to the truck is on.

The first time the hand terminal is connected to the regulator the brake switch must be open, brakes applied, until the hand terminal has read in all the regulator parameters. The hand terminal then displays the regulator’s model number, date of manufacture and the software’s version number. The hand terminal then prompts for further instruction.

The hand terminal has three primary operating modes: PROGRAM, TEST and DIAGNOSTICS.

•PROGRAM mode used to show, and change the regulator’s parameters. The shown parameters can also be changed in this mode.

•TEST mode shows real time information on the status of the inputs, outputs and the regulator temperature. In the TEST mode the points of interest are not always at the top of the list. They only need to be shown among the four rows displayed in the window. The TEST mode can be used to check the operation of the regulator during initial installation and for trouble shooting.

•DIAGNOSTICS mode shows the active error detected by the regulator.

Two other operating modes can be activated SPECIAL PROGRAM and SPECIAL DIAGNOSTIC.

•The SPECIAL PROGRAM mode allows a number of different tasks including: erasing the diagnostic history file, adjusting the display contrast, language selection, saving settings, etc.

•In the SPECIAL DIAGNOSTICS mode the regulator’s diagnostic history is shown. This file contains a list of all faults observed and saved by the regulator since the file was last cleared.

PROGRAM

8.1 Using the PROGRAM mode to check and adjust parameters

•Press on the PROGRAM mode key. The corresponding LED for PROGRAM operating mode comes on.

The hand terminal now shows the first four parameters. See illustration below.

Parameters are shown four at a time. Each row represents one parameter. A indicates the name of the parameter. The arrow B indicates the parameter currently selected for adjustment. C indicates the current parameter value.

Press on one of the SCROLLDISPLAY keys to show other parameters.

Scroll the display up or down to adjust a specific parameter so that the arrow (B) points on the actual parameter.

•Increase the value by pressing the key CHANGE VALUE “up” or decrease it by pressing on the key CHANGEVALUE “down”. The LEDs on these keys indicate whether there is still room for adjustment, i.e. that when the upper limit for a parameter range has been reached, the LED on the “up” key does not come on thereby indicating that the value cannot be further increased. When the lower limit has been reached the LED on the “down” key goes out.

NOTE!

As soon as a displayed parameter is modified, the new value is transferred directly to the regulator.

See the appropriate service manual for the regulator in question for information on parameters, standard parameter values and adjustments.

8.1.1 Using the key MORE INFO in PROGRAM mode

The MORE INFO key in PROGRAM mode shows a bar chart together with the min. and max. values for the selected parameters. The parameters can either be changed from the PROGRAM main menu or after the key MORE INFO has been pressed to show extra information, see the example below.

8.2 Using SPECIAL PROGRAM mode

SPECIAL PROGRAM makes it possible to perform a number of different tasks of which most are self-explaining. Via the SPECIAL PROGRAM you can return to previous settings, save regulator settings in the hand terminal’s memory, load regulator settings from the hand terminal to a regulator, erase the diagnostics history file, adjust the contrast on the programmer’s LCD display, select the display language on the hand terminal and show basic information about the regulator and hand terminal.

SPECIAL PROGRAM is accessed by first pressing the MORE INFO key. Keep the MORE INFO key held down and press the PROGRAM key. The LED on the PROGRAM key comes on, exactly as when the hand terminal is in the PROGRAM mode. The key MORE INFO is first used to reach the SPECIAL PROGRAM mode, and once the mode is active, used to execute the different measures. For example, to adjust the contrast on the display, you select “Contrast Adjustment” by scrolling the screen until the option is shown at the top of the window and then press the MORE INFO key to find out how to make the adjustment.

8.3 Using TEST mode

•Press on the TEST key. The corresponding LED comes on.

The hand terminal’s display shows the real time status of the different inputs, outputs and values. See the illustration below.

Parameters are shown four at a time. Each row represents one input, one output or one value. A is the name and B is the current value. In TEST mode the test value does not need to be at the top of the display. It only needs to be among the four visible rows in the window. The TEST mode can be used with the installation of the regulator, and with later trouble shooting.

Show other values by pressing the SCROLLDISPLAY keys.

Example

The operation of the truck’s throttle can be controlled by moving the toggle switch forwards or backwards. The value THROTTLE % should changed with the movement of the throttle to show the speed’s set value in per cent of the value for maximum speed. It should be possible to set a value of 100% in both travel directions.

The table shows the meaning of the TEST values.

Test valueDescription

THROTTLE %

BATT VOLTAGE

HEATSINK °C

BRAKE INPUT

SPEED IN

EMR REV INPUT

FORWARD INPUT

REVERSE INPUT

FWD CONTACT

REV CONTACT

MAX TEMP °C

MIN TEMP °C

The throttle’s input signal in per cent.

