BT LT 2200-6 LT 2200-8 Product Family PT Master Service Manual - PDF DOWNLOAD

Master Service Manual Product family PT LT 2200-6 LT 2200-8

C-code revision 2 © BT Industries AB

Part number:173666-040 Issued: 1999-06-23 SSD

F-code

Section

C-code

PT Introduction to BT’s Service Manual IIssued by

Approved by

Version no

SSD

T-code

001

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: M

Machine information

P

Preventive maintenance

S

Service instructions

O

Options

At the top of each page you can find information on which section the page belongs: Section M 4 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

© BT Industries AB

Service Manual

1998-11-04

English

1 (2)

F-code

Section

C-code

PT Introduction to BT’s Service Manual Version no

T-code

001

2 (2)

Service Manual

1998-11-04

English

F-code

Section

C-code

PT Contents Master Service Manual (MSM) IIssued by

Approved by

Version no

T-code

SSD

Iréne Karlsson

001

184,288

Contents Master Service Manual (MSM) Part number:

xxxxxx-040 Issued 1999-06-23

Valid from serial number: T-code

Model

Serial No

184

LT 2200-8

256000AA-

288

LT 2200-6

256000AA-

Notes

1. Document list Section

C-code

T-code

M

Document

Issued

Introduction to BT’s Service Manual

1998-11-04

Contents, M

1998-03-13

M1

184, 288

Issued Operator’s manuals

1999-04-14

M2

184, 288

General product information

1999-01-02

M4

184, 288

Technical data

1999-01-07

Ordering Spare Parts

1995-11-30

M6 M7

184, 288

Quality Parts

1999-06-21

M8

184, 288

Recommended Spare Parts

1999-06-21

P

Contents, P

1995-12-01

P1

Introduction, maintenance

1998-11-04

P2

184, 288

Preventive maintenance

1998-11-16

P3

184, 288

Oil and grease specification

1998-12-23

Contents, S

1998-11-04

S S1

1760

184, 288

Electric drive motor

1999-05-11

S2

2550

184, 288

Mechanical drive gear unit

1998-01-09

S3

3370

184, 288

Electromagnetic parkingbrake

1998-10-01

© BT Industries AB

Service Manual

1999-06-23

English

1 (2)

F-code

Section

C-code

PT Contents Master Service Manual (MSM) Version no

T-code

001

184,288

Section

C-code

T-code

Document

Issued

S5

5000

184, 288.1

Electrical system

1998-02-12

5000

184.2

Electrical system

1998-04-20

5000

184.3

Electrical system

1999-01-07

5000

288.2

Electrical system, Transistor regulator

1998-04-21

5230

184, 288

Volt-/battery indicator

1999-01-02

5460

184, 288.1

Transistor panel

1998-01-09

5460

184, 288.2

Transistor panel

1998-04-23

5710

184

Electronic card, drive/multi function

1998-04-30

5710

288

Electronic card, drive/multi function

1998-05-04

Hydraulic/pneumatic system

1999-01-08

S6

2 (2)

Service Manual

1999-06-23

English

F-code

Section

PT

M

C-code

Contents, M IIssued by

Approved by

Version no

T-code

SSD

Contents, M 1 Truck information

© BT Industries AB

M1

Operator’s Manual

M2

General product information

M3

Product sheet

M4

Technical data

M5

Product improvements

M6

Spare Part ordering

M7

Quality Parts

M8

Recommended Spare Parts

Service Manual

1998-03-13

English

1 (2)

F-code

Section

C-code

PT M Contents, M Version no

2 (2)

T-code

Service Manual

1998-03-13

English

F-code

Section

PT

M1 Operator’s manual

C-code

IIssued by

Approved by

Version no

T-code

SSD

Iréne Karlsson

001

184,288

Operator’s manual Valid from serial number: T-code

Model

Serial No

184

LT 2200-8

278519AA-

288

LT 2200-6

276974AA-

Notes

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-code

Model

Serial number

Order number

Issued

184

LT 2200-8

278519AA-285754AA

151004

1995-11-13

184

LT 2200-8

285755AA-310599AA

153289

1996-04-23

288

LT 2200-6

142886

1994-12-31

288

LT 2200-6

276974AA-310599AA

147338

1996-04-29

184/288

LT 2200-8/2200-6

310600AA-319124AA

161896

1997-10-23

184/288

LT 2200-8/2200-6

319125AA-

165000

1998-04-17

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

© BT Industries AB

Service Manual

1999-04-14

English

1 (2)

F-code

Section

C-code

PT M1 Operator’s manual Version no

T-code

001

184,288

2 (2)

Service Manual

1999-04-14

English

F-code

Section

C-code

PT M2 General product information IIssued by

Approved by

Version no

T-code

SSD

Fredrik Wigh

001

184,288

General product information Valid from serial number: T-code

Model

Serial No

Notes

184

LT 2200-8

340037AA-

9,5 km/h

288

LT 2200-6

340037AA-

1 Presentation of the truck The truck is a battery driven support arm truck. The truck is equipped with a tiller arm for optional control: standing on the ride-on platform or walking LT 2200-8 is a faster version, equipped with protective gates, where the maximum speed is increased to 9,5 km/h.

The truck’s maximum speed is 6 km/h when the protective gates are retracted in the direction of the forks and the driver is standing on the platform.

© BT Industries AB

Service Manual

1999-01-02

English

1 (10)

F-code

Section

C-code

PT M2 General product information Version no

001

T-code

184,288

The truck’s maximum speed is 9,5 km/h when the protective gates are retracted in the direction of the drive wheel and the driver is standing on the ride-on platform.

A standard LT 2200 (6 km/h) can also be equipped with gates. The maximum speed is then always 6 km/h, irrespective of the position of the gates and platform.

CAUTION! Pinch risk.

There is a risk of pinching if you drive the truck with the platform raised and the gates extended.

Always retract the gates when the platform is raised.

The truck has a maximum lifting capacity of 2200 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 a footstep and anti-slip guard (for order picking), load support and writing console. 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.

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.

2 (10)

Service Manual

1999-01-02

English

F-code

Section

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PT M2 General product information Version no

T-code

001

184,288

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

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

Truck type

LT 2200

LT 2200-8

Lifting capacity with rated load *, kg

2200

2200

Lift height, mm

205

205

Ride-on platform height (collapsed), mm

190-210

200

Travel speed without load, m/s

1,7

2,2

Travel speed with rated load, m/s

1,3

1,5

Max. operating gradient with rated load, %

9

9

Weight without battery, kg

465

495

Weight with battery, kg (Ah)

740 (320)

770 (320)

Turning radius with raised forks (Wa), mm (depending on the length of the forks)

1245-3335

1245 - 3335

Continuous noise level, dB (A)

<70

< 70

Full body vibration value, m/s2

0,7

0,7

Permitted drive wheel, material

Vulkollan siped Vulkolan Elastomer

Vulkollan siped Vulkolan Elastomer

* Deviations may occur on trucks adapted to specific application; the correct value can be found on the trucks’s type plate.

In such cases the truck is also fitted with a modification plate. © BT Industries AB

Service Manual

1999-01-02

English

3 (10)

F-code

Section

C-code

PT M2 General product information Version no

001

T-code

184,288

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

LT 2200-8

4 (10)

Service Manual

1999-01-02

English

F-code

Section

C-code

PT M2 General product information Version no

T-code

001

184,288

LT 2200

Item

Measurement in mm LT 2200

LT 2200-8

Measurement in mm LT 2200

LT 2200-8

A

350

I

810-2900

810-2900

B

850

J

85

85

1380-1500

K

550

1080

L

880

C

1380-1500

D

© BT Industries AB

Item

E

620

620

M

800

800

F

180

200

N

685

685

G

1095

1175

O

180

180

H

880-1000

880-1000

P

450-685

450-685

Service Manual

1999-01-02

English

5 (10)

F-code

Section

C-code

PT M2 General product information Version no

001

T-code

184,288

4 Identification plate CE The illustration shows the identification plate for the truck in CE-design.

Item

Text

Unit

A

MODEL

B

NO

C

RATED CAPACITY

kg

D

WEIGHT WITHOUT BATTERY

kg

E

BATTERY WEIGHT

kg kg

F

BATTERY VOLTAGE

MAX MIN

V

5 Identification plate CE + ASME The picture shows the identification plates for the truck in CE and ASME designs.

A B C D E E

Item

Text

Unit

A

MODEL

B

NO

C

RATED CAPACITY

kg

D

WEIGHT WITHOUT BATTERY

kg

E

BATTERY WEIGHT

F

BATTERY VOLTAGE

G

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

MAX MIN

F G

6 (10)

Service Manual

1999-01-02

kg kg V

English

F-code

Section

C-code

PT M2 General product information Version no

T-code

001

184,288

6 Identification plate ASME A B C D E E F G

The illustration shows the identification plate for the truck in ASME-design.

Item

Text

Unit

A

MODEL

B

NO

C

RATED CAPACITY

kg

D

WEIGHT WITHOUT BATTERY

kg

E

BATTERY WEIGHT

F

BATTERY VOLTAGE

G

BATTERY TYPE ACCORDING TO ASME-NORM UL583

MAX MIN

kg kg V

7 Modification plate The picture 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.

© BT Industries AB

Item

Text

A

Modification plate

B

Type

C

Serial number

D

Place of manufacture

E

Place of manufacture

F

Modification number

G

Date

Service Manual

1999-01-02

English

7 (10)

F-code

Section

C-code

PT M2 General product information Version no

001

T-code

184,288

8 Main components 1. Tiller arm: The truck can be controlled by the operator standing on the ride-on platform or walking. 185 degrees steering arc is available. The brake is applied in the tiller arm’s upper and lower positions.

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

3. Protective gates: A higher speed of 9,5 km/h is possible with the gates folded out, while the truck can only be driven at a speed of 6 km/h with the gates folded forward.

4. Covers: Easily opened and removable which allows good access when servicing.

5. Drive unit with brake: Suspended drive unit with two stage electromagnetic brake, drive motor, gears and drive wheel combined into a compact unit. Steering bearings between motor and gears. The pressure on the drive wheel is automatically adapted according to the load.

6. Hydraulic unit: Pump motor, pump, valves and oil tank integrated in a compact unit.

7. Platform: Folding ride-on platform which automatically folds up when not loaded.

8. Platform switch: Switch for control of the speed range and brake function.

9. Support castor wheels: Two support castor wheels to ensure stability. Fitted with rubber guard to prevent foot injuries.

10. Electric panel: Can be swung, which provides good access when servicing. 24 volt electrical system. The speed is controlled by resistor (three speed) or transistor (variable) systems.

11. Lift cylinders: Located along the sides of the truck.

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

13. Serial number: Serial number plate fitted to the chassis. Partly hidden by the emergency disconnector.

8 (10)

Service Manual

1999-01-02

English

F-code

Section

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PT M2 General product information Version no

T-code

001

184,288

14. Emergency disconnector and battery connector: The battery is charged via the permanently fitted charging connector.

15. Battery: 24 V with different Ah values. Stands on rollers to facilitate replacement.

© BT Industries AB

Service Manual

1999-01-02

English

9 (10)

F-code

Section

C-code

PT M2 General product information Version no

001

T-code

184,288

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

1.

2.

3.

4.

5.

6.

7.

8.

9.

10 (10)

Signal/Horn Hydraulic control: Lower Hydraulic control: Lift Travel direction Hydraulic oil filling Lifting points Serial number Identification plate Modification plate

Service Manual

1999-01-02

English

F-code

Section

PT

M4

C-code

Technical data IIssued by

Approved by

Version no

T-code

SSD

Fredrik Wigh

001

184,288

Technical data Valid from serial number: T-code

Model

Serial No

Notes

184

LT 2200-8

319025AA-

9,5 km/h

288

LT 2200

319025AA-

Model

LT 2200

Drive motor Type

TTL 140BB-D11

Power, kW

1,4

Intermittens, %

60

Min. carbon brush length, mm

11

Min. commutator diameter, mm

60

Transmission/drive gear Type

2-step angular

Gear ratio

16,29:1

Oil volume, litre

1,0

Oil type: Normal temperature < -15oC

Hypoid oil SAE 80W/90 SAE 75W

Wheels

© BT Industries AB

Drive wheel, mm

Dia 215x70

Axle pressure without load, kg

400

Axle pressure at rated load, kg

590

Tightening torque for wheel bolts, Nm

65

Fork wheels, Single, mm

Dia 85x100

Fork wheels, Boggie, mm

Dia 85x75

Axle pressure without load, kg

130

Axle pressure at rated load, kg

1890

Support wheels, mm

Dia 140x60

Axle pressure without load, kg

140

Axle pressure at rated load, kg

500

Service Manual

1999-01-07

English

1 (4)

F-code

Section

C-code

PT M4 Technical data Version no

T-code

001

184,288

Model

LT 2200

Hydraulic system Power, kW

2,0

Intermittens, %

10

Min. carbon brush length, mm

12

Min. commutator thickness/diameter, mm

43

Pressure at rated load, bar

-

Relief pressure, bar

-

Pump flow, cc/r

2,5

Tank volume, litre

1,2

Oil type: Normal temperature < -15oC

ISO-L-HM32 ISO-L-HV32

Fuses Control circuits, transistor machine

7,5 A /122308-075

Control circuits, resistance machine

8 A / 29023

Drive motor

125 A / 29584

Pump motor

160 A /29223

Batteries Dimensions W x L x H, mm

-

Capacity, Ah

240-320

Weight, kg

275

Driving speed

2 (4)

Without load, km/h Without load, m/s

6 1,7

With rated load, km/h With rated load, m/s

5,1 1,4

Without load, LT 2200-8, km/h Without load, LT 2200-8, m/s

9,5 2,6

With rated load, LT 2200-8, km/h With rated load, LT 2200-8, m/s

7,3 2,0

Service Manual

1999-01-07

English

F-code

Section

PT

M4

C-code

Technical data Version no

T-code

001

184,288

Model

LT 2200

Lifting-/lowering speed Lifting without load, s

2,0

Lifting with rated load, s

3,0

Lowering without load, s

4,0

Lowering with load, s

2,0

Power consumption

© BT Industries AB

Driving without load, A

50

Driving with rated load, A

55

Lifting without load, A

40

Lifting with rated load, A

75

Service Manual

1999-01-07

English

3 (4)

F-code

Section

C-code

PT M4 Technical data Version no

T-code

001

184,288

4 (4)

Service Manual

1999-01-07

English

F-code

Section

PT IIssued by

Approved by

Version no

SSD

C-code

M6 Ordering Spare Parts T-code

001

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.

© BT Industries AB

Service Manual

1995-11-30

English

1 (2)

F-code

Section

C-code

PT M6 Ordering Spare Parts Version no

T-code

001

2 (2)

Service Manual

1995-11-30

English

F-code

Section

PT

C-code

M7 Quality Parts

IIssued by

Approved by

Version no

T-code

SSD

Iréne Karlsson

001

184,288

Quality Parts Valid from serial number: T-code

Model

Serial No

184

LT 2200-8

276974AA-

288

LT 2200

256600AA-

Notes

1 Issued Quality Parts T-kod

Model

Serial No

Order number

Issued

288

LT 2200-6

256600AA-271116AA

141680

1994-04-01

288

LT 2200-6

271117AA-276173AA

148910

1995-06-01

288

LT 2200-6

276174AA-276973AA

150195

1995-11-01

184/288

LT 2200-8/2200-6

276974AA-285754AA

151578

1995-12-01

184/288

LT 2200-8/2200-6

285755AA-294079AA

153149

1996-05-01

184/288

LT 2200-8/2200-6

294080AA-310599AA

156120

1996-12-01

288

LT 2200-6

310600AA-319124AA

161880

1997-12-01

184/288

LT 2200-8/2200-6

319125AA-324231AA

164436

1998-08-10

184/288

LT 2200-8/2200-6

324214AA-328786AA

166627

1998-08-31

184/288

LT 2200-8/2200-6

328787AA-

170833

1999-06-01

© BT Industries AB

Service Manual

1999-06-21

English

1 (2)

F-code

Section

C-code

PT M7 Quality Parts Version no

001

2 (2)

T-code

184,288

Service Manual

1999-06-21

English

F-code

Section

C-code

PT M8 Recommended Spare Parts (RSP) IIssued by

Approved by

Version no

T-code

SSD

Iréne Karlsson

001

184,288

Recommended Spare Parts (RSP) Valid from serial number: T-code

Model

Serial No

184

LT 2200-8

310600AA-

288

LT 2000-6

310600AA-

Notes

1 Issued RSP T-code

Version

Model

Serial No

Issued

184/288

01

LT 2200-8/2200-6

310600AA-319124AA

1998-09-03

184/288

02

LT 2200-8/2200-6

319125AA-324123AA

1998-09-03

184/288

03

LT 2200-8/2200-6

324124AA-

1998-09-03

© BT Industries AB

Service Manual

1999-06-21

English

1 (2)

F-code

Section

C-code

PT M8 Recommended Spare Parts (RSP) Version no

001

2 (2)

T-code

184,288

Service Manual

1999-06-21

English

F-code

Section

PT

C-code

P Contents, P

IIssued by

Approved by

Version no

SSD

T-code

001

Contents, P 1 Preventive Maintenance

© BT Industries AB

P1

Introduction

P2

Preventive Maintenance

P3

Oil and grease specification

P4

Tools

Service Manual

1995-12-01

English

1 (2)

F-code

Section

C-code

PT P Contents, P Version no

T-code

001

2 (2)

Service Manual

1995-12-01

English

F-code

PT IIssued by

Approved by

Section

Version no

SSD

C-code

P1 Introduction, maintenance T-code

001

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. © BT Industries AB

Service Manual

1998-11-04

English

1 (4)

F-code

Section

C-code

PT P1 Introduction, maintenance Version no

T-code

001

• 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 (4)

Service Manual

1998-11-04

English

F-code

PT

Section

C-code

P1 Introduction, maintenance

Version no

T-code

001

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

© BT Industries AB

Service Manual

1998-11-04

English

3 (4)

F-code

Section

C-code

PT P1 Introduction, maintenance Version no

T-code

001

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.

