BT P20 Service Manual 178826-040 - PDF DOWNLOAD

Service Manual P20 Valid from serial number: 364690AA-

Order number: 178826-040 Issued: 2002-04-29 ITS

© BT Industries AB

GB

2

© BT Industries AB

C-code

T-code

Version

Date 2002-04-29

Service Manual P20

Valid from serial number 364690AAOrder number 178826-040

Approved by:

Contents Valid from serial number 364690AAOrder number 178826-040

T-code

C-code/Section

Date 2002-04-29

Version

Contents Technical data

1 ....................................................... 2 - 1

Introduction Maintenance

........................... 3 - 1

Safety regulations with maintenance work

1

Cleaning and washing

3

Safe lifting

4

Preventive maintenance

............................... 4 - 1

Maintenance schedule

1

Lubrication schedule

6

Oil and grease specifica tion Tools

.................... 5 - 1

.............................................................................. 6 - 1

Super Seal connectors

1

Electric drive motor

.......................................... 7 - 1

Component parts

1

Dismantling/assembling of motor from truck

3

Service/Repairs

4

Technical data

6

Drive unit/gear

....................................................... 8 - 1

Component parts

2

Leakage from top cover

4

Changing of the drive shaft’s sealing ring

4

Service Manual P20

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1–3

Contents C-code/Section

T-code

Version

Date 2002-04-29

Valid from serial number 364690AAOrder number 178826-040

Electro magnetic brake .................................. 9 - 1 Main components of the brake

1

Maintenance

2

Exchange of brake disc

3

Steering system

................................................. 10 - 1

Component parts, tiller arm

1

Adjustments

4

Tiller arm handle

5

Electrical systems ............................................ 11 - 1 Electrical parts

1

List of symbols and electrical wiring diagram

3

Functional description

11

Hour meter

13

Fault codes

14

Parameters

19

Part numbers

28

Transistor panel

28

Diagnostic and troubleshooting

29

Technical specifications – Curtis 1243

31

Hydraulic/pneumatic system .................. 12 - 1

1–4

Hydraulic chart and list of symbols

1

Adjusting the pressure limit valve

2

Service Manual P20

Approved by:

Contents Valid from serial number 364690AAOrder number 178826-040

T-code Date 2002-04-29

C-code/Section Version

PowerTrak cylinder ......................................... 13 - 1 Component parts

1

Dismantling of PowerTrak cylinder

2

Control/computer equipment

................ 14 - 1

General

1

Connection

1

Layout

2

Function

4

Specifications

Service Manual P20

12

Approved by:

1–5

Contents

1–6

C-code/Section

T-code

Version

Date 2002-04-29

Service Manual P20

Valid from serial number 364690AAOrder number 178826-040

Approved by:

Technical data Valid from serial number 364690AAOrder number 178826-040

T-code 662 Date 2002-04-29

C-code/Section M4 Version 001

Technical data Model

2

P20-6

P20-8

Type

TSL140S-DS30

TSL140S-DS40

Output, kW

1.4

1,7

Duty cycle

S2,60 min

S2,60 min

Minimum carbon brush length, mm

13

13

Nominal commutator diameter, mm

50

63

Minimum commutator diameter, mm

47

60

Resistance, shunt field winding, Ω at 25 C°

0,49

0,498 (26C°)

Resistance armature winding, Ω at 24 °C

0,0156

0,0161 (26C°)

Insulation resistance between the windings and motor casing

>= 1Mohm

>= 1Mohm

Weight, kg

14

17

Type

BFK457-08

BFK458-12

Braking force, Nm

16

32

Output, W

25

40

Resistance coil, Ω

23

14.4

Nominal play in actuated position, mm

0.2-0.4

0.3-0.5

Minimum thickness brake disc, mm

5.5

8.8

Thickness of a new brake disc, mm

7.0

10.0

Type

2-stage angle transmission

2-stage angle transmission

Gear ratio

19,14:1

19,14:1

Oil volume, litre

1.0

1.0

Oil type at normal temperature at temperature < -15oC

Hypoid olja SAE 80W/90 SAE 75W

Hypoid olja SAE 80W/90 SAE 75W

Drive motor

Broms

Transmission/drive gear

Service Manual P20

Approved by: L-G Andersson

2–1

Technical data C-code/Section M4 Version 001

T-code 662 Date 2002-04-29

Valid from serial number 364690AAOrder number 178826-040

P20-6

P20-8

Drive wheel, mm

Dia 215x70

Dia 215x70

Axle pressure without load, kg

374

374

Axle pressure at rated load, kg

565

565

Tightening torque for wheel bolts, Nm

65 Nm

65 Nm

Fork wheel, mm

Dia 85x75

Dia 85x75

Axle pressure without load, kg

2x65 (240)