Current battery voltage

Current regulator temperature

Status of brake input, on/off

Status of pin 14, the input signal to the regulator on/ off

Status of the safety reversing input, on/off

Status of the input for driving forwards, on/off

Status of the input for reversing, on/off

Status of contactor input for direction forwards, on/off

Status of contactor input for direction reversing, on/off

Highest recorded regulator temperature since DIAGNOSTIC HISTORY was last cleared

Lowest recorded regulator temperature since DIAGNOSTIC HISTORY was last cleared

DIAGNOSTICS MORE INFO DIAGNOSTICS

8.4 Using DIAGNOSTICS mode

•Press the DIAGNOSTICS key. The corresponding LED comes on.

The hand terminal’s display shows a list of the active errors detected by the regulator. The illustration below shows the display when no errors have been detected.

NOTE!

See the appropriate service manual for the regulator in question for information on possible error codes shown in the DIAGNOSTICS mode.

8.5 Using SPECIAL DIAGNOSTICS mode

The regulator file with diagnostic history is shown in SPECIAL DIAGNOSTICS mode. This file is a list of all the regulator’s detected and recorded errors since the file was last cleared. Each error is only recorded once in the file diagnostic history irrespective of how many times the error has occurred.

SPECIAL DIAGNOSTICS is accessed by first pressing on the MORE INFO key. Keep the MORE INFO held down and then press the DIAGNOSTICS key. The LED on the DIAGNOSTICS key comes on, exactly as when the hand terminal is in the DIAGNOSTICS mode.

To clear the diagnostic history file, switch to SPECIAL PROGRAM mode, and select “Clear Diagnostic History” and then press the MORE INFO key for instruction. Clearing the diagnostic history file also resets the max. and min. temperatures in the TEST mode.

003200,201,202,454

Electronic card Resistance Control

Valid from serial number:

T-codeModelSerial NoNotes

200PPT 1400MX/MXC237000AA-

201PPT 2000MX237000AA-

202PPT 1600MX237000AA-

1 Controller

The BT PPT 1400MX/1600MX/2000MX controller contains a logic-unit (micro processor) which detects signals from microswitches, armature voltage, etc. The controller’s inputs and outputs are equiped with connectors for connection/disconnection of cables.

The controller is equipped with a green LED (labelled PWR/ ERROR), which indicates correct main voltage. The LED for PWR/ERROR also indicates faults in the emergency stop circuit or in the contactor circuits.

The inputs are suited for the 24 V voltage level and will draw a certain current in order to clean the opening contacts and, also, to indicate input signals with green LED’s.

The contactor outputs are electronically short circuit proof and indicate output signals with red LED’s. The drive contactor outputs are controlled by transistors and will receive the full main voltage when the current is turned on, i.e. 24 V and after the contactors have closed, the voltage will drop to half this value, i.e. 12 V.

In addition to signals from switches, the drive motor’s armature voltage is monitored, so that speed step 3 will be engaged at a pre-determined voltage level or, alternatively, after a fixed time lapse.

Connection contacts

PositionConnection

1Shunt field

2Battery +, armaturevoltage, contactors, horn

3Key switch(S17), battery -, instrument, magnetic valve (Y41)

4Micro switches

I = Input, green LED O = Output, red LED

Version noT-code

Terminal NoLED NoConnectionFunction

105105IFork lift

106106IFork lower

107107IHorn

108O24 V (+)

109109IBrake

110ISafety reversing (S20)

111ISafety reversing (S20)

201IBattery controller

202I24 V (+)

203OBattery controller

204OMagnetic valvel

205O24 V (+)

206OHour meter

207I(-)

301OShunt field (+)

302OShunt field (-)

401401OContactor, fork direction

402402OContactor, steer wheel direction

403403OContactor, speed 2

404404OContactor, speed 3

405405OContactor, pump motor

406OHorn

407I24 V (+)

408IArmature voltage

409O(-)

001 200,201,202

Electronic card

Transistor Control

Valid from serial number:

1 General

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. The card is also equipped with a potentiometer for adjustment of the maximum speed.

1.1 Connection/adjustments

PositionConnection/Adjustment

1Key switch (S17), battery -, instrument, magnetic valve (Y41)

2Battery +, armature voltage, contactors, horn

3Shunt field

4RV1, adjustment of maximum speed

5Micro switches Terminal

I = Input, green LED O = Output, red LED

steer wheel direction

Version noT-code

Terminal NoLED NoConnectionFunction

110ISafety reversing (S20)

111ISafety reversing (S20)

201IBattery controller

202I24 V (+)

203OBattery controller

204OMagnetic valve

205O24 V (+)

206OHour meter

301OShunt field(+)

302OShunt field(-)

401401IContactor (-), fork direction

402402IContactor (-), steer wheel direction

403403UContactor drive direction, common (+)

404404OInput signal, pump contactor closed

405405OContactor, pump motor

406OHorn

407I24 V (+)

408OInput signal, brake released

409I(-)

410O24 V (+), to transistor controller

411ODriving, fork direction

412ODriving, steer wheel direction

413ISpeed control

414OReferens value, speed

415OSafety reversing (S20)

416OSafety reversing (S20)

417IShunt field(-)

002 200,201,202