4 (4)

Service Manual

1998-11-04

English

F-code

PT

Section

C-code

P2 Preventive maintenance

IIssued by

Approved by

Version no

T-code

SSD

Fredrik Wigh

001

184,288

Preventive maintenance Valid from serial number: T-code

Model

Serial No

Notes

184

LT 2200-8

256000AA-

9.5 km/h

288

LT 2200-6

256000AA-

1 Service schedule Pos. nr.

Work to carry out Interval in hours

5

20

80

160

250

500

1000

Interval in days/weeks/months

1d

1w

1m

2m

3m

6m

12m

0000.

Chassis

0000.1

Check all links and locking pins

X

0000.2

Check for crack formation and damage

X

0000.3

Check the mounting of the lift cylinders

X

0000.4

Check the cover catches

0000.5

Check for damage on the platform

0380

Fork carriage

0380.1

Check for crack formation and damage

0380.2

Check for play on the bushes and rollers

0380.3

Check the lift limit switch

1700.

Motors

1700.1

Check for loose connections

X

1700.2

Check the carbon brushes

X

1700.3

Clean the motor

X

1700.4

Check the mounting bolts

X

1700.5

Check for abnormal noises from the bearings

© BT Industries AB

Service Manual

X X

X X X

X

1998-11-16

English

1 (6)

F-code

Section

C-code

PT P2 Preventive maintenance Version no

T-code

001

184,288

Pos. nr.

Work to carry out Interval in hours

5

20

80

160

250

500

1000

Interval in days/weeks/months

1d

1w

1m

2m

3m

6m

12m

2550.

Drive unit

2550.1

Check for leakage

X

2550.2

Check the oil level

X

2550.3

Check for abnormal noises

2550.4

Check the mounting

2550.5

Change the oil in the drive gear

3100

Brake

3100.1

Clean

3100.2

Check the brake discs for wear

3100.3

Check the play in the released position

3500.

Wheels

3500.1

Remove string and other rubbish

3500.2

Check for wear to the drive wheel and bolts

X

3500.3

Check that the castor wheels rotates and moves freely

X

3500.4

Check for wear to castor wheel

X

3500.5

Dismantle and grease the fork wheel´s bearings

X

5110.

Battery

5110.1

Check the function of the battery isolator

5110.2

Check the electrolyte level, 10-15 mm above the cell plates

X

5110.3

Check the connections to the battery truck and charger

X

5110.4

Check that the cell and pole guard are undamaged

X

5110.5

Check the fluid density and temperature

2 (6)

X X X*

X

Service Manual

X X

X

X

X

1998-11-16

English

F-code

PT

Pos. nr.

Section

C-code

P2 Preventive maintenance

Version no

T-code

001

184,288

Work to carry out Interval in hours

5

20

80

160

250

500

1000

Interval in days/weeks/months

1d

1w

1m

2m

3m

6m

12m

4110.

Tillerarm

4110.1

Check the mounting

X

4110.2

Check the steering force

X

4110.3

Check the force of the gas suspension

X

4380

Steering bearing

4380.1

Lubricate the steering bearing

5000.

Electrical operations

5000.1

Check the operation of the microswitches

X

5000.2

Check the brake microswitch

X

5000.3

Check the operation of the safety switch for collision

X

5000.4

Check the operation of the gate switches

X

X

5000.5

Check the operation of the platform switch and the brake switch

X

X

5400

Power system driving

5400.1

Clean and check mountings

X

5400.2

Tighten cable connections

X

5400.3

Check the contactor points

X

5400.4

Check the contactor’s movement

X

5700

Electronic card

5700.1

Clean the electronic card

X

5700.2

Check contacts and cables

X

5700.3

Check the LEDs

X

6100.

Hydraulic system

6100.1

Check for leakage from hoses and couplings

X

6100.2

Check for wear to the hoses

X

© BT Industries AB

Service Manual

X

1998-11-16

English

3 (6)

F-code

Section

C-code

PT P2 Preventive maintenance Version no

T-code

001

184,288

Pos. nr.

Work to carry out Interval in hours

5

20

80

160

250

500

1000

Interval in days/weeks/months

1d

1w

1m

2m

3m

6m

12m

6100.3

Check the tank

X

6100.4

Change the oil

X*

X

6100.5

Change the oil filter

X*

X

6600.

Lift cylinders

6600.1

Check for leakage

X

6600.2

Check the mountings

X

*= The oil/oil filter should be changed for the first time after 80h/1 month then every 1000h/12 months. For the drive shaft the oil is changed every 3000h/36 months.

4 (6)

Service Manual

1998-11-16

English

F-code

PT

© BT Industries AB

Service Manual

1998-11-16

Section

C-code

P2 Preventive maintenance

Version no

T-code

001

184,288

English

5 (6)

F-code

Section

C-code

PT P2 Preventive maintenance Version no

T-code

001

184,288

2 Lubrication chart Pos no

Service point

Interval/Running hours 250h

1

Wheel bearings

2

Hydraulic system

3

Steering bearings

4

Drive gear

3000h L

C

Service Manual

A

O

B

L

D

C L= Lubrication

6 (6)

1000h

Lubricant

O C = Check

1998-11-16

C

O = Oil change

English

F-code

PT

Section

C-code

P3 Oil and grease specification

IIssued by

Approved by

Version no

T-code

SSD

Fredrik Wigh

001

184,288

Oil and grease specification Valid from serial number: T-code

Model

Serial No

Notes

184

LT 2200-8

256000AA-

9,5 km

288

LT 2200

256000AA-

Lubricant

Specification > - 15°C

< - 15°C

Application area

A

Grease

26777 (Spray)

26777 (Spray)

Bearings and bushings

B

Hydraulic oil

ISO-LHM32

ISO-VG32

Hydraulic system

C

Transmission oil

Hypoid oil SAE 80W/ 90

Hypoid oil SAE 75W

Gears

D

Grease

Staburags NBU 8EP

Staburags NBU 8EP

Steering bearings

© BT Industries AB

Service Manual

1998-12-23

English

1 (2)

F-code

Section

C-code

PT P3 Oil and grease specification Version no

001

2 (2)

T-code

184,288

Service Manual

1998-12-23

English

F-code

Section

PT

C-code

S Contents, S

IIssued by

Approved by

Version no

SSD

T-code

001

Contents, S 1 Service instructions C-code

© BT Industries AB

S0

Chassis

0000

S1

Primary motor

1000

S2

Transmission/Drive gear

2000

S3

Brake/Wheel/Caterpillar system

3000

S4

Steering system

4000

S5

Electrical system

5000

S6

Hydraulic/pneumatic system

6000

S7

Working functions, lift mast/cylinders

7000

S8

Peripheral/installation equipment

8000

S9

Options, attatchments

9000

Service Manual

1998-11-04

English

1 (2)

F-code

Section

C-code

PT S Contents, S Version no

T-code

001

2 (2)

Service Manual

1998-11-04

English

F-code

Section

PT

C-code

S1 1760 Electric drive motor

IIssued by

Approved by

Version no

T-code

SSD

Jan Pettersson

001

184,288

Electric drive motor Valid from serial number: T-code

Model

Serial number

Notes

184

LT 2200-8/11

256600AA-

9,5 km/h

288

LT 2200/11

256600AA-

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. å

(

'

'

(

$

(

'

© BT Industries AB

Service Manual

'

1999-05-11

$

(

$

English

$

1 (14)

F-code

Section

PT S1 Electric drive motor Version no

001

C-code

1760

T-code

184,288

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 in a terminal block.

11

15

03

02

10

26

25

09

24

02) 03) 09) 10) 11) 2 (14)

Carbon brush Brush bridge Armature Yoke with stator Bearing shield

Service Manual

1999-05-11

15) 24) 25) 26)

Ball Bearing Ball Bearing Bearing shield Sealing English

F-code

Section

PT

C-code

S1 1760 Electric drive motor

Version no

T-code

001

184,288

1.2 Special tools Tool Torque wrench

>70Nm

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 uncover the motor by removing the motor casings and protective cage.

• Loosen the motor cables (armature winding, series field winding and shunt field winding), the cables from the brake microswitch and the brake unit cables from the drive motor terminal block. Remove any cable ties.

• Remove the terminal block from the motor.

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

© BT Industries AB

Service Manual

1999-05-11

English

3 (14)

F-code

Section

PT S1 Electric drive motor Version no

001

C-code

1760

T-code

184,288

• Remove the three screws for the tiller arm bracket, lift the tiller arm together with bracket straight up, move it to the side and fix it so that it cannot fall down.

• 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.

4 (14)

Service Manual

1999-05-11

English

F-code

Section

PT

C-code

S1 1760 Electric drive motor

Version no

T-code

001

184,288

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, 26.6 Nm. • Install the brake unit and adjust as per the instructions.

• 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.

© BT Industries AB

Service Manual

1999-05-11

English

5 (14)

F-code

Section

PT S1 Electric drive motor Version no

001

C-code

1760

T-code

184,288

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 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.

6 (14)

Service Manual

1999-05-11

English

F-code

Section

PT

C-code

S1 1760 Electric drive motor

Version no

T-code

001

184,288

3.2 Removal of motor 11

15 03 02 10

26 25 09 24

• Remove the brake unit from the motor commutator end.

• 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. It may need to be pulled off with a suitable tool.

© BT Industries AB

Service Manual

1999-05-11

English

7 (14)

F-code

Section

PT S1 Electric drive motor Version no

001

C-code

1760

T-code

184,288

• 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. Next, lay the motor with a fixed stop against the edge of the bearing shield. Strike the end of 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 removing the bearing and the washer under it.

• 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.

8 (14)

Service Manual

1999-05-11

English

F-code

Section

PT

C-code

S1 1760 Electric drive motor

Version no

T-code

001

184,288

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.

Install a woodruff key in the armature shaft keyway. Check that both the woodruff keyway and the woodruff key are undamaged. Check also the gear wheel woodruff key groove.

If there is play in any of these they must be replaced. Put the washer in place and fit the gear wheel in place on the armature woodruff key, apply a film of Loctite 243 onto the shaft threads and screw on the nut. The nut must be tightened to the prescribed torque, 70 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 bearing 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.

© BT Industries AB

Service Manual

1999-05-11

English

9 (14)

F-code

Section

PT S1 Electric drive motor Version no

001

C-code

1760

T-code

184,288

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.

10 (14)

Service Manual

1999-05-11

English

F-code

Section

PT

C-code

S1 1760 Electric drive motor

Version no

T-code

001

184,288

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 turn the commutator in 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 turning, 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 it to be machined 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 turning 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.

P 5

© BT Industries AB

Service Manual

1999-05-11

P

English

11 (14)

F-code

Section

PT S1 Electric drive motor Version no

001

C-code

1760

T-code

184,288

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 protecting oil.

12 (14)

Service Manual

1999-05-11

English

F-code

Section

PT

C-code

S1 1760 Electric drive motor

Version no

T-code

001

184,288

5 Data Torque

Nm

Nut for drive end gear wheel

70 + locking with centre punch

Nuts for motor attachment to drive gearbox

26.6

Grease specification Armature bearings

© BT Industries AB

HT24

Component

Item

Min.

Max.

Unit

Insulation resistance

New motor

2

Mohm

Insulation resistance

Used motor

1

Mohm

Carbon brushes

Length

11

mm

Commutator

Diameter

60

mm

Turning the commutator

Cutting speed, hard metal cutting tool

200

m/min

Turning the commutator

Cutting speed, diamond cutting tool

>>200

m/min

Turning the commutator

Cutting depth

Turning the commutator

Feed

Commutator

0.05

mm

0.1

mm

Eccentricity

0.02

mm

Commutator

Surface unevenness

4

µm

Commutator segment

Height difference

0.02

mm

Service Manual

1999-05-11

0.08

English

13 (14)

F-code

Section

PT S1 Electric drive motor Version no

001

14 (14)

C-code

1760

T-code

184,288

Service Manual

1999-05-11

English

F-code

PT

Section

C-code

S2 2550 Mechanical drive gear unit

IIssued by

Approved by

Version no

T-code

SSD

L-G Andersson

001

184,288

Mechanical drive gear unit Valid from serial number: T-code

Model

Serial No

Notes

184

LT 2200

246664AA-

9,5 km/h

288

LT 2200

246664AA-

6 km/h

1 General technical description

© BT Industries AB

Service Manual

1998-01-09

English

1 (12)

F-code

Section

C-code

PT S2 2550 Mechanical drive gear unit Version no

T-code

001

184,288

1.1 Technical data

2 (12)

Data

Description

Type

2-step angular

Upper gear wheels

Cylindrical with helical gear

Lower gear wheels

Angle gear 90 degrees

Gear ratio, overall LT2200

16,29:1

Gear ratio, upper gear LT 2200

3,35:1

Gear ratio, lower gear LT2200

4,86:1

Oil volume

1,0 litre

Oil type, normal temperature

Hypoid oil SAE 80W/90

Oil type, < -15oC

Hypoid oil SAE 75

Oil change

First time: 250 hours Regular change: 3000 hours

Service Manual

1998-01-09

English

F-code

PT

Section

C-code

S2 2550 Mechanical drive gear unit

Version no

T-code

001

184,288

1.2 Gear components

1

2 3 4 5

A

12 11 6

10

9

© BT Industries AB

8

7

Pos No

Component

1

Primary gear wheels

2

Upper pinion bearing

L2

3

Bearing shim

S2

4

Bearing shim

S1

5

Lower pinion bearing

L1

6

Set of pinion and crown wheel

7

Inner drive shaft bearing

L3

8

Bearing shim

S3

9

Outer drive shaft bearing

L4

10

Bearing shim

S4

Service Manual

1998-01-09

English

3 (12)

F-code

Section

C-code

PT S2 2550 Mechanical drive gear unit Version no

T-code

001

184,288

Pos No

Component

11

Drive shaft

12

Drive shaft seal

A

Built-in measure, pinion height

65 mm

1.3 Special tools

4 (12)

Pos No

Tool

1

Bearing withdrawer: part no = 08-13022

2

Dial indicator with magnetic bracket

3

Thickness gauge

4

Micrometer 0-25 mm (0-1 inch)

5

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

6

Measuring gauge: part no = 08-13020

7

Assembly axle: part no 08-13021

Service Manual

1998-01-09

English

F-code

PT

Section

C-code

S2 2550 Mechanical drive gear unit

Version no

T-code

001

184,288

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 (6 mm 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. © BT Industries AB

Service Manual

1998-01-09

English

5 (12)

F-code

Section

C-code

PT S2 2550 Mechanical drive gear unit Version no

T-code

001

184,288

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.

6 (12)

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English

F-code

PT

Section

C-code

S2 2550 Mechanical drive gear unit

Version no

T-code

001

184,288

• 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 300 Nm (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: 26,6 Nm (19,5 ft-lb).

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

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

© BT Industries AB

Service Manual

1998-01-09

English

7 (12)

F-code

Section

C-code

PT S2 2550 Mechanical drive gear unit Version no

T-code

001

184,288

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.

8 (12)

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English

F-code

PT

Section

C-code

S2 2550 Mechanical drive gear unit

Version no

T-code

001

184,288

• 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 0,5 mm 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 30 Nm (22,5 ft-lb), using the old nut.

© BT Industries AB

Service Manual

1998-01-09

English

9 (12)

F-code

Section

C-code

PT S2 2550 Mechanical drive gear unit Version no

T-code

001

184,288

• 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 100 Nm (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 + 1 mm 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.