2x65 (240)

Axle pressure at rated load, kg

2x790 (240)

2x790 (240)

Support castors, mm

Dia 125x40

Dia 125x40

Axle pressure without load

2X75 (240)

2x75 (240)

Axle pressure at rated load, kg

2x210 (240)

2x210 (240)

Output, kW

2.2

2.2

Duty cycle,%

10

10

Minimum carbon brush length, mm

12

12

Minimum commutator thickness/diameter, mm

4.7

4.7

Pressure at rated load, bar

150

150

Overflow pressure, bar

170

170

Pump flow, litre/minute

4.6

4,6

Tank volume, litre

1,0

1,0

Oil type: at normal temperature at temperature < -15oC

Hydraulic oil ISO-L-HM32 ISO-L-HV32

Hydraulic oil ISO-L-HM32 ISO-L-HV32

Drive motor circuits, A

125

125

Pump motor circuits, A

125

125

Control circuits, A

7,5

7,5

Model Wheels

Hydraulic system

Fuses

2–2

Service Manual P20

Approved by: L-G Andersson

Technical data Valid from serial number 364690AAOrder number 178826-040

Model

T-code 662 Date 2002-04-29

C-code/Section M4 Version 001

P20-6

P20-8

Dimensions LxWxH, mm

193x642x450-510

193x642x450-510

Capacity, Ah

240-320

240-320

Weigh, kg

210-250

210-250

Without load, km/t Without load, m/s

6,0 1.7

8,0 2.22

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

6,0 1,7

7.2 2.0

Lift without load, s

1.7

1.7

Lift with rated load, s

2.3

2.3

Lowering without load, s

1.4

1.4

Lowering with rated load, s

1.5

1.75

Driving without load, A

28

46

Driving with rated load, A

46

65

Lift without load, A

49

49

Lift with rated load, A

52

52

9%

9%

Medium Lång

660 1008

660 1008

Turning radius WA

1960

1960

Lift height

205

205

420

440

Battery compartment, Batteries

Driving speed

Lift/lowering speed

Power consumption

Incline climbing ability With rated load

Measurement, L2

Weight Truck without battery, Medium

Service Manual P20

Approved by: L-G Andersson

2–3

Technical data C-code/Section M4 Version 001

2–4

Service Manual P20

T-code 662 Date 2002-04-29

Valid from serial number 364690AAOrder number 178826-040

Approved by: L-G Andersson

Introduction Maintenance Valid from serial number 364690AAOrder number 178826-040

T-code 662 Date 2000-06-01

C-code/Section P1 Version 001

Introduction Maintenance

3

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: - 2-shifts: - 3-shifts:

08.00-17.00 (20 hr./week) 06.00-14.00, 14.00-22.00 (40 hr./week) 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.

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, short-circuiting/ burns can occur if a metal object comes into contact with live electrical connections.

Remove watches, rings or other types of metal jewellery.

• Always disconnect the battery by pulling out the battery isolator when carrying out maintenance work on the truck unless otherwise stated in this Service Manual • Always switch off the truck’s power supply before opening the covers on the drive unit or electrical system Service Manual P20

Approved by:

3–1

Introduction Maintenance C-code/Section P1 Version 001

T-code 662 Date 2000-06-01

Valid from serial number 364690AAOrder number 178826-040

• 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.

3–2

Service Manual P20

Approved by:

Introduction Maintenance Valid from serial number 364690AAOrder number 178826-040

T-code 662 Date 2000-06-01

C-code/Section P1 Version 001

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.

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.