10 (12)

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English

F-code

PT

Section

C-code

S2 2550 Mechanical drive gear unit

Version no

T-code

001

184,288

• 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 70 Nm (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 300 Nm (217 ft-lb) • Measure the flank clearence with the crown wheel in three different positions. Carefully point the dial indicator 90 degrees to the gear tooth surface.

• Shim (S3) bearing L3 so that a flank clearence of 0,10– 0,15 mm 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.

© BT Industries AB

Service Manual

1998-01-09

English

11 (12)

F-code

Section

C-code

PT S2 2550 Mechanical drive gear unit Version no

T-code

001

184,288

• 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 70 Nm (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 300 Nm (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: 26,6 Nm (19,5 ft-lb).

• Fit the driving gear into the truck.

Tightening torque: 26,6 Nm (19,5 ft-lb). Fill up with new oil.

• Fit the drive wheel.

Tightening torque: 65 Nm (47,7 ft-lb)

12 (12)

Service Manual

1998-01-09

English

F-code

Section

C-code

PT S3 3370 Electromagnetic parkingbrake IIssued by

Approved by

Version no

T-code

SSD

Fredrik Wigh

001

184,288

Electromagnetic parkingbrake Valid from serial number: T-code

Model

Serial No

Notes

184

LT 2200-8

165296AA-

9,5 km/h

288

LT 2200

165296AA-

6 km/h

1 General The brake is a two-stage electromagnetic brake with a common magnetic coil for both stages. The brake has two halfcircle pressure plates.

The delay between the stages is partly due to the first stage having a higher spring pressure and partly due to the plastic coating on the underside of that half of the magnet coil that affects stage one, the magnetic force is reduced, see the first picture in chapter 2.

The delay between the stages is approx: 0,15-0,2 seconds.

© BT Industries AB

Service Manual

1998-10-01

English

1 (8)

F-code

Section

C-code

PT S3 3370 Electromagnetic parkingbrake Version no

001

T-code

184,288

2 Function The magnetic brake is the trucks service brake and parking brake.

2.1 Releasing the brake With the ignition switched on and the tiller arm in the driving position, the solenoid is voltage fed and switches when the two pressure plates hit against the magnet housing with magnetic force.

Because of the plastic coating on the half of the magnetic coil for the 1:st stage it is released at different speeds, a double clicking sound can be heard from the brake.

The brake disc is now free/released.

2 (8)

Service Manual

1998-10-01

English

F-code

Section

C-code

PT S3 3370 Electromagnetic parkingbrake Version no

T-code

001

184,288

2.2 Braking When the current is cut, the tiller arm is moved to one of the braking positions, the first stage’s pressure plate releases from the magnet housing and actuates the brake disc, see illustration.

After the delay time the 2:nd stage pressure plate is released and increases the braking force.

The brake force is divided approx: 65% for the 1:st stage and 35% for the 2:nd stage.

© BT Industries AB

Service Manual

1998-10-01

English

3 (8)

F-code

Section

C-code

PT S3 3370 Electromagnetic parkingbrake Version no

001

T-code

184,288

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

3.1 Adjustment of gap

As the brake disc wears, it is necessary to adjust the gap between the magnetic coil and the pressure discs. The nominal gap between the coil housing and pressure plate, in applied position, shall be 0.5 mm. The maximum gap before readjustment is necessary is 1.0 mm.

3.1.1 Adjustment procedure: • Loosen the tension of the four mounting bolts.

• Turn the locking nut anticlockwise and pull the bolt a little, and at the same time check the gap on the four (4) measurement points with a O.5 mm feeler gauge.

• Tighten the mounting bolts 25 Nm. • Recheck the gap with the feeler gauge.

4 (8)

Service Manual

1998-10-01

English

F-code

Section

C-code

PT S3 3370 Electromagnetic parkingbrake Version no

T-code

001

184,288

3.2 Exchange of brake disc/magnetic coil The brake disc shall be exchanged when its total thickness has been reduced to 6 mm.

6mm

3.2.1 Exchange procedure: • Disconnect the electrical wires of the brake.

• Loosen and remove the four mounting bolts and remove the brake coil.

• Replace the brake disc on the hub/magnetic coil and make a visual check of the wear of the friction plate. Replace the friction plate if the surface is worn uneven.

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

• Mount the coil on the motor end and carry out adjustment of the gap according to the chapter “Adjustment of gap”.

• Reconnect the electrical wiring of the brake.

© BT Industries AB

Service Manual

1998-10-01

English

5 (8)

F-code

Section

C-code

PT S3 3370 Electromagnetic parkingbrake Version no

001

T-code

184,288

3.2.2 Transport securing screws

When mounting a new brake coil, it is necessary to remove the transport securing screws before mounting.

Unscrew the four slotted screws and apply a drop of Loctite 270 on each of the screws. Now screw in the screws so that the screw heads are level with the outside of the magnet housing.

6 (8)

Service Manual

1998-10-01

English

F-code

Section

C-code

PT S3 3370 Electromagnetic parkingbrake Version no

T-code

001

184,288

3.3 Check/adjustment of the braking force The braking force is adjusted with eight Allen screws on the top of the magnetic coil, four for each brake stage.

The brake force is set and adjusted at the factory and should normally not require any readjustment. However ensure that the brake force is correctly adjusted if the magnetic coil is exchanged.

Adjustment and checking of the setting is done by measuring how much the screws have been screwed up/down in the magnet housing.

The correct adjustment, measurement T, is: For LT 2200 6 km/h: Stage 1: 2 turns down from the upper side of the coil.

Stage 2: 1 turn up from the upper side of the coil.

For LT 2200 9,5 km/h: Stage 1: 5 turns down from the upper side of the coil.

Stage 2: 3 turns down from the upper side of the coil.

WARNING! Too weak brake.

Incorrect setting of the brake force.

This type of brake is used in other trucks with a different setting. Ensure that you have mounted a correct magnetic coil by checking the setting after renewal of the magnetic coil.

© BT Industries AB

Service Manual

1998-10-01

English

7 (8)

F-code

Section

C-code

PT S3 3370 Electromagnetic parkingbrake Version no

001

8 (8)

T-code

184,288

Service Manual

1998-10-01

English

F-code

Issued by

SSD

Approved by

Fredrik Wigh

Section

C-code

PT

S5 5000 Electrical system

Version no

T-code

001

184,288

Electrical system Transistor regulators 6 and 8 km/h Valid from serial numbers: T-code

Model

Serial number

Notes

184

LT 2200

310738AA-319124

8 km/h

288

LT 2200

310738AA-319124

6 km/h

1. Electrical panel A1

H1

F3 K30

F50

K11 F1 K13 K14

© BT Industries AB

Service Manual

1998-02-12

English

1 (14)

F-code

Section

C-code

PT S5 Electrical system Version no

5000

T-code

001

184,288

2. List of symbols Symbol

2 (14)

Description

Function

Notes

A1

Transistor panel, logic card

A2

Electronic card

Bt

Battery

F1

Fuse

Motor circuit

100 A

F3

Fuse

Pump

160 A

F50

Fuse

Control circuit

8A

H1

Horn

K11

Contactor

Driving direction

K13

Contactor

Driving direction

K14

Contactor

Max. speed

K30

Contactor

Pump

M1

Motor

Driving

M3

Motor

Pump

P3

Indicator

Battery indicator, running meter

R1

Potentiometer

Throttle

S10

Microswitch

Brake

S15

Microswitch

Driving direction

Forwards

S16

Microswitch

Driving direction

Reverse

Service Manual

Monitoring, safety reversing

1998-02-12

English

F-code

Section

PT Version no

T-code

001

Symbol

C-code

S5 5000 Electrical system 184,288

Description

Function

Notes

S18

Microswitch

Horn

S19

Microswitch

Platform

S20

Microswitch

Safety reversing

S31

Microswitch

Lift limit

S41

Microswitch

Lowering forks

S52

Microswitch

Lifting forks

S53

Microswitch

Gate

Option

S54

Microswitch

Gate

Option

S59

Microswitch

PowerTrak

Y10

Magnetic brake

Brake

Y41

Magnet valve

Lowering forks

2.1. List of symbols for logic card Symbol

Description

Function

LD1

Green LED

Current ON

LD2

Red LED

Error indication

P1

Potentiometer

Current limit

S2

Strap

Throttle

S3

Strap

Speed

S4

Strap

Speed

Notes

3. Electrical diagram On the three following pages are three different electrical drawings.

The first drawing applies to standard trucks (6 km/h) without gates.

The second drawing applies to trucks equipped with the small EUgates.

The third drawing applies to machines equipped with the large safety gates. © BT Products AB

Service Manual

1998-02-12

English

3 (14)

F-code

Section

PT S5 Electrical system Version no

001

C-code

5000

T-code

184,288

3.1. Electrical diagram, standard 1/3

A2

4 (14)

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English

F-code

Section

PT

C-code

S5 5000 Electrical system

Version no

T-code

001

184,288

3.2. Electrical diagram, EU gates 2/3

102

29

36

36A

© BT Products AB

Service Manual

1998-02-12

English

5 (14)

F-code

Section

PT S5 Electrical system Version no

001

C-code

5000

T-code

184,288

3.3. Electrical diagram, safety gates 3/3

101

36A 102

29

36

36A

6 (14)

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1998-02-12

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Section

PT

C-code

S5 5000 Electrical system

Version no

T-code

001

184,288

4. Operating description 4.1. General The task of the transistor unit is to control a compound motor mounted in the LT truck. The unit contains a regulator section for the rotor circuit and a regulator for the shunt field. The inputs for the control reference values and the logic functions are connected via clamps. The power supply is connected with pole bolts M6. There are freewheel diodes on the logic card for the external relays.

The transistor unit has two integrated control systems, one for the series circuit and one for the shunt field circuit. Both circuits are of the quadrant type. The negative return cable to the contactors and other components is also fed through the safety transistors in the transistor unit.

The logic card is equipped with a fuse on the regulating current’s negative side. The fuse is marked with F1 on the logic card. This fuse is 10 A. The unit consists of two principal components, a regulation section and a power supply.

The regulation section is placed on a circuit board with connection terminals on both long sides for the inputs and the outputs. An angled plate acts as a heatsink for the power components mounted on the board and also acts as a holder for the lower section.

In this operating description all connections to the logic card, centre terminal, are marked as connections 1-40.

The components are only marked with a symbol. The description is provided in the list of symbols in the chapter “List of symbols for the logic card”.

REFERENCES For further information on the transistor unit, see C-code 5460.

© BT Products AB

Service Manual

1998-02-12

English

7 (14)

F-code

Section

PT S5 Electrical system Version no

001

C-code

5000

T-code

184,288

4.2. Description The description is divided into different phases that correspond with the operating sequence stages.

4.2.1. Tiller arm in parking position, S17 in OFF position The battery voltage (+) through the charging plug to F3 and to contactor K30. Through F1, series field to the contactors on K11 and K13 and through cable 4 to terminal K and through cable 5 to terminal B. The battery’s negative pole (-) to pump motor M3, terminal H and via the negative fuse F to terminal 40. Terminal 40 is always negative.

4.2.2. Tiller arm in parking position, S17 in ON position Battery voltage via F50 and S17, cable 22 through the drive motor’s shunt field to terminal 18. Via S17 also to terminal 22.

Terminal 22 is always the battery’s positive (+). This feeds the voltage converter on the logic card with voltage and LED1 comes on. The safety transistor D receives (+) on its base and is prepared to conduct. (+) is received from terminal 22 through the coil on K11 to terminal 2, terminal 28, S20 and to A2 and via K11 to S15.

Through K13 to terminal 4 and on to A2, via K14 to terminal 5.

From terminal 22 (+) is also fed through Y10 to S10 and S20 to S15 and S16 and via S20 to terminal 29, A2, S20 to terminal 28. Through H1 to terminal 26 and S18, K30 to terminal 30 via a BDI breaker contactor, which is optional equipment.

Through Y41 to S41 and to terminal 39.

4.2.3. Driving forwards, S15 in ON position The driving direction is determined by switching the current direction in the rotor by means of K11 and K13.

With the tiller arm in the driving position S10 makes and feeds Y10 with the negative return via terminal 36, safety transistor D and terminal 40. The electric brake releases.

The throttle is actuated so that S15 makes. The coil of K11 then receives (-) via S15, S20, S10, terminal 36, transistor D and terminal 40. K11 is activated. The stop circuit’s lower input becomes negative and the upper positive and driving is permitted. Depending on the position of the throttle, terminal 11 receives a voltage of between 1 and 4 V.

8 (14)

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English

F-code

Section

PT

C-code

S5 5000 Electrical system

Version no

T-code

001

184,288

The transistor unit controls the current in both the shunt and series circuits. Transistor B controls the shunt field and transistor C the series circuit. The motor now starts as a compound motor with a powerful starting torque. When the speed increases, the current in the series circuit falls below 90 A, which results in the series field decreasing. The shunt field is also used as a max. speed governor with bypassing, unloaded truck.

When driving LT 2200-8 forwards: Gates and platform not used, S19 in OFF position, S53 in OFF position (S54 in OFF position).

See electrical drawings 2/3 and 3/3.

With the tiller arm in the driving position S10 will make and feed Y10 with the negative return via cable 36 and proximity switch S53 (and S54 if the safety gates are used) to terminal 36, safety transistor D and terminal 40. The electric brake is released.

The throttle is activated so that S15 makes. The coil of K11 then receives (-) via S15, S20, S10, cable 36, proximity switch S53 (and S54 if the safety gates are used), to terminal 36, transistor D and terminal 40. K11 is activated. The stop circuit’s lower input becomes negative and the upper positive and driving is permitted. Depending on the position of the throttle, terminal 11 receives a voltage of between 1 and 4 V. When driving LT 2200-8 forwards: Gates and platform are used, S19 in ON position, S53 in ON position (S54 in ON position).

See electrical drawings 2/3 and 3/3.

With the tiller arm in the driving position S10 will make and feed Y10 with the negative return via cable 36 and proximity switch S19 (activated by the platform) through the made contactors in the proximity switch S53 (and S54 if the safety gates are used), to terminal 36, safety transistor D and terminal 40. The electric brake is released.

The throttle is actuated so that S15 makes. The coil of K11 then receives (-) via S15, S20, S10, cable 36, proximity switch S19 (activated by the platform), proximity switch S53 (and S54 if the safety gates are used), to terminal 36, transistor D and terminal 40. K11 is activated. The stop circuit’s lower input becomes negative and the upper positive and driving is permitted. Depending on the position of the throttle, terminal 11 receives a voltage of between 1 and 4 V.

© BT Products AB

Service Manual

1998-02-12

English

9 (14)

F-code

Section

PT S5 Electrical system Version no

001

C-code

5000

T-code

184,288

4.2.4. Free wheeling Both transistor stages are made when the current measuring shunt in the regulator measures a current equal to the current limit, or if the truck reaches the requisite speed. When the truck free wheels the stored energy in the motor will be led off through the freewheel diodes in the series circuit and the shunt field. When the current starts to fall, or when the speed drops, the regulator permits the current to flow through the series circuit and shunt field again, and so the cycle is repeated continuously and switches between the driving mode and free wheeling to maintain the required speed.

4.2.5. Reversing, S16 in ON position With the tiller arm in the driving position S10 will make and make Y10 live through feeding a negative return via terminal 36, safety transistor D and terminal 40. The electromagnetic brake releases.

A2 in the safety circuit becomes live by receiving a positive feed via terminal 28 and a negative return via S10, terminal 36, safety transistor D and terminal 40.

When the throttle acts in the reversing position S16 makes.

K13 is made live through feeding a negative return via the made contactors in the safety circuit A2, S16, S20, S10, terminal 36, safety transistor D and terminal 40.

The inputs to the stop circuit (on the board) differ, the upper becomes negative and the lower positive so that driving (pulsing of the transistors) is permitted.

Control of the speed and current is achieved in exactly the same way as when driving forwards.

A fault in the monitoring card A2 for the protection of the driver means that the negative return for K13 disappears and reversing is no longer possible.

When reversing LT 2200-8: Gates and platform not used, S19 in the OFF position, S53 in OFF position (S54 in the OFF position).

See electrical drawings 2/3 and 3/3.

With the tiller arm in the driving position S10 will make and make Y10 live through feeding a negative return via cable 36, proximity switch S53 (and S54 if the safety gates are used), terminal 36, safety transistor D and terminal 40. The electromagnetic brake releases.

10 (14)

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F-code

Section

PT

C-code

S5 5000 Electrical system

Version no

T-code

001

184,288

A2 in the safety circuit becomes live by receiving a positive feed via terminal 28 and a negative return via S10, cable 36, proximity switch S53 (and S54 if the safety gates are used), terminal 36, safety transistor D and terminal 40.

When the throttle is set in the reversing position S16 makes.

K13 is made live through feeding a negative return via the made contactors in the safety circuit A2, S16, S20, S10, proximity switch S53 (and S54 if the safety gates are used), terminal 36, safety transistor D and terminal 40.

When reversing LT 2200-8: Gates and platform used, S19 in the ON position, S53 in the ON position (S54 in the ON position).

See electrical drawings 2/3 and 3/3.

With the tiller arm in the driving position S10 will make and make Y10 live through feeding a negative return via cable 36, proximity switch S53 (and S54 if the safety gates are used), terminal 36, safety transistor D and terminal 40. The electromagnetic brake releases.

A2 in the safety circuit becomes live by receiving a positive feed via terminal 28 and a negative return via S10, cable 36, proximity switch S19 (activated by the platform) through the made contactors on the proximity switch S53 (and S54, if the safety gates are used), terminal 36, safety transistor D and terminal 40.

When the throttle is set in the reversing position S16 makes.

K13 is made live through feeding a negative return via the made contactors in the safety circuit A2, S16, S20, S10, proximity switch S19 (activated by the platform), through the made contactors on the proximity switch S53 (and S54, if the safety gates are used), terminal 36, safety transistor D and terminal 40.

4.2.6. Maximum speed When the modulation rate reaches 100% and the series current is lower than the current limit, the regulator gives a negative return to the shunt conductor’s contactor (bypass contactor) K14 via terminal 5 and transistor A. The series circuit transistor C is now effectively disconnected and the current in the series circuit flows through the contacts on K14.

The maximum speed is regulated via the shunt field. The strap S3 determines the maximum settings. See table “Setting the speed adjustment” C-code 5460.

© BT Products AB

Service Manual

1998-02-12

English

11 (14)

F-code

Section

PT S5 Electrical system Version no

001

C-code

5000

T-code

184,288

When the modulation rate falls or the motor current rises to the current limit, K14 is disconnected and the transistor stage starts to operate again.

4.2.7. Motor braking The truck can be stopped through motor braking. This means that the throttle is set in the opposite direction to the truck’s direction of travel. This switches the magnetism in the rotor circuits and the motor rotates in the “wrong” direction until the truck comes to a complete standstill. During this interval the motor acts as a generator and the current in the series field is regulated by the transistor unit.

The current generated by the motor is led off in the brake diodes as heat. The shunt field is disconnected during motor braking.

4.2.8. Safety reversing, S20 in the ON position If S20 is operational while the truck is reversed, the negative return for K13 is cut via A2 and S16. The contacts on K13 are open. K11 is fed with a negative return via terminal 2, diode, terminal 28, S20, S10, terminal 36, safety transistor D and terminal 40. The contacts on K11 make. The truck now drives forwards and accelerates with maximum current limit. When S20 returns to its neutral position K11 opens and the truck stops irrespective of whether S16 is still active. The throttle must be released so that S16 returns to its neutral position, only until driving is permitted.

Safety reversing when using the platform and gates: See electrical drawings 2/3 and 3/3 If S20 is operational while the truck is reversed, the negative return for K13 is cut via A2 and S16. The contacts on K13 are open. K11 is fed with a negative return via terminal 2, diode, terminal 28, S20, S10, proximity switch S19 (activated by the platform), through the made contactors on proximity switch S53 (and S54, if the safety gates are used), terminal 36, safety transistor D and terminal 40. The contacts on K11 make. The truck now drives forwards and accelerates with maximum current limit. When S20 returns to its neutral position K11 opens and the truck stops irrespective of whether S16 is still active.

The throttle must be released so that S16 returns to its neutral position, only until driving is permitted.

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4.2.9. Load dependent current limiting The system PowerTrak on a transistor controlled truck has a microswitch (S59) which is activated when the load on the truck falls within a predetermined range. When the forks have no load, S 59 makes and terminal 8 is earthed via S59 to terminal 40. The regulator current supply is limited to 70% of the maximum output. When the load on the forks falls within a given range S59 opens and terminal 8 is no longer earthed.

The regulator can deliver the maximum current supply.

4.2.10. Forks lifting/lowering Lift S52 is activated. K30 receives a negative return via the contacts in P3 (if installed), terminal 30, diode, terminal 38, S31, S52, to terminal 40. K30 contactors make and the pump motor M3 starts. When the forks reach the lift height limit, S31 is activated and the negative return to K30 is cut. K30 opens and the pump motor M3 stops.

Lower S41 is activated. The electric valve for fork lowering, Y41, receives a negative return via S41, terminal 40. The valve opens.

4.2.11. Horn S18 is switched on. The horn, H1, receives a negative return via S18 to terminal 40. The horn sounds.

© BT Products AB

Service Manual

1998-02-12

English

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Section

PT

C-code

S5 5000 Electrical system

IIssued by

Approved by

Version no

T-code

SSD

Fredrik Wigh

002

184

Electrical system Transistor regulator 9,5 km/h Valid from serial number: T-code

Model

Serial number

Note

184

LT 2200-8

319125AA-

9,5 km/h

1 Electrical panel H1

F50

A1

K11

A5

K13

F3 F1

K30 RV1

© BT Industries AB

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1998-04-20

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2 List of symbols Symbol

Description

A1

Transistor regulator

A5

Electronic card

G1

Battery

E8

Handle heater

Heating of tiller arm (control arm)

Cold storage

F1

Fuse

Motor circuit

125 A

F3

Fuse

Pump circuit

160 A

F50

Fuse

Control circuit

7,5 A

F51

Fuse

External equipment

Option

H1

Horn

K11

Contactor

Driving direction

Fork direction

K13

Contactor

Driving direction

Steer wheel direction

K30

Contactor

Pump motor

M1

Motor

Drive motor

M3

Motor

Pump motor

P3

Indicator

Battery indicator/ hourmeter

R1

Potentiometer

Speed

RV1

Potentiometer

Maximum speed reduction

2 (20)

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Notes

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Symbol

Description

Function

S10

Switch

Brakes

S15

Switch

Driving direction

Fork direction

S16

Switch

Driving direction

Steer wheel direction

S17

Switch

Ignition switch

S18

Switch

Horn

S20

Switch

Safety reversing

S31

Switch

Lifting limit

S41

Switch

Lowering forks

S43

Switch

Platform switch

S52

Switch

Lifting forks

S59

Switch

PowerTrak function

S88

Switch

Side guard

S89

Switch

Side guard

Y1

Magnetic brake

Brake

Y41

Solenoid valve

Lowering forks

© BT Industries AB

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C-code

S5 5000 Electrical system

Notes

1998-04-20

English

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2.1 Electrical diagram 1/5

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2.2 Electrical diagram 2/5

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1998-04-20

English

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2.3 Electrical diagram 3/5

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2.4 Electrical diagram 4/5

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1998-04-20

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2.5 Electrical diagram 5/5

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3 Description of function 3.1 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 connection card, see C-code 5460 and 5710.

4 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.

4.1 Ignition switch S17 in the ON position

106 105 104 103 102 101

RE6

111 209 110 208 207 206 109 205 108 107 204 203 202 RE5 201 303

217 216 215 214

409 408 407 406

417 416 415 414

405 213 404 212 403 211 210 401

413 412 411 410

305

302 301

RE4

RE3

304

RE2

RE1

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

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1998-04-20

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• When S17 is made, it feeds 24 V to A5’s connection pin 202 and LED 202 comes on. 24 V is also fed to connection pins 108, 212 and 303. A5 (-) returns form 409.

The battery voltage to A1.16 via A5-connection pin 410.

LED status on the transistor regulator starts to flash.

LEDs 214 and 215 also come on when S17 is made.

These inputs are only used on LS-machines and should always be lit on LT-machines.

LED 217 comes on when S17 is made, if the option “Brake when leaving platform” is not active.

4.2 Tiller arm in driving position, S10 in the On position 106 105 104 103 102 101

RE6

209 111 110 208 207 206 109 205 108 107 204 203 202 RE5 201 303

217 216 215 214

417 416 415 414

409 408 407 406

405 213 404 212 403 211 210 401

413 412 411 410

305

302 301

RE4

RE3

304

RE2

RE1

• When the tiller arm is pushed down to the driving position, S10 is activated and makes so that 24 V is fed via cable 31 to the connection pin 301 and makes RE1, LED 301 comes on. Depending on whether the switches for platform and gates are activated, 24 V is fed to connection pin 210 or 211, through the contacts on RE2 and RE1 to connection pin 305 and thereby activates the magnetic brake Y10 and the brake is released. The signal is also fed out to connection pins 109 and 408, A1.15. Activation of S10 means that 24 V is also fed to the shunt field and internally to connection pin 206, LED 206 comes on and the running meter starts and the voltage is also fed to connection pin 403 that then feeds K11 and K13.

The LED pattern shows the machine when the platform and gates are not used.

• The transistor regulator now regulates the current through the shunt field. 0.9 A. (-) is returned via connection pins 302, 417 and A1.1.

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4.3 Driving in the fork direction

106 105 104 103 102 101

RE6

111 209 110 208 207 206 109 205 108 107 204 203 202 RE5 201 303

217 216 215 214

409 408 407 406

417 416 415 414

405 213 404 212 403 211 210 401

413 412 411 410

305

302 301

RE4

304

RE3

RE2

RE1

The LED pattern shows the machine when using the platform and gates (9.5 km/h).

The table below shows the different conditions that apply if driving is permitted and at what speed the machine can be driven.

Tiller arm in driving position (S10 active, LED 301 on)

X

X

X

X

Driving in the fork direction (S15 active, LED 101 on)

X

X

X

X

Gates used

X

X

Man on platform

Driving permitted Speed

YES 6 km/h

NO

X

X

YES 6 km/h

YES 9.5km/h

• When the throttle is activated for driving in the fork direction, S15 is made. Driving is permitted.

• Battery voltage is received via the connect pin 101, RE 5 contactors 2 and 4, to 411 and on to A1.11, LED 101 is on.

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

• Depending on throttle’s (R1:s) position and the adjustment of potentiometer RV1, A1.8 will receive a voltage between 4.8–0.25 V. © BT Industries AB

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1998-04-20

English

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• When the platform and gates are used, connection pin 216 receives 24 V(+) via S43 and S89, LED 216 comes on, RE 4 makes so that the shunt field current flows through a resistance and the current drops. This means the machine travels at 9.5 km/h.

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

Also see the chapter “Switch operations for platform and gates”

4.4 Driving in the steer wheel direction

The LED pattern shows the machine when using the platform and gates (9.5 km/h).

The table below shows the different conditions that apply if driving is permitted and at what speed the machine can be driven.

Tiller arm in driving position (S10 active, LED 301 on)

X

X

X

X

Driving in the drive wheel direction (S16 active, LED 102 on)

X

X

X

X

Gates used

X

Man on platform

Driving permitted Speed

12 (20)

Service Manual

X X

YES 6 km/h

1998-04-20

NO

X

YES YES 6 km/h 9.5 km/h

English

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

• Battery voltage is received via the connect pin 102, RE 5 contactors 5 and 7, to 412 and on to A1.12, LED 102 is on.

• Battery voltage to K13 via connection pin 403. A1.3 now gives (-) return to K13, (-) input on connection pin 402, LED 402 is on.

• Depending on the throttle’s (R1:s) position and the adjustment of potentiometer RV1, A1.8 will receive a voltage between 4.8 - 0.25 V. • When the platform and gates are used, connection pin 216 receives 24 V(+) via S43 and S89, LED 216 comes on, RE 4 makes so that the shunt field current flows through a resistance and the current drops. This means the machine travels at 9.5 km/h.

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

Also see the chapter “Switch operations for platform and gates”

4.5 Load dependent current limit The PowerTrak system contains a microswitch (S59), which is activated when the load on the forks falls within a predetermined range.

106 105 104 103 102 101

RE6

111 209 110 208 207 206 109 205 108 107 204 203 202 RE5 201 303

217 216 215 214

409 408 407 406

417 416 415 414

405 213 404 212 403 211 210 401

413 412 411 410

305

302 301

RE4

© BT Industries AB

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RE3

1998-04-20

304

RE2

English

RE1

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•

Without any load on the forks, S59 makes and 24 V is fed from connection pin 212 via S59 to connection pin 213.

LED 213 comes on. The signal is then fed to connection pin 404 and on to A1.14.The transistor regulator’s output is limited to a factory set value M2 MAIN C/L of 150 A.

• When the load on the forks falls within the predetermined range (see table), S59 breaks; LED 213 dims and the signal to A1.14 becomes low. The transistor regulator can deliver the full current supply determined by the regulator parameter M1 MAIN C/L which is set at the factory to 200 A.

4.6 S59 Activation range S59

Min (kg) load

Max (kg) load

Activated

300

400

4.7 Reverse/motor brake, fork direction to steer wheel direction • 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 A2, and reduces the series field current to a value, which is dependent on the load on the forks. If S59 is not activated (i.e. no load on the forks) then the series field current is limited by the regulator parameter M2 MAIN PLUG C/L, which has a factory set value of 50 A. If S59 is activated (fork load greater than 300 kg) then the series field current is limited by the regulator parameter M1 MAIN PLUG C/L, which has a factory set value of 70 A. 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, M-, transistor regulator’s brake diode, A2 and K13 during the braking sequence.

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4.8 Reverse/motor brake, steer wheel direction to fork direction • 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 A2, and reduces the series field current to a value, which is dependent on the load on the forks.

• If S59 is not activated (i.e. no load on the forks) then the series field current is limited by the regulator parameter M2 MAIN PLUG C/L, which has a factory set value of 50 A. • If S59 is activated (fork load greater than 300 kg) then the series field current is limited by the regulator parameter M1 MAIN PLUG C/L, which has a factory set value of 70 A. 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, M-, transistor regulator’s brake diode, A2 and K11 during the braking sequence.

4.9 Safety reversing function

106 105 104 103 102 101

RE6

209 111 110 208 207 206 109 205 108 107 204 203 202 RE5 201 303

217 216 215 214

417 416 415 414

409 408 407 406

405 413 412 411 410

213 404 212 403 211 210 401 305

302 301

RE4

RE3

304

RE2

RE1

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. © BT Industries AB

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1998-04-20

English

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• 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 A1.2 to K11, LED 401 comes on.

• The motor will now be connected for motor braking with the maximum current determined by the regulator Current Limit, Emergency Reverse. The truck will then accelerate in the fork direction until S20 returns to its neutral position.

• When S20 returns to its neutral position, the (+) disappears from connection pint 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.

4.10 Lifting the forks 106 105 104 103 102 101

RE6

209 111 110 208 207 206 109 205 108 107 204 203 202 RE5 201 303

217 216 215 214

417 416 415 414

409 408 407 406

405 413 412 411 410

213 404 403 212 211 210 401 305

302 301

RE4

RE3

304

RE2

RE1

• The microswitch S52 makes. K30 receives (+) voltage via connection pins 105, 203, strapping or battery guard, connection pins 201 and 405 as well as S31. LEDs 105, 405 and 206 come on and the running meter starts.

• (-) return via line 40. K30 makes and the pump motor M3 starts.

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4.11 Lowering the forks 106 105 104 103 102 101

RE6

111 209 110 208 207 206 109 205 108 107 204 203 202 RE5 201 303

217 216 215 214

409 408 407 406

417 416 415 414

405 213 404 212 403 211 210 401

413 412 411 410

305

302 301

RE4

304

RE3

RE2

RE1

• S41 makes and feeds 24 V (+) to connection pin 106 and on to pin 204 and activates the solenoid valve Y41; LED 106 comes on.

4.12 Horn 106 105 104 103 102 101

RE6

111 209 110 208 207 206 109 205 108 107 204 203 202 RE5 201 303

217 216 215 214

409 408 407 406

417 416 415 414

405 213 404 212 403 211 210 401

413 412 411 410

305

302 301

RE4

RE3

304

RE2

RE1

• S18 makes and feeds 24 V(+) to connection pin 107 and on to pin 406 so that the horn H1 is activated; LED 107 comes on.

© BT Industries AB

Service Manual

1998-04-20

English

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4.13 Switch operation for the platform and gates 106 105 104 103 102 101

RE6

111 209 110 208 207 206 109 205 108 107 204 203 202 RE5 201 303

217 216 215 214

417 416 415 414

409 408 407 406

405 213 404 212 403 211 210 401

413 412 411 410

305

302 301

RE4

RE3

304

RE2

RE1

See chapters “Driving in the fork direction” and “Driving in the steer wheel direction” as well as electrical diagrams 3/5, 4/5 and 5/5.

The LED pattern shows the truck when using the platform and gates (9.5 km/h).

4.13.1 Driving with the platform raised and without using the gates • By moving the tiller arm in the driving position S10 is activated and 24 V (+) is fed via line 31 to connection pin 301, LED 301 comes on and RE1 makes.

• 24 V is also fed via line 22 to S43, via line 47 to S88, to connection pin 210, through RE2’s contactors 3 and 2 and the contactors on RE1 and thereafter the voltage is fed on to connection pin 305 so that the brake Y10 is activated.