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

Service Manual P20

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3–3

Introduction Maintenance C-code/Section P1 Version 001

T-code 662 Date 2000-06-01

Valid from serial number 364690AAOrder number 178826-040

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.

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 trestle-blocks and secured by a lifting device.

3–4

Service Manual P20

Approved by:

Preventive maintenance Valid from serial number 364690AAOrder number 178826-040

T-code 662 Date 2002-04-29

C-code/Section P2 Version 001

Preventive maintenance

4

Maintenance schedule I: Inspect, rectify and change if necessary. T: Tighten. C: Clean. L: Lubricate.

M: Control measurement, rectify if necessary

Pos. No.

Work to carry out Interval in hours

5

20

80

500

1000

3000

Interval in days/weeks/months

1d

1w

1m

6m

12m

36m

0000

Chassis

0000.1

Check all links and locking pins

l

0000.2

Check wear on cover/battery locking

l

0000.3

Check of cracking and damage

l

0000.4

Check the cover locks

I

0000.5

Check finger guard

I

0000.6

Check signs and stickers

I

0380

Fork carriage

0380.1

Check for crack formation and damage

l

0380.2

Check clearance in bushes and links

I

0380.3

Press grease into grease nipples (Option)

0380.4

Check the lift limit switch

0560

Platform and mountings

0560.1

Check for any cracks or damage

l

0560.2

Check gas damper and cup springs

l

1700.

Drive motor

1700.1

Check clearance in connections

1700.2

Check the carbon brushes in the drive motor

M

1700.3

Clean the drive motor

C

1700.4

Re-tighten the attachment bolts

1700.5

Check for abnormal noise in bearing

Service Manual P20

I/L l

I/T1

I/T

T2 l

Approved by: L-G Andersson

4–1

Preventive maintenance C-code/Section P2 Version 001

T-code 662 Date 2002-04-29

Valid from serial number 364690AAOrder number 178826-040

I: Inspect, rectify and change if necessary. T: Tighten. C: Clean. L: Lubricate.

M: Control measurement, rectify if necessary

Pos. No.

Work to carry out Interval in hours

5

20

80

500

1000

3000

Interval in days/weeks/months

1d

1w

1m

6m

12m

36m

2550

Drive gear

2550.1

Check for leakage

2550.2

Check the oil level

I

2550.3

Check for abnormal noise

I

2550.4

Check the attachment and clearance in steering bearing

I

2550.5

Change the oil in the drive gear

3100.

Brake

3100.1

Clean

3100.2

Check for wear on the brake disc

M

3100.3

Check the clearance in disengaged position

M

3500

Wheels

3500.1

Remove string and other rubbish

3500.2

Check the drive wheel for wear and the tightening torque on bolts

I/T

3500.3

Check that the support wheel turns and rotates freely

I

3500.4

Check for wear on the support wheel

I

4110

Tiller arm

4110.1

Check the mountings

4110.2

Check the power in the gas damper

5000

Electrical functions

5000.1

Check the operation of the brake microswitch in the upper and lower brake positions.

Lubricate the switch head.

I

5000.2

Check the function of the collision safety switch

I

5000.3

Check the function of the gate switches

I

4–2

I3

I

L4

L

C

Service Manual P20

I

I I

I/L

I Approved by: L-G Andersson

Preventive maintenance Valid from serial number 364690AAOrder number 178826-040

T-code 662 Date 2002-04-29

C-code/Section P2 Version 001

I: Inspect, rectify and change if necessary. T: Tighten. C: Clean. L: Lubricate.

M: Control measurement, rectify if necessary

Pos. No.