• 24 V is also fed to connection pin 109 - line 44, pin 403 line 53, pin 408 - line 44 - A1.15.

• The truck can now been driven normally at a speed of 6 km/h.

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4.13.2 Driving with the platform lowered and without using the gates • When the platform is lowered, S43 is activated. By moving the tiller arm in the driving position S10 is activated and 24 V (+) is fed via line 31 to connection pin 301, LED 301 comes on and RE1 makes.

• 24 V is also fed via line 22 to the now made contact (21 and 22) on S43 and on to connection pin 211, LED 211 comes on and RE2 makes.

• In this position RE2 is locked by feeding connection pin 301 (S10), through RE2’s contacts 7 and 8. RE2 remains active as long as the tiller arm is in the driving position.

• 24 V is also fed to connection pin 109 - line 44, pin 403 line 53, pin 408 - line 44 - A1.15.

• The truck can now been driven normally at a speed of 6 km/h.

4.13.3 Driving with the platform lowered and using the gates • When the driver platform is lowered and the gates are used, S43 and S89 are activated. By moving the tiller arm in the driving position S10 is activated and 24 V (+) is fed via line 31 to connection pin 301, LED 301 comes on and RE1 makes.

• 24 V is also fed via line 22 to the now made contact (21 and 22) on S43 and on to via line 48 to the now made contact on S89 and via line 58 to connection pin 216 and also to pin 211, LEDs 211 and 216 come on.

• When connection pin 211 is fed with 24 V, RE2 makes and is locked through receiving a supply from connection pin 301 (S10), through RE2’s contacts 7 and 8. RE2 remains active as long as the tiller arm is in the driving position.

• Connection pin 211 also feeds connection pin 305, connection pin 109 and connection pins 403 and 408 with 24 V, via RE2 contacts 1 and 2 and RE1 contacts 7 and 8.

• When connection pin 216 is fed with 24 V, RE4 makes and a resistance of 10 kOhm is connected in series with the shunt field. The shunt field current now drops and the truck is driven with a speed of 9.5 km/h.

© BT Industries AB

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1998-04-20

English

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4.13.4 Brake function when alighting from the platform • The function is only active if connection pin 217 is disconnected.

• If the driver alights or jumps off of the platform after the truck has started to move (that is the tiller arm is still in the driving position) S43 will be deactivated. 24 V(+) is cut from cable 48, connection pin 211. As RE2 is now locked this results in connection pin 109 (microswitch supply), pin 408 an pin 305 (Y10) all losing the 24 V(+) supply and the brakes are immediately applied, LED 211 dims.

• By returning the tiller arm to the parking position, S10 is deactivated, which results in connection pin 301 becoming low and RE2 is deactivated. Normal driving can now be resumed as described in steps 1), 2) and 3) above.

• If connection pin 217 is instead connected, the brakes are not applied if the driver alights from the platform. Connection pin 217 bridges the loss in feed to pin 211 and the brakes are not deactivated.

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Approved by

SSD

Version no

Fredrik Wigh

C-code

S5 5000 Electrical system T-code

003

184, 288

Electrical system Resistance regulation Valid from serial number: T-code

Model

Serial number

Notes

184

LT 2200

319039AA-

9.5 km/h

288

LT 2200

319039AA-

6 km/h

1. Electrical panel

Picture is missing

© BT Industries AB

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1999-01-07

English

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003

5000

T-code

184, 288

2. List of symbols Symbol

Description

A1

Electronic card

A2

Circuit board

Bt

Battery

F1

Fuse

Motor circuit

125 A

F3

Fuse

Pump

160 A

F50

Fuse

Control circuit

8A

H1

Horn

K11

Contactor

Driving direction

K13

Contactor

Driving direction

K17

Contactor

Speed stage

Stage 2

K18

Contactor

Speed stage

Stage 3

K30

Contactor

Pump

M1

Motor

Drive

M3

Motor

Pump

P3

Indicator

Battery indicator, running meter

R11

Resistance

Speed stage

R12

Resistance

Speed stage

2 (12)

Function

Notes 139198-001 for 6km/h 139199-001 for 9,5 km/h

Monitor, safety reversing

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Symbol

Description

Function

Notes

S10

Microswitch

Brakes

S12

Microswitch

Speed stage

Stage 2

S13

Microswitch

Speed stage

Stage 3

S15

Microswitch

Driving direction

Forwards

S16

Microswitch

Driving direction

Reversing

S17

Microswitch

Ignition key

S18

Microswitch

Horn

S19

Microswitch

Platform

S20

Microswitch

Safety reversing

S31

Microswitch

Lifting limit

S41

Microswitch

Lowering forks

S52

Microswitch

Lifting forks

S53

Microswitch

Gates

Option

S54

Microswitch

Gates

Option

Y10

Magnetic brake

Brakes

Y41

Solenoid valve

Lowering forks

2.1. List of symbols for the logic card A1 Symbol

Description

Function

Notes

F70

Fuse

Logic card

10 A

Re13

Relay

Intermediate relay for K11 and K13

Re17

Relay

Intermediate relay for K17

Re18

Relay

Intermediate relay for K18

Re26

Relay

Shunt field

Re32

Relay

Switch speed range

© BT Industries AB

Service Manual

1999-01-07

English

Only on logic card 139199-001 3 (12)

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3. Electrical diagrams Three different electrical drawings can be found on the following three pages.

• The first drawing applies to standard machines (6 km/h) without gates. This machine has logic card 139198-001.

• The second drawing applies to machines equipped with the small EEC-gates.

• The third drawing applies to machines equipped with the large safety gates. Machines type LT 2200-9.5 are equipped with logic card 139199-001.

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184, 288

3.1. Electrical diagram, standard

© BT Industries AB

Service Manual

1999-01-07

English

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3.2. Electrical diagram, EEC-gates

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Version no

T-code

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184, 288

3.3. Electrical diagram, safety gates

© BT Industries AB

Service Manual

1999-01-07

English

7 (12)

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003

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184, 288

4. Description of function 4.1. General The connections to the circuit board, the central terminal block, are named as connections 1 to 40 in this operating description. Components are only named by designation as a description can be found in the list of symbols. The description is divided into different phases representing the operating sequence.

The circuit board’s inputs and outputs are equipped with LEDs, which come on when the inputs respective outputs are activated. The inputs have green LEDs and the outputs red.

The +24 V supply on the circuit board is indicated by a yellow LED.

4.2. Ignition switch, S17 ON Battery voltage via F50 and S17 to connection 22. The relays Re13, Re18, Re26 and Re32 receive +24 V, but the relays cannot be activate as the negative return is missing. Re17, which also receives +24 V from connection 22, can now switch as a positive voltage is received via connection 17 to input A on the control circuit for Re17 and Re18.

The magnetic brake’s Y10 and the horn H1 are fed by connection 22. When S10 is open there is no negative return and the brakes are applied.

Voltage is also fed to K11, K13, K17, K18 and K30 to Y41 from connection 22.

Via connection 22 a voltage is received on Re13’s contacts through K11’s and K13’s coils, terminal 2 and 4.

The safety reversing cable is monitored by the circuit A2. A2 receives voltage from connection 22 through K17’s coil to connection 7 and out on connection 8. The negative return for A2 is received via cable 29 to S10, on to connections 36 and 40.

The relay in A2 switches when S10 is actuated, and then makes between cables 45 and 6. If a break occurs in cables 29 or 28 the relay releases and makes reversing impossible by breaking between cables 45 and 6.

The fork lifting microswitch S52 also receives voltage from connection 22 via K30’s coil, through P3’s breaker contacts and to connection 30 and out to connection 38, through S31 and to S52.

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C-code

S5 5000 Electrical system

Version no

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184, 288

4.3. Driving When the tiller arm is moved to the driving position S10 is actuated and makes giving Y10 negative return via connections 36 and 40. The brakes are released.

When S10 makes, Re26 also switches and receives negative return via connection 29 and S10.

Re13 can now switch, when the control circuit for Re13 receives negative on its lower input via connection 27, S16, S15 to S20 and on through S10 to connection 36 and 40. At the same time the upper input on the control circuit for Re13 loses its negative when Re26 switches.

LT 2200-8 The negative for Y10, Re13 and Re26, takes place on a LT 2200-8 via the platform and gate switches that are connected between S10 and connection 36. See electrical diagram.

In order to drive the machine requires one of the following: • Platform raised and gates not in use. Speed: 6 km/h.

• Platform lowered and gates not in use. Speed: 6 km/h • Platform lowered and gates in use. Speed: 9.5 km/h

4.4. Driving forwards, direction of the forks, first speed stage When the drive rocker is actuated for driving forwards, 1st speed stage, S15 makes. K11 receives negative return via connection 2, Re13’s contacts, connection 3, S15, through S20 to S10 and to connection 36 and 40. When S15 is activated the negative return to the lower input on the control circuit for Re13 is cut, but as the upper input lacks negative R13 still remains activated.

When K11 switches, the motor current passes via F1 through both resistors R11 and R12 to the series field D1-D2, on to one of the contacts on K11 and through the armature to the other contact K11 and on to negative.

The shunt field is connected via connection 18, on to connection 14 and through a diode to connection 16 and Re26 to negative.

LT 2200-8 A logic card is used on LT 2200-8 that has an extra relay, Re32. This relay is used to connect/disconnect the shunt field and in this way change the speed of the truck. The relay switches when the gates are used, that is when S53, S54 are actuated. © BT Industries AB

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1999-01-07

English

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184, 288

When the gates are not used the shunt field current passes through the shunt field to connection 18, through the contact on Re32 and out on connection 15, on through a diode to connection 16 to the contact on Re26 to negative.

When the gates are used S53, S54 make and Re32 switches.

This results in the negative return line for the shunt field current is cut and no current can flow through the shunt field. The machine’ speed then increases.

4.5. Reversing, direction of the drive wheel, first speed stage When the drive rocker is actuated for reversing, 1st speed stage, S16 makes. K13 receives negative return line via connection 4, Re13’s contacts, connection 6, through the contact on A2 to S16 and through S15 to S20 and S10 to connections 36 and 40.

When K13 switches, the motor current passes via F1 through both resistors R11 and R12 to the series field D1-D2, on to one of the contacts on K13 and through the armature to the other contact K13 and on to negative.

The shunt field is connected via connection 18, on to connection 14 and through a diode to connection 16 and Re26 to negative.

4.6. Driving forwards or reversing, second speed stage When S12 is actuated by the drive rocker, K17 receives negative return line via connection 7, Re17, out on connection 33 to S12, to S20 and S10, and on to connection 36 and 40. K17 switches.

When K17 switches, the motor current passes via F1 through the contact on K17, the resistor R12 to the series field D1-D2, on to one of the contacts on K11 or K13 and through the armature to the other contact on K11 or K13 and on to negative.

The shunt field is connected as in the first speed stage.

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S5 5000 Electrical system

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184, 288

4.7. Driving forwards or reversing, third speed range When S13 s actuated by the drive rocker, input B on the control circuit for Re17 and Re18 receives negative return line via S13 to S20, S10, connections 36 and 40. Input A already has 0.8 V and the condition is therefore met in order for Re18 to switch, which is does after a delay of one second.

When Re18 switches, K18 receives negative return line via connection 8, Re18 to negative (40).

When K18 switches, the motor current passes via F1 through the contact on K18, the series field D1-D2, on to one of the contacts on K11 or K13 and through the armature to the other contact on K11 or K13 and on to negative.

The shunt field is connected as in the first speed stage.

4.8. Reversing/ motor brake When reversing the drive rocker is actuated from the front to the back position (the function is the same if you go from the back to the front position). S15 the returns to its neutral position while S16 makes. Re13 remains activated. When switching the negative for a brief moment from S12 and S13 and to the input B on the control circuit for Re17 and Re18 and both these relays release. This causes K17 and K18 to release too.

When switching between S15 and S16 releases K11 and K13 switch. If S12 and S13 are actuated, the control circuit for Re17 and Re18 receives negative on input B, but when input A lacks 0.8 V (connection 17 becomes negative when motor braking) Re17 and Re18 remain in the idle position during braking, which accordingly takes place at the first speed stage.

The motor current now passes F1, R11, R12, D1-D2, K13, A1A2 and K13 to negative. The current in the series field means that the motor acts as a generator during braking, connection 17 becomes negative when the drive wheel rotates in the “wrong direction”. When the wheel rotates in the “right” direction acceleration take place as usual.

© BT Industries AB

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1999-01-07

English

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4.9. Safety reversing When S20 is actuated, the upper input on the control circuit for Re13 receives negative return from connection 28, via diode, whereby Re13 releases as does K13.

When S20 is actuated, the negative return line for the switches S12, S13, S15 and S16 disappears. The A2 relay releases and breaks the connection between 45 and 6.

K11 receives negative return via connection 2 and out on connection 28, through the now made contact on S20, to S10 and on to connection 36 and 40.

K17 receives negative return via connection 7 and out on connection 28 through S20 and on to connection 40 via S10. K17 switches.

The motor is now connected for motor braking to then accelerate forwards until S20 becomes deactivated again. Safety reversing takes place at the second speed stage.

When S20 returns to the neutral position the negative to K11 and K17 is cut and both release. If the drive rocker is still actuated for reversing, S16 activated, Re13 cannot switch and the truck stops, when either K11 or K13 receives negative.

However, A2 makes the relay connection between cable 45 and 6.

In order to start again the drive rocker must be moved back to the neutral position after which a new drive direction can be selected.

4.10. Lifting the forks Microswitch S52 makes. K30 receives negative return via breaker contact in P3 (if such is installed), connection 30, connection 38, S31 and S52.

K30 switches and M3 starts. S31 is the lifting height limit and breaks the negative return line for K30 at maximum lifting height.

4.11. Lowering the forks When S41 is actuated, Y41 is activated and releases the oil in the return to the hydraulic oil tank.

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C-code

S5 5000 Electrical system

IIssued by

Approved by

Version no

T-code

SSD

Fredrik Wigh

002

288

Electrical system Transistor regulator 6 km/h Valid from serial number: T-code

Model

Serial number

Notes

288

LT 2200

319125AA-

6 km/h

1 Electrical panel

© BT Industries AB

Service Manual

1998-04-21

English

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2 List of symbols Symbol

Description

A1

Transistor regulator

A5

Electronic card

G1

Battery

E8

Handle heater

Heating of tiller arm

Cold storage

F1

Fuse

Motor circuit

125 A

F3

Fuse

Pump circuit

160 A

F50

Fuse

Control circuit

7,5 A

F51

Fuse

External equipment

Options

H1

Horn

K11

Contactor

Travel direction

Fork direction

K13

Contactor

Travel direction

Steer wheel direction

K30

Contactor

Pump motor

M1

Motor

Drive motor

M3

Motor

Pump motor

P3

Indicator

Battery indicator/ running meter

R1

Potentiometer

Speed

RV1

Potentiometer

Maximum speed reduction

2 (18)

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Notes

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T-code

002

288

Symbol

Description

Function

S10

Switch

Brakes

S15

Switch

Travel direction

Fork direction

S16

Switch

Travel direction

Steer wheel direction

S17

Switch

Ignition switch

S18

Switch

Horn

S20

Switch

Safety reversing

S31

Switch

Lifting limit

S34

Switch

Lifting forks

S41

Switch

Lowering forks

S43

Switch

Platform switch

S59

Switch

PowerTrak function

Y1

Magnetic brake

Brake

Y41

Solenoid valve

Lowering forks

© BT Industries AB

Service Manual

C-code

S5 5000 Electrical system

Notes

1998-04-21

Option

English

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002

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2.1 Electrical diagram 1/5

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2.2 Electrical diagram 2/5

© BT Industries AB

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1998-04-21

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2.3 Electrical diagram 3/5

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Version no

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2.4 Electrical diagram 4/5

© BT Industries AB

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1998-04-21

English

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288

2.5 Electrical diagram 5/5

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3 Description of function 3.1 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 adjusting the speed potentiometer, transistor regulator and electronic card, see C-code 5460 and 5710.

3.2 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.

3.3 Ignition switch S17 in 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. 24 V on connection pins 202, 212, 303 and 410.

A5 (-) return via connection pin 409. © BT Industries AB

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1998-04-21

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288

• The battery voltage to A1.16 via A5 connection pin 410, the LED-status on transistor regulator starts to flash.

3.4 Tiller arm in driving position, S10

• When the tiller arm is pushed down into the driving position, S10 is activated and makes so that 24 V is fed via cables 31 and 47 to connection pin 210, through RE2’s contactors 3 and 2 and then out to connection pin 305 so that the magnetic brake Y1 is activated and releases the brake. The signal is also fed out to connection pins 109 and 408, A1.15.

• The activation of S10 also feeds 24 V to connection pin 301, LED 301 comes on, to the shunt field and internally to connection pin 206, LED 206 comes on and the running meter starts and to connection pin 403 so that K11 and K13 are voltage fed.

• The transistor regulator now regulates the current through the shunt field. 0.9 A. (-) return via the connection pins 302, 417 and A1.1.

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3.5 Driving, direction of the forks

• When the toggle arm is activated for driving in the direction of the forks, S15 is made. Driving is permitted.

• Battery voltage is received via the connect pins 101 and 411 to A1.11, LED 101 is on.

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

• Depending on the throttle’s (R1:s) position and the adjustment 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 A1-A2 and K11 to the battery’s negative pole via A1.M-.

© BT Industries AB

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1998-04-21

English

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3.6 Driving, steer wheel direction

• When the toggle arm is activated for driving in the steer wheel direction, S16 is made. The transistor regulator checks that S10 is closed before S16 is made. If not, driving is not permitted.

• Battery voltage is received via the connect pin 102 and 412 to A1.12, LED 102 is on.

• Battery voltage to K13 via connection pin 403. A1.3 now gives (-) return to K13, (-) input on connection pin 402, LED 402 is on.

• Depending on throttle’s (R1:s) position and the adjustment 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 A2-A1 and K13 to the battery’s negative pole via A1.M-.

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3.7 Switch function for platform (option) =1 207

106

111

105

110 206

104

109

102

108

213

409

417

408

416

407

415

406

414

404

413

212 211

205

RV1

103

=0

204 203 202

101 107

201

210

405

209

412

208 402

411

401 302 RE2 301

If the platform is not installed a strap links X2:1 and X2:2 and connection pin 211 is not used. See electrical diagram 5/5.

3.7.1 Driving with the platform raised • When the driver platform is raised and the tiller arm is in the driving position, S10 is activated 24 V(+) is fed via 31 to S43 and on to connection pin 210, through RE2’s contactors 3 and 2 and then on to connection pins 109, 403, 408 and 305. Magnetic brake Y1 is activated, the brake releases and the truck can be driven as normal.

3.7.2 Driving with the platform lowered • When the driver platform is lowered, S43 is activated. By moving the tiller arm to the driving position, S10 is activated and 24 V(+) is fed via line 31 to S43 and on to connection pin 211. LED 211 comes on. The signal continues to RE 2 and feeds this. The signal now flows through RE2’s contactors 1 and 2 to connection pin 305 and thereby Y1.

• The brake releases and the truck can be driven as normal as long as the driver remains on the platform. In this position RE2 is locked by receiving a supply from connection pin 301 through RE2’s contactors 7 and 8. RE2 remains active as long as the tiller arm is in the driving positions.

3.7.3 Alighting from the platform while driving If the driver alights or jumps off of the platform after the truck has started to move, that is, the tiller arm is still in the driving position, S43 will be activated. 24 V(+) is cut from connection pin 211. As RE2 is now locked this results in connection pins 109, 403, 408 and 305 losing the 24 V(+) supply and the brakes are immediately applied; LED 211 dims. © BT Industries AB

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1998-04-21

English

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• By returning the tiller arm to the parking position, S10 is deactivated, which results in connection pin 301 becoming low and RE2 is deactivated. Normal driving can now be resumed as described in steps “Driving with the platform raised/lowered” above.

3.8 Load dependent current limit The PowerTrak system contains a microswitch S59, which is activated when the load on the forks falls within a predetermined range.

=1 207

106

111

105

110 206

104

205

409

417

408

416

407

415

406

414

404

413

211

204

109

102

213 212

RV1

103

=0

203

108

202

101

210

405

209

107

412

208

201

402

411

401 302 RE2 301

• Without any load on the forks, S59 makes and 24 V is fed from connection pin 212 via S59 to connection pin 213; LED 213 comes on. The signal is then fed to connection pin 404 and on to A1.14.The transistor regulator’s output is limited to a factory set value, M2 MAIN C/L of 150 A. • When the load on the forks falls within the predetermined range, see table, S59 breaks; LED 213 dims and the signal to A1.14 becomes low. The transistor regulator can deliver the full current supply determined by the regulator parameter M1 MAIN C/L which is set at the factory to 200 A.

3.9 S59 Activation range

14 (18)

S59

Min (kg) load

Max (kg) load

Activated

300

400

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002

288

3.10 Reversing/motor brake, fork direction to steer wheel direction • 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 A2, and reduces the series field current to a value, which is dependent on the load on the forks.

• If S59 is not activated (i.e. no load on the forks) then the series field current is limited by the regulator parameter M2 MAIN PLUG C/L, which has a factory set value of 50 A. • If S59 is activated (fork load greater than 300 kg) then the series field current is limited by the regulator parameter M1 MAIN PLUG C/L, which has a factory set value of 70 A. 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, M-, transistor regulator’s brake diode, A2 and K13 during the braking sequence.

3.11 Reversing/motor brake, steer wheel direction to fork direction • 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 A2, and reduces the series field current to a value, which is dependent on the load on the forks.

• If S59 is not activated (i.e. no load on the forks) then the series field current is limited by the regulator parameter M2 MAIN PLUG C/L, which has a factory set value of 50 A. • If S59 is activated (fork load greater than 300 kg) then the series field current is limited by the regulator parameter M1 MAIN PLUG C/L, which has a factory set value of 70 A. 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, M-, transistor regulator’s brake diode, A2 and K11 during the braking sequence. © BT Industries AB

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1998-04-21

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3.12 Safety reversing function

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

• S20 is activated and makes connections 110, 415 and A1.13 becomes positive, A1 now cuts the (-) return to K13 which breaks. At the same time A1 will give (-) at A1.2 to K11; LED 401 comes on.

• The motor will now be connected for motor braking with the maximum current determined by the regulator Current Limit, Emergency Reverse. 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 A1.2 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 can be selected.

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3.13 Lifting the forks

• The microswitch S34 makes and (+) is fed to connection pin 208 via S31. K30 receives (+) voltage via connection pin 208, LED 208 comes on, connection pin 203, strapping or battery guard, connection pin 201; LED 201 comes on, and out on connection pin 405. The running meter starts when connection pin 201 becomes active.

• (-)-return via line 40. K30 makes and the pump motor M3 starts.

3.14 Lowering the forks =1 207

106

111

105

110 206

104

109

102

108

213

409

417

408

416

407

415

406

414

404

413

212 211

205

RV1

103

=0

204 203 202

101 107

201

210

405

209

412

208 402

411

401 302 RE2 301

• S41 makes and (+) is fed to connection pin 106; LED 106 comes on and on to connection pin 204 so that Y41is activated.

© BT Industries AB

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1998-04-21

English

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3.15 Horn

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

18 (18)

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F-code

Section

PT

C-code

S5 5230 Volt-/battery indicator

IIssued by

Approved by

Version no

T-code

SSD

K Hallman

001

184,288

Volt-/battery indicator Valid from serial number: T-code

Model

Serial No

Notes

184

LT 2200

326647AA-

9,5 km/h

288

LT 2200

326647AA-

6 km/h

1 General This instrument consists of a single, quartz, hourmeter, H, a 10 bar 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.

© BT Industries AB

Service Manual

1999-01-02

English

1 (8)

F-code

Section

PT S5 Volt-/battery indicator Version no

T-code

001

184,288

C-code

5230

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 switching resistive loads.

Open Contact Voltage

200

VDC

Max

Closed Contact Current

3

ADC

Max

Volt Ampere Product

50

W

Max

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.

2 (8)

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1999-01-02

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PT

Section

C-code

S5 5230 Volt-/battery indicator

Version no

T-code

001

184,288

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. .

© BT Industries AB

SETTING

VPC

K

1.57

L

1.63

M

1.68

N

1.73

O

1.78

P

1.82

Q

1.84

R

1.86

S

1.91

T

1.93

Service Manual

1999-01-02

English

3 (8)

F-code

Section

PT S5 Volt-/battery indicator Version no

T-code

001

184,288

C-code

5230

Pin No.

Function

1

Hour meter (-)

2

Keyswitch (+)

3

Relay arm (+)

4

Relay NC (-)

5

Battery (-)

6

Hour meter (+)

7

24 Volt (+)

8

48 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.

4 (8)

Service Manual

1999-01-02

English

F-code

PT

Section

C-code

S5 5230 Volt-/battery indicator

Version no

T-code

001

184,288

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 No 1 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.

© BT Industries AB

Service Manual

1999-01-02

English

5 (8)

F-code

Section

PT S5 Volt-/battery indicator Version no

T-code

001

184,288

C-code

5230

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.

6 (8)

Service Manual

1999-01-02

English

F-code

PT

Section

C-code

S5 5230 Volt-/battery indicator

Version no

T-code

001

184,288

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 pin 7 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.

Vad är J ?

SCR?

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.

© BT Industries AB

Service Manual

1999-01-02

English

7 (8)

F-code

Section

PT S5 Volt-/battery indicator Version no

T-code

001

184,288

C-code

5230

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.

8 (8)

Service Manual

1999-01-02

English

F-code

Issued by

SSD

Section

C-code

PT

S5 5460 Transistor panel

Version no

T-code

Approved by

Fredrik Wigh

001

184,288

Transistor panel Valid from serial number: T-code

Model

Serial number

Notes

184

LT 2200

256600AA-319124AA

8 km/h

288

LT 2200

256600AA-319124AA

6 km/h

1. General The drive motor mounted in the truck is a compound motor, i.e. it has a combination of an armature, series and shunt field windings. The magnetic field in the shunt windings flows in the same direction as the series field. The greater the current flowing through the shunt windings, stronger magnetic field, the lower the speed. At the same time the motor becomes stronger. This is used during start up and e.g. when driving up ramps.

During acceleration or driving up ramps the current in the series circuits is large. The transistor regulator also feeds a larger current to the shunt field to increase the motor power and thereby reduce any speed loss. When the current in the series circuits drops, increased speed, the shunt field current also drops. The shunt field is also used as a speed governor at top speed.

The transistor regulator has two integrated control systems, one for the series circuit and one for the shunt field circuit.

Both circuits are of the type single quadrant. The negative return to the contactors and other components is also fed through the safety transistor in the regulator.

1.1. Construction The regulator consists of two primary components, a regulation section and a power supply.

The regulation section is built on a circuit board with connection pins on both of the long sides for the inputs and outputs.

An angled plate acts as a heatsink for the power components on the board and at the same time makes up a bracket for the lower section.

© BT Industries AB

Service Manual

1998-01-09

English

1 (8)

F-code

Section

PT S5 Transistor panel Version no

001

C-code

5460

T-code

184,288

The power supply is built on an 8 mm thick aluminium plate.

The power components for the rotor circuit are the terminal blocks for connection of the electrical power and located on this plate. The power components, transistor and diode modules are insulated from the aluminium plate and are secured using bolts locked with LOCTITE. This means the power semi-conductors can easily be replaced.

The regulation section can be loaded with a continuous current of 75 A with an ambient temperature of +55° C, due to a good thermic contact between the chassis and the regulator.

The bracket and heatsinks in the power supply are galvanically insulated from the live components. The insulation voltage is in accordance with EU’s directive 86/663 500 V AC.

1.2. Operation The truck’s speed is regulated by a potentiometer, 5 kOhm, in the tiller arm. The potentiometer is fed with approximately +12 V from connection 10. The potentiometer is connected to (-) via connection 12 and a series resistance. Connection 11 is the input for the reference value from the potentiometer. The reference value determines the speed of the truck and can vary from 1 to 4 V. Depending on the position of the throttle, connection 11 receives a voltage somewhere within this range.

A ramp limits the acceleration. A long or short acceleration ramp is selected using S2. From the ramp the signal continues to a speed regulator. The speed regulator’s signal is compared with the returned value for the true speed collected from an amplifier. whose inputs measure the rotor current.

The collected signal forms the basis for the current regulator.

The signal is compared with a sawtooth current in a comparator, which builds a pulse width modulated signal that controls the rotor circuit’s output stage transistor.

The armature regulator is voltage controlled when driving and current controlled when braking.

The current value from the armature controls the shunt field’s current regulator. When the current in the armature increases, the shunt field current falls so that a constant truck speed can be maintained independent of the load weight within the normal load range. When the current is high, >90 A, the current in the shunt field increases to maximum to reach maximum torque for large load weights. The shunt field current is also affected by the strapping S3.

2 (8)

Service Manual

1998-01-09

English

F-code

Section

PT

C-code

S5 5460 Transistor panel

Version no

T-code

001

184,288

The shunt field regulator is also used to adjust the maximum speed for an unloaded truck.

When the output stage transistors modulate fully, i.e. with 100% pulse width, the output connection 5 switches low and the bypass contactor K14 is activated. The bypass contactor K14, straps the output transistor so that the voltage drop is as little as possible. The current feed still functions even when the bypass contactor is made. The bypass contactor release when the speed regulator demands a reduced signal, i.e. when the speed is reduced using the tiller arm or when the motor reaches the current limit.

The transistor regulator has two current limits, one for an unloaded truck and one for a loaded truck. The current limits can be adjusted between 100 and 165 A using potentiometer P1.

The correct current limits are set at the factory before delivery.

With a light load on the forks the available current is limited to 70% of the current limit’s setting. This occurs when connection 8 is earthed via S59.

The shunt field regulator is current controlled so as not to affect the temperature of the shunt windings. The shunt field is connected when the throttle is activated. To guarantee good braking once the throttle has been released a shunt field current of 3 to 3.5 A is maintained for approximately 3 seconds once the throttle has returned to its neutral position.

2. Technical specification

© BT Products AB

Characteristics

Value

Unit

Supply voltage

24

V~

Minimal static drive voltage >200 ms

16

V~

Minimum instantaneous drive voltage <200 ms

12

V~

Switching frequency.........................+10%

500

Hz

Maximum rotor current

165

A

Maximum shunt field current

10

A

Maximum current - safety transistor

4

A

Working temperature

0 to +55

°C

Storage temperature

0 to +85

°C

Service Manual

1998-01-09

English

3 (8)

F-code

Section

PT S5 Transistor panel Version no

001

C-code

5460

T-code

184,288

3. Settings and indications Speed

S3* S4**

Connection pin 23

Rotor Shunt current field current

4 km/h

R

open

20 A

>7 A

4 km/h

R

open

40 A

>7 A

5 km/h

L

open

20 A

4.8 +0.2 A

5 km/h

L

open

40 A

3.4 +0.2 A

6 km/h

L

0V

20 A

3.1 +0.05 A

6 km/h

L

0V

40 A

1.7 +0.01 A

Max

R

0V

0-90 A

<0.2 A

Max

R

open or 0 V

>90 A

>7 A

*L = left-hand position, R = right-hand position. ** This controls the walking speed function and is no longer used. Normal position is R.

4 (8)

S2:s position

Ramp time

Left

0.5 s, standard setting

Right

1.2 s.

LED No.:

Colour Normal status

Explanation

LD1

Green

ON

Normally on. Indicates correct power supply to the logic board.

LD2

Red

OFF

Normally dimmed. If on, indicates that the safety circuit for the contactor has been activated.

Service Manual

1998-01-09

English

F-code

Section

PT

C-code

S5 5460 Transistor panel

Version no

T-code

001

184,288

4. Maintenance 4.1. Watchdog When the throttle is activated a check is made for a possible short-circuit in the rotor circuit’s output stage. This takes place as follows: When the throttle is activated, a pulse of 100 ms is generated from an IC circuit. This pulse blocks the reference value so that no current can directly reach the motor when the throttle is activated. During blocking the regulator checks whether the current flows to the motor. If a current strength in excess of 50 A flows to the motor, a transistor in the safety circuit is activated and LD 2 comes on.

4.2. Adjusting the current limit • Block the truck against an obstacle or disconnect cable 29 to the electromechanical brake.

• Connect a mV-instrument to metering points TP1 and TP2 on the control card. 1 mV on the instrument corresponds to a current of 1 A. • Move the throttle to the position for top speed.

NOTE! No longer than 10 seconds.

• Adjust the potentiometer P1 so that the following values apply.

- Truck with load: 165 mV = 165 A - Truck without load: 115 mV = 115 A • Reading off and adjustment can be carried out simultaneously. Note that a clip-on ammeter must not be used.

NOTE! Potentiometer P2 must not be changed.

© BT Products AB

Service Manual

1998-01-09

English

5 (8)

F-code

Section

PT S5 Transistor panel Version no

001

C-code

5460

T-code

184,288

4.3. Trouble shooting • LD1 is not on after S17 has been switched on. None or incorrect power supply to the transistor regulator.

• If LD2 comes on when the throttle is activated, can be due to one of the following reasons.

Possible cause 1

Short-circuit in the rotor’s drive transistor.

2

The rotor’s output stage tries to supply full output.

3

Short-circuit in the bypass contactor, switch points welded together

4

Short-circuit in the drive circuit for the bypass contactor, or if the drive circuits tries to supply full output.

5

Short-circuit in forward/reverse contactor’s coils.

6

Short-circuit between connection pin 36, the brake’s microswitch and 24 V

7

Activation of S17 when the forward/reverse driving direction has already been selected.

4.4. Main transistor check • Switch off S17.

• Disconnect the bypass contactors.

• Connect a lamp, 24 V, 5 W, and a voltmeter between connection bolt A and K. • Switch on S17.

• Check the lamp and instrument. If the lamp does not come on and the scale shows a value less than 100 mV this indicates that the transistor is intact.

If the lamp comes on and the scale shows a value greater than 100 mV this indicates the transistor is damaged.

• Switch off S17 and connect the bypass contactor again.

6 (8)

Service Manual

1998-01-09

English

F-code

Section

PT

C-code

S5 5460 Transistor panel

Version no

T-code

001

184,288

4.5. Check the transistor regulator’s safety circuit As this is included in a part of an EU-standard, the instructions should be made available on request to those parties concerned.

Perform the following test to check whether the safety circuits function.

• Support the truck in a suitable manner so that the drive wheel is free from the ground.

NOTE! To prevent the truck from moving, the drive wheel must not under any circumstances come into contact with the ground during the test.

• Remove the dust cover from the electrical panel.

• Turn the ignition switch S17 to ON. • Hold or secure the tiller arm in a position so that the brakes are released.

• Activate the manual bypass contactor K14 and keep it held down.

• Set the throttle either in the forward or reverse direction.

• Check and ensure that the steering wheel starts to rotate, but stops immediately again once the safety circuit trips.

• Make sure LD2 on the control card comes on.

• Return the truck to its normal condition. The test is now complete.

© BT Products AB

Service Manual

1998-01-09

English

7 (8)

F-code

Section

PT S5 Transistor panel Version no

001

8 (8)

C-code

5460

T-code

184,288

Service Manual

1998-01-09

English

F-code

Issued by

SSD

Approved by

Section

C-code

PT

S5 5460 Transistor panel

Version no

T-code

Fredrik Wigh

002

184,288

Transistor panel Valid from serial number: T-code

Model

Serial number

Notes

184

LT 2200

319125AA-

9,5 km/h

288

LT 2200

319125AA-

6 km/h

1. General Curtis 1207A-4109, version 163770-001 is similar to Curtis 1207-1129 (t ex 143850-003). 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 Model 1207A offers superior potential to regulate the truck’s drive motor speed. The current strength to the motor is set by varying the pulse rate for the regulator’s MOSFET output transistors. This technique, called pulse width modulation (PWM) provides, silent, variable operations. Pulse width modulation also know as “chopping”, is a technique that rapidly switches the battery voltage to the motor on and off and in this way control the motor speed. Model 1207A uses high frequency PWM, -15 kHz. During acceleration and speed reduction the regulator permits a larger current flow to the motor than the current flow from the battery. The regulator acts as a DC transformer, which takes in a low current strength and high voltage (full battery voltage) and supplies a high current strength and low voltage.

An internal micro-control circuit automatically monitors the regulator’s operation. When an error occurs the error code in question is shown by LEDs, which are visible 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 will stop working. Normally the error can be rectified and is only temporary, e.g. a low voltage error disappears when the condition no longer exists. © BT Industries AB

Service Manual

1998-04-23

English

1 (18)

F-code

Section

C-code

PT S5 Transistor panel Version no

5460

T-code

002

184,288

1207A-4109 has functions such as “Start on incline” and “Automatic speed reduction” (also called neutral braking). The function “Start on incline” allows the driver to give the reverse command (S16 and acceleration) before the tiller arm is set in the drive position. If the driver gives the forward command (S15 and acceleration), the truck will not work and an error code is shown, LED code 1.4 flashes (SRO error).

The function “Start on incline” is set at the factory and is always valid. The function “Automatic speed reduction” is activated by setting a parameter using the hand terminal. When this function is connected (ON), the truck will motor brake when the driver releases the throttle (toggle lever). The current limit for this function can be set using the hand terminal.

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

1

2

M-

A2 B-

2 (18)

B+

Connection pin

Connection

1

Hand terminal connection

2

Low output electronic card with 16 pins

M-

Output to the motor armature

B-

Negative connection to the battery

B+

Positive connection to the battery/series field

A2

Brake 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 internal connections.

Service Manual

1998-04-23

English

F-code

Section

PT

C-code

S5 5460 Transistor panel

Version no

T-code

002

184,288

2.1. Connection to the control circuits The transistor regulator has an integrated connector with 16 pins for the low output connections to the logic card. Pin configuration is as set out in the table below.

Pin No.

Connection

Contactor driving P1

Shunt field

P2

Fork direction, contactor

P3

Steering wheel direction, contactor

P4

Not connected

Connections for throttle P5

Not connected

P6

Not connected

P7

Potentiometer: potentiometer, low

P8

Potentiometer: 2-wire 5 kohm-0, input

Basic control signals

© BT Products AB

P9

Not connected

P10

Check of safety reversing, output

P11

Driving in fork direction, input

P12

Driving in steering wheel direction, input

P13

Safety reversing, input

P14

Selection of mode 1 or 2, input (PowerTrak)

P15

Brake switch, input

P16

Ignition switch, input (KSI)

Service Manual

1998-04-23

English

3 (18)

F-code

Section

PT S5 Transistor panel Version no

002

C-code

5460

T-code

184,288

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

Range

Unit

Description

Nominal input voltage

24

V

Maximal operating voltage

30

V

Overvoltage point

33

V

Minimum operating voltage

16

V

undervoltage point

Electrical insulation for heatsink

500

V~

Minimum

PWM-operating frequency

15

kHz

Output current*

250

A

During 1 minute

200

A

During 2 minutes

150

A

During 5 minutes

100

A

During 1 hour

Contactor voltage

24

V

Contactor current, max.

1

A

Current limit at 2 A

Shunt drive current

2

A

Standard, approx. 1 A

KSI-input voltage

16-30

V

KSI-input current

80

mA

Logic card, input current

10

mA

Logic card, input threshold

8

V

Ambient operating temperature

-25 to +50

°C

Heatsink, limitation of upper temperature

85

°C

Heatsink, limitation of lower temperature

-25

°C

at 24 V

*Nominal output current under specific test conditions.

4 (18)

Service Manual

1998-04-23

English

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Section

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C-code

S5 5460 Transistor panel

Version no

T-code

002

184,288

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 “Curtis 1307 hand terminal”.

Parameter (1307-display)

Range

Std. value

Unit

Description

M1 MAIN C/L

100-200

200

A

Current limit for driving in Mode 1

M1 MAIN PLUG C/L

50-70

70

A

Maximum braking current in Mode 1

M1 RAMP C/L

100-200

200

A

Maximum braking current during ramp start in Mode 1

M1 ACCEL RATE

0-3

0,8

s.

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

M1 MAX SPEED

40-100

100

%

Max speed in Mode 1

M2 MAIN C/L

100-150

150

A

Current limit for driving in Mode 2

M2 PLUG C/L

40-50

50

A

Maximum braking current Mode 2

M2 RAMP C/L

40-50

50

A

Maximum braking current during ramp start in Mode 2

M2 ACCEL RATE

0-3

0,8

s.

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

M2 MAX SPEED

40-100

100

%

Max speed in Mode 2

NEUT BRAKE C/L

20-70

20

A

Maximum braking current with automatic speed reduction

NEUTRAL BRAKE

ON/OFF

OFF

© BT Products AB

Service Manual

Select braking or freewheeling when the throttle is moved to the neutral position

1998-04-23

English

5 (18)

F-code

Section

PT S5 Transistor panel Version no

002

C-code

5460

T-code

184,288

4.1. Mode 1 and 2 Curtis 1207 is a Multimode regulator, which means you can switch between different parameter settings. This is done to make the machine perform as optimally as possible loaded and unloaded. Switching between Mode 1 and Mode 2 takes place by means of pin 14 in the logic connector.

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

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

5. Diagnostics and trouble shooting 5.1. Trouble shooting An internal micro-control circuit automatically monitors the operation of the regulator. When an error is detected this is shown by the LEDs, which are visible 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 will stop working. Normally the error can be rectified and is only temporary, e.g. a low voltage error disappears when the condition no longer exists.

The automatic system for error detection comprises: • Contactor coils open/ short-circuited driving.

• Overcurrent, contactor driving/ contactor coil shortcircuited.

• Contactor welded together.

• Control of circuit for safety reversing.

• M-output error.

• Memory controlled during start-up.

• Overvoltage broken.

• Current supply outside range (internal).

• Throttle error.

• Undervoltage, reduction.

• Watchdog.

6 (18)

Service Manual

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English

F-code

Section

PT

C-code

S5 5460 Transistor panel

Version no

T-code

002

184,288

5.2. Error codes During normal conditions and without any error indications the STATUS LEDs flash with a frequency 1 flash/second. If the regulator detects an error, a two digit code is shown until the error is rectified, see the table below.

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

5.2.1. LED indications Only one error at a time is shown errors are not queued.

LED code

Programmer’s LCDdisplay

Explanation

Probable cause

LED off

No current or defective regulator

Fuse has tripped, bad connection, no connection

LED on

Defective regulator

Regulator defective

1,2

¤ ¤¤

HW FAILSAFE

Failsafe hardware 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. Short-circuited to earth internally in motor

1,4

¤ ¤¤¤¤

SRO

SRO-error

1. Incorrect sequence in KSI, braking and direction input 2. Switching circuit for braking or direction not made

2,1

¤¤ ¤

THROTTLE FAULT 1

5 kOhm-0 or lever error

1. Break in cable, throttle input 2. Cable for throttle input shortcircuited to earth or B+ 3. Throttle potentiometer defective 4. Wrong throttle type

2,2

¤¤ ¤¤

BB WIRING CHECK

Cable error for safety reversing

1. Safety reversing cable breakage 2.Safety reversing check cable breakage

© BT Products AB

Service Manual

1998-04-23

English

7 (18)

F-code

Section

C-code

PT S5 Transistor panel Version no

5460

T-code

002

184,288

LED code

Programmer’s LCDdisplay

Explanation

Probable cause

2,3

¤¤ ¤¤¤

HPD

HPD-sequence error

1. Incorrect sequence on KSI, brake/throttle input 2. Incorrectly adjusted throttle

2,4

¤¤ ¤¤¤¤

THROTTLE FAULT 2

Potentiometer low off or short-circuited

1. Cable open to potentiometer low 2. Cable short-circuited to potentiometer low 3. Wrong throttle type

3,1

¤¤¤ ¤

CONT DRVR OC

Driving output, overcurrent

1. Direction contactor’s coil short-circuited 2. Shunt field short-circuited

3,2

¤¤¤ ¤¤

DIR CONT WELDED

Welded direction contactors

1. Direction contactor locked in made position

3,4

¤¤¤ ¤¤¤¤

MISSING CONTACTOR

Contactor or shunt missing

1. Direction contactor’s coil open 2. Direction contactor missing 3. Break in shunt field 4. Cable to the shunt or direction contactor broken

4,1

¤¤¤¤ ¤

LOW BATTERY VOLTAGE

Low battery voltage

1. Battery voltage <16 V 2. Corrosion on battery terminals 3. Loose connection on the battery or regulator

4,2

¤¤¤¤ ¤¤

OVERVOLTAG E

Overvoltage

1. Battery voltage >33 V 2. Truck used with charger connected

4,3

¤¤¤¤ ¤¤¤

THERMAL CUTBACK

Reduction of upper/ lower temperature

1. Temperature >85o C or <-25o C 2. Overload 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 being made in the mentioned order. However, operations are permitted if a reverse input precedes the brake input. This can be used when starting of the truck on an incline, this is called “Starting on incline”.

8 (18)

Service Manual

1998-04-23

English

F-code

Section

PT

C-code

S5 5460 Transistor panel

Version no

T-code

002

184,288

5.3. Testing circuits for error detection Special materials handling directives such as nprEN1175, demand regular testing of the transistor regulator’s error detection circuits. It is therefore recommended that the detection circuit M-Fault is 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. • Connect the regulator’s connection pins M and B to a fuse holder with a 10 A fuse and crocodile clips.

• Switch ON the ignition switch, release the brake and activate 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 fuse cable. The truck’s status should still be inactive.

• Switch the ignition on and off, release the brake and activate 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 CEASE TO BE VALID!

However, the outside of the transistor regulator should be cleaned regularly. The regulator’s diagnostic history can be checked when cleaning by using a hand terminal if one is available.

6.1. Safety Basically the transistor regulator is a heavy current unit.

Appropriate safety precautions must always be taken when working on a battery powered vehicle. These include: suitable training, the use of protective glasses, not wearing loosely hanging clothes, watches or jewellery to name but a few.

Always use insulated tools.

WARNING Risk of short-circuiting.

Do not wear watches or jewellery and always use insulated tools.

© BT Products AB

Service Manual

1998-04-23

English

9 (18)

F-code

Section

PT S5 Transistor panel Version no

002

C-code

5460

T-code

184,288

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.

• Remove the power supply 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 connections B+ and B- before carrying out any work on the regulator.

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

• Make sure the connections on the busbar are tightened correctly. Use two insulated spanners so as not to apply and strain on the busbars.

10 (18)

Service Manual

1998-04-23

English

F-code

Section

PT

C-code

S5 5460 Transistor panel

Version no

T-code

002

184,288

7. Curtis 1307 hand terminal Transistor regulators of the type Curtis PMC 1207/ 1207A can be programmed, tested and trouble shot using the Curtis hand terminal 1307. The programmer is powered by the host regulator 1207/ 1207A via a modular PLUG RJ11 located on the adjustment panel above the regulator 1207, or a 4 way Molex connector located on the front of regulator 1207 A. Connection to Curtis 1207

Connection to Curtis 1207A

A2

MB-

© BT Products AB

Service Manual

1998-04-23

B+

English

11 (18)

F-code

Section

PT S5 Transistor panel Version no

002

C-code

5460

T-code

184,288

Pos.

Function

Notes

1

Display window

4 row LCD-display.

2

PROGRAM MODE key

Select this mode to show (and change) the regulator’s parameters.

3

TEST MODE key

Select this mode to show the status of the inputs/ outputs, etc.

4

DIAGNOSTICS MODE key

Select this mode to show the current error condition detected by the regulator.

5

SCROLL DISPLAY keys

Scroll the displayed rows of text (up and down).

6

MORE INFO key

Press this key to receive more information about the current status.

7

LED for active keys

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

8

CHANGE VALUE keys

Increase or decrease the value of the selected parameter

9

LED for operating mode

States which operating mode is currently active.

12 (18)

Service Manual

1998-04-23

English

F-code

Section

PT

C-code

S5 5460 Transistor panel

Version no

T-code

002

184,288

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 programmer is connected to the regulator the brake switch must be open (brakes applied) until the programmer has gathered all the regulator parameters. Once this stage has been completed the programmer displays the regulator’s model number, date of manufacture and the software version number. After this a prompt is displayed for further instruction.

The programmer has three primary operating modes: PROGRAM, TEST and DIAGNOSTICS. • PROGRAM mode used to show the regulator’s parameters. The shown parameters can also be changed in this mode.

• TEST mode shows real time information of the status of the inputs, outputs and the regulator temperature. In the TEST mode the points of interest do not need to be at the top of the list. They only need to be shown among the four rows displayed by the window. The test mode can be used to check the operation of the regulator during initial installation and also for trouble shooting if a problem should occur.

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

Two other operating modes are available: SPECIAL PROGRAM and SPECIAL DIAGNOSTIC. • The SPECIAL PROGRAM mode allows you to perform a number of different tasks including: erasing the file containing diagnostic history, adjusting the contrast on the LCD display, language selection, saving settings, etc.

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

© BT Products AB

Service Manual

1998-04-23

English

13 (18)

F-code

Section

PT S5 Transistor panel Version no

002

C-code

5460

T-code

184,288

8.1. Using the PROGRAM mode, checking and adjusting parameters • Press the PROGRAM key. The corresponding LED for PROGRAM operating mode comes on.

PROGRAM

The programmer 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 one of the SCROLL DISPLAY 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 CHANGE VALUE “down”. The LEDs on these keys indicate whether there is still room for adjustment. This means that when the upper limit for a parameter has been reached, the LED on the up key dims and thereby indicating that the value cannot be further increased. When the lower limit has been reached the LED on the down key dims.

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, standardised values and adjustments.

14 (18)

Service Manual

1998-04-23

English

F-code

Section

PT

C-code

S5 5460 Transistor panel

Version no

T-code

002

184,288

8.1.1. Using the key MORE INFO in PROGRAM mode The MORE INFO key, used 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 menu or after the key MORE INFO has been pressed and the extra information has been shown on the display (see the example below).

MODE 1 ACCELERATION RATE; SECS MIN 0.2

1.3

MAX 3.0

8.2. Using SPECIAL PROGRAM mode

MORE INFO

PROGRAM

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

SPECIAL PROGRAM is accessed by first pressing the MORE INFO key and then pressing the PROGRAM key at the same time as you keep MORE INFO held down. The LED on the PROGRAM key comes on, exactly as when the programmer is in the PROGRAM mode. The key MORE INFO is first used to reach the SPECIAL PROGRAM mode, and once in the SPECIAL PROGRAM mode it is used to execute the desired task. If, for example, you wish 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.

© BT Products AB

Service Manual

1998-04-23

English

15 (18)

F-code

Section

PT S5 Transistor panel Version no

002

C-code

5460

T-code

184,288

8.3. Using TEST mode

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

The programmer now 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 to check the operation of the regulator during the initial installation and also for trouble shooting.

Show other values by pressing on the SCROLL DISPLAY keys.

Example The effect of the truck’s throttle can be controlled by either moving the lever forwards or backwards. The value THROTTLE % is changed in an equivalent manner and shows the percentage of the request top speed. It should be possible to set a value of 100% in both travel directions.

16 (18)

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1998-04-23

English

F-code

Section

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C-code

S5 5460 Transistor panel

Version no

T-code

002

184,288

The table below shows the meaning of the TEST values.

© BT Products AB

Test value

Description

THROTTLE %

Speed input in per cent.

BATTERY VOLTAGE

Current battery voltage

HEATSINK °C

Current regulator temperature

BRAKE INPUT

Status of brake input (on/off)

SPEED IN

Status of the input on pin 14 to the regulator (on/off)

EMR REV INPUT

Status of the input- safety reversing (on/off)

FORWARD INPUT

Status of the input (on/off), driving forwards

REVERSE INPUT

Status of the input (on/off), reversing

FWD CONTACT

Status of contactor output (on/off), direction forwards

REV CONTACT

Status of contactor output (on/off), reversing

MAX TEMP °C

Highest recorded regulator temperature since DIAGNOSTIC HISTORY was last cleared

MIN TEMP °C

Lowest recorded regulator temperature since DIAGNOSTIC HISTORY was last cleared

Service Manual

1998-04-23

English

17 (18)

F-code

Section

PT S5 Transistor panel Version no

002

C-code

5460

T-code

184,288

8.4. Using DIAGNOSTICS mode • Press the DIAGNOSTICS key. The corresponding LED comes on.

DIAGNOSTICS

The programmer now shows a list of the current 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

MORE INFO

DIAGNOSTICS

The regulator file with diagnostic history is shown in SPECIAL DIAGNOSTICS mode. This file contains a list of all the regulator’s observed 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. Thereafter press the DIAGNOSTICS key at the same time as the MORE INFO key is held down. The LED on the DIAGNOSTICS key comes on, exactly as when the programmer is in the DIAGNOSTICS mode.

The file containing the diagnostic history is cleared by putting the programmer in the SPECIAL PROGRAM mode, and selecting “Clear Diagnostic History” and then pressing the MORE INFO key for instructions. When the file containing diagnostic history is cleared even the maximum/minimum temperatures in the TEST mode are reset.

18 (18)

Service Manual

1998-04-23

English

F-code

Section

C-code

PT S5 5710 Electronic card, drive/multi function IIssued by

Approved by

Version no

T-code

SSD

Fredrik Wigh

001

184

Electronic card, drive/multi function Transistor regulator 9,5 km/h Valid from serial number: T-code

Model

Serial number

Notes

184

LT 2200-8

319125AA-

9,5 km/h

1 General The connection card is equipped with green LEDs on the input from the microswitches and red LEDs on the output to the contactors. The card also is equipped with a potentiometer to adjust the maximum speed.

2 Components

1 2

106 105 104 103 102 101

3 4

RE6

111 209 110 208 207 206 109 205 108 107 204 203 202 RE5 201

5

303

217 216 215 214

409 408 407 406

417 416 415 414

8

405

213 404 403 212 211 210 401

413 412 411 410

305

9

304

10

302

6

301

7

11 RE4

© BT Industries AB

Service Manual

RE3

1998-04-30

RE2

English

RE1

1 (4)

F-code

Section

C-code

PT S5 5710 Electronic card, drive/multi function Version no

T-code

001

184

2.1 Connection/adjustments Position

Connection/ adjustment

1

Microswitches (forwards, reverse, horn, support arm lift/lower, speed ref)

2

Microswitches (ignition, fork lift, PowerTrakthrottle, platform, gates) lower solenoid valve, instrument

3

RE 5 control relay for driving permitted

4

RE 6, not used on LT (LS-function)

5

Microswitches: brakes, magnet brake, shunt field winding

6

RE 3, control relay for lift function

7

RE 4, control field for shunt field, 9,5 km/h

8

Battery +/-, connections to transistor regulator, contactors, horn

9

RV 1, adjustment of max. speed

10

RE 2, control relay for breaker function, platform

11

RE 1, control relay for magnet brake

2.2 Connections for inputs and outputs The table below describes all the inputs and outputs on the card. The column Signal name refers to the description located after the pin number on the electrical diagram for the truck, see C-code 5000.

Pin No.

LED No.

I/O LT

Function

101

101

I

DRIVE FORK DIRECTION

Driving, fork direction

102

102

I

DRIVE STEERING WHEEL DIR

Driving, steering wheel direction

Signal name

103

O

Throttle

104

I

SPEED REFERENCE VALUE

Reference value, speed

105

105

I

INP. SUP. ARM LIFT

Forks lifted

106

106

I

INP. SUP. ARM LOW

Forks lowered

107

107

I

INP. HORN

Horn

108

O

109

O

2 (4)

24 V (+)

OUT BELLY BUTTON Service Manual

Driving, microswitch feed 1998-04-30

English

F-code

Section

C-code

PT S5 5710 Electronic card, drive/multi function Version no

T-code

001

Pin No.

LED No.

I/O LT

184

Function

Signal name

110

I

BELLYBUTTON

Safety reversing (S20)

111

I

SUPERVISION BELLY BUTTON

Safety reversing, monitoring (S20)

201

I

INP. LIFT LOCK OUT

Battery guard

202

202

I

+ 24 VDC KEY SWITCH

Ignition on 24 V (+)

203

203

O

OUT LIFT LOCK OUT

Battery guard

204

204

O

OUT LOW. VALVE

Fork lower valve, Y41

O

OUT. KEY SWITCH

24 V (+) to battery guard

O

OUT. HOUR METER

Running meter

207

0V

0V

208

NOT USED

205 206

206

209

209

O

OUT. SUP ARM VALVE

Support arm, lift valve, Y52

210

210

I

INP. PLATFORM UP AND GATES OPEN

Platform and gates not used

211

211

I

INP. PLATFORM DOWN

Platform used

O

OUT.P. TRAK SWITCH

PowerTrak-switch, feed of 24 V(+) PowerTrak-switch

212 213

213

I

INP. P. TRAK SWITCH

214

214

I

NOT USED

215

215

I

NOT USED

216

216

I

INP.PLATFORM DOWN AND GATES CLOSED

Platform and gates used

217

217

I

INP.BRAKE WHEN LEAVING PLATFORM NOT ACTIVE

If not connected the truck automatically brakes when the driver leaves the platform.

301

301

I

INP. BRAKE SWITCH

Brake switch

302

O

INP. SHUNT FIELD

Shunt field (-)

303

O

OUT. BRAKE SWITCH

Brake switch 24 V(+)

0V

Magnet brake (-)

304

© BT Industries AB

Service Manual

1998-04-30

English

3 (4)

F-code

Section

C-code

PT S5 5710 Electronic card, drive/multi function Version no

001

Pin No.

T-code

184

LED No.

305

I/O LT

Function

Signal name O

OUT. BRAKE

Magnet brake 24 V(+)

401

401

I

DRIVE FORK DIR

Contactor (-), fork direction

402

402

I

OUT. ST. WH. DIR

Contactor (-), steering wheel direction

403

O

404

O

OUT. CURRENT LIMIT

Input signal to PowerTrak switch

O

OUT. PUMP

Output signal, pump contactor made

406

O

OUT. HORN

Horn

407

I

+ 24VDC BATTERY

24 V (+)

408

O

409

I

410

O

411

O

DRIVE FORK DIR

Driving, fork direction

412

O

DRIVE STEERING WHEEL DIR

Driving, steer wheel direction

413

I

414

O

SPEED REFERENCE VALUE

Reference value, speed

415

O

BELLY BUTTON

Safety reversing (S20)

416

O

SUPERVISION BELLY BUTTON

Safety reversing, monitoring (S20)

417

O

405

4 (4)

405

Contactor, driving 24 V(+)

Input signal to regulator, brake.

0V

(-) 24 V (+) to transistor regulator

Throttle

Shunt field (-)

Service Manual

1998-04-30

English

F-code

Section

C-code

PT S5 5710 Electronic card drive/multi function IIssued by

Approved by

Version no

T-code

SSD

Fredrik Wigh

001

288

Electronic card drive/multi function Transistor regulator 6 km/h Valid from serial number: T-code

Model

Serial number

Notes

288

LT 2200

319125AA-

6 km/h

1 General The connection card is equipped with green LEDs on the input from the microswitches and red LEDs on the output to the contactors. The card also is equipped with a potentiometer to adjust the maximum speed.

2 Components

© BT Industries AB

Service Manual

1998-05-04

English

1 (4)

F-code

Section

C-code

PT S5 5710 Electronic card drive/multi function Version no

T-code

001

288

2.1 Connections/adjustments Position

Connections/adjustments

1

Microswitches (forwards, reverse, horn, support arm lift/lower, speed ref)

2

Microswitches (ignition, fork lift, PowerTrak, platform), support arm lift/lower, solenoid valve, instrument

3

Microswitches brakes, magnet brake, shunt field winding

4

Battery +/-, Curtis connections, contactors

5

RE2, control relay for breaker function, platform

6

RV1, adjustment of max. speed

2.2 Connections for inputs/outputs The table below describes all the inputs and outputs on the card. The column Signal name refers to the description located after the pin number on the electrical diagram for the truck, see C-code 5000.

Pin No.

LED No.

I/O

LT

Function

101

101

I

DRIVE FORK DIRECTION

Driving, fork direction

102

102

I

DRIVE STEERING WHEEL DIR

Driving, steering wheel direction

Signal name

103

O

Throttle

104

I

SPEED REFERENCE VALUE

Reference value, speed

105

105

I

Not used

106

106

I

INP. FORK DOWN

107

107

I

INP. HORN

Horn

108

O

Not used

24 V (+)

109

O

OUT BELLY BUTTON

Drive, microswitch feed

110

I

BELLY BUTTON

Safety reversing (S20)

111

I

SUPERVISION BELLY BUTTON

Safety reversing, monitoring (S20)

2 (4)

Service Manual

1998-05-04

English

F-code

Section

C-code

PT S5 5710 Electronic card drive/multi function Version no

T-code

001

Pin No.

LED No.

201

I/O

LT

288

Function

Signal name I

INP. LIFT LOCK OUT

Battery guard

202

202

I

+24 V DC KEY SWITCH

Ignition on 24 V (+)

203

203

O

OUT LIFT LOCK OUT

Battery guard

204

204

O

OUT LOWERING VALVE

Fork lower valve, Y41

O

OUT KEY SWITCH

24 V (+) to battery guard

O

OUT HOUR METER

Running meter

0V

(-) Fork lift

205 206

206

207 208

208

I

INP. FORK LIFT

209

209

O

Not used

210 211

211

212

I

Platform switch - raised (option)

I

Platform switch - lowered (option)

O

OUT P. TRAK

PowerTrak switch, feed of 24 V(+)

213

213

I

INP. P.TRAK

PowerTrak switch

301

301

I

INP. BRAKE SWITCH

Brake switch

302

O

INP. SHUNT FIELD

Shunt field (-)

303

O

OUT BRAKE SWITCH

Brake switch 24 V(+)

0V

Magnet brake(-)

O

OUT BRAKE

Magnet brake 24V(+)

304 305

401

401

I

DRIVE FORK DIR

Contactor (-), fork direction

402

402

I

DRIVE ST. WH. DIR

Contactor (-), steering wheel direction

403

O

OUT 24 V DC

Contactor, driving 24 V(+)

404

O

OUT CURRENT LIMIT

Input signal to regulator PowerTrak switch

O

OUT PUMP

Output signal, pump contactor closed

405

405

© BT Industries AB

Service Manual

1998-05-04

English

3 (4)

F-code

Section

C-code

PT S5 5710 Electronic card drive/multi function Version no

001

Pin No.

T-code

288

LED No.

I/O

LT

Function

Signal name

406

O

OUT HORN

Horn

407

I

+24 VDC BATTERY

24 V (+)

408

O

409

I

0V

(-)

410

O

OUT 24 V

24 V (+) to transistor regulator

411

O

DRIVE FORK DIR

Driving, fork direction

412

O

DRIVE STEERING WHEEL DIR

Driving, steering wheel direction

413

I

414

O

SPEED REFERENCE VALUE

Reference value, speed

415

O

BELLY BUTTON

Safety reversing (S20)

416

O

SUPERVISION BELLY BUTTON

Safety reversing, monitoring (S20)

417

I

INP. SHUNT FIELD

Shunt field (-)

4 (4)

Input signal to regulator, brake (and platform switch status)

Throttle

Service Manual

1998-05-04

English

F-code

Section

C-code

PT S6 6000 Hydraulic/pneumatic system IIssued by

Approved by

Version no

T-code

SSD

Fredrik Wigh

001

184,288

Hydraulic/pneumatic system Valid from serial number: T-code

Model

Serial number

Notes

184

LT 2200

319039AA-

9.5 km/h

288

LT 288

319039AA-

1 General The hydraulic system consists of a complete hydraulic unit, two lift cylinders and a PowerTrak cylinder. The PowerTrak cylinder has the task of increasing the drive wheel pressure when the machine is loaded, and in this way increase the tractive capacity and reduce the risk of the drive wheel slipping.

© BT Industries AB

Service Manual

1999-01-08

English

1 (4)

F-code

Section

C-code

PT S6 6000 Hydraulic/pneumatic system Version no

001

T-code

184,288

2 Hydraulic chart and list of symbols

2.1 List of Symbols

2 (4)

Symbol

Description

Function

Notes

1

Lift cylinders

Lifting the forks

2 pcs

2

PowerTrak cylinder

Increase the tractive capacity with a loaded machine

3

Pressure limit valve

4

Flow valve

5

Non-return valve

6

Filter

One filter on the pump’s suction side and one on the return

M3

Motor

Pump motor

P

Pump

2.5 ccpr Service Manual

1999-01-08

English

F-code

Section

C-code

PT S6 6000 Hydraulic/pneumatic system Version no

T-code

001

184,288

Symbol

Description

Function

Notes

S59

Switch

Input signal to the transistor panel that current limit switching shall be performed.

Only on transistor machines

T

Tank

Y41

Valve

1.2 litre Lowering valve for the forks

3 Operating description 3.1 Lifting the forks When the control for lifting the forks is actuated the pump contact makes and starts the pump motor. This pumps oil through the non-return valve (5) and onto both lift cylinders that lift the fork carriage.

When the machine has a load on the forks, oil will also flow to the PowerTrak cylinder, which increases the drive wheel pressure.

3.2 Lowering the forks When the control for lowering the forks is actuated the solenoid valve Y41 opens fully so that the oil in the pressure line can flow back into the oil tank via the flow valve (4).

3.3 Switch, S59 This switch is only fitted on transistor machines.

The task of the switch is to give a signal to the transistor panel, when current limit switching shall take place. This occurs when the load on the forks exceeds approximately 350-400 kg.

© BT Industries AB

Service Manual

1999-01-08

English

3 (4)

F-code

Section

C-code

PT S6 6000 Hydraulic/pneumatic system Version no

001

T-code

184,288

4 Adjustments 4.1 Adjusting the pressure limit valve The pressure limit valve is set to the correct value at the factory, but may need to be adjusted if the valve or the complete hydraulic unit is replaced.

The truck should be capable of lifting a load of between 22502300 kg.

• Cover nut.

• Adjuster screw, pressure limit.

Adjusting clockwise results in increased pressure.

Adjusting anticlockwise results in decreased pressure.

• Screw off the cover nut (1) using a 13 mm spanner.

• Place a load of 2200 kg on the forks and check that the machine can lift it.

• If the machine lifts 2200 kg, place a further 100 kg on the forks. Check whether the machine can lift the load.

• If the machine lifts 2300 kg, adjust the pressure limit by turning the adjuster screw (2) anticlockwise using a 4 mm allen key until the machine cannot lift the load.

4 (4)

Service Manual

1999-01-08

English