Work to carry out Interval in hours

5

20

80

500

1000

3000

Interval in days/weeks/months

1d

1w

1m

6m

12m

36m

5000.4

Check the function of platform switch

I

I

5000.5

Check the function of the horn

I

I

5000.6

Check for wear on cabling

5000.7

Check the function of the driver’s control

I

I

5000.8

Check the error code log and operating times

I

I

5110

Battery

5110.1

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

M

5110.2

Check connections to battery, truck and charger

I

5110.3

Check that the cell and pole guards are undamaged

I

5110.4

Check the fluid density and temperature

M

5110.5

Remove overflow fluid from the battery trough

C

5110.6

Check the battery locking

5400

Power system

5400.1

Cleaning and checking of mounting in chassis

C/ T1

5400.2

Re-tighten cable connections

T1

5400.3

Check the contactor points on K10 and K30

I

5400.4

Check the movement of the contactors

I

5400.5

Check the cable insulation

I

5700

Electronic circuit board

5700.1

Check connectors and cables

5700.2

Check all segments on the display

Service Manual P20

I

I

T1

I

C/T

I I

Approved by: L-G Andersson

4–3

Preventive maintenance C-code/Section P2 Version 001

T-code 662 Date 2002-04-29

Valid from serial number 364690AAOrder number 178826-040

I: Inspect, rectify and change if necessary. T: Tighten. C: Clean. L: Lubricate.

M: Control measurement, rectify if necessary

Pos. No.

Work to carry out Interval in hours

5

20

80

500

1000

3000

Interval in days/weeks/months

1d

1w

1m

6m

12m

36m

6100

Hydraulic system

6100.1

Check hoses and connections for wear

I

6100.2

Check hoses for wear and damage

I

6100.3

Check the oil tank for cracks, leakage and damaged mountings

I

6100.4

Check that the oil level is correct

6100.5

Change the oil and clean the filter

6600.

Lift cylinder

6600.1

Check for leakage

I

6600.2

Check the mountings

I

6680

Power Trak

6680.1

Check if there is any damage or cracks on the PowerTrak spring

6680.2

Grease in the contact pressure spring’s guides

I L5

L

I C/L

1 = The connections are re-tightened for the first time after 80 h, and then every 1000 h/12 months.

2 = The attachment bolts are re-tightened after 80 h/ 1 month to 45 Nm. 3 = Check for leakage in conjunction with the first oil change.

4 = The oil is changed for the first time after 80 h/1 month, and then every 3000 h/36 months 5 = The oil is changed and the filter cleaned for the first time after 80 h/ 1 month, and then every 1000 h/12 months When points with higher hour intervals are carried out the points with lower hour intervals should also be carried out unless otherwise specified above.

4–4

Service Manual P20

Approved by: L-G Andersson

Preventive maintenance Valid from serial number 364690AAOrder number 178826-040

T-code 662 Date 2002-04-29

C-code/Section P2 Version 001

5000

5000

6680 4110 5110 5700

5000

0380

5400

6600

3100 1700 6100

0560 0000

2550

5000 3500

Service Manual P20

Approved by: L-G Andersson

4–5

Preventive maintenance C-code/Section P2 Version 001

T-code 662 Date 2002-04-29

Valid from serial number 364690AAOrder number 178826-040

Lubrication schedule Pos. No.

Service point

Interval/Operating hours

0380

Lubricating nipples (Option)

2550

Drive gear

O4

C

6100

Hydraulic system

O5

O

80 h

500

1000 h

3000 h

L

L = Lubrication

C = Check

Type of lubricant E

O

C B

O = Oil change

4 = The oil is changed for the first time after 80 h/1 month, and then every 3000 h/36 months 5= The oil is changed and the filter cleaned for the first time after 80 h/1 month, and then every 1000 h/12 months.

6100

2550

0380

4–6

Service Manual P20

Approved by: L-G Andersson

Oil and grease specifica tion Valid from serial number 364690AAOrder number 178826-040

T-code 662 Date 2002-04-29

C-code/Section P3 Version 001

Oil and grease specifica tion Pos.

Type of lubricant

Specification

5

Application

> -15° C

< -15o C

A

Grease

BT 26777 (Spray)

BT 26777 (Spray)

Bearings and bushes

B

Hydraulic oil

ISO-L-HM32

ISO-L-VG 32

Hydraulic system

C

Transmission oil

Hypoid oil SAE 80W/90

Hypoid oil SAE 75W

Gears

D

Grease

Staburags NBU 8EP

Staburags NBU 8EP

Guide bearing

E

Grease

BT 73942XX5 TOTAL N3942

BT 73942XX5 TOTAL N3942

Lubricating nipples, Contact pressure spring

Service Manual P20

Approved by: L-G Andersson

5–1

Oil and grease specifica tion C-code/Section P3 Version 001

5–2

Service Manual P20

T-code 662 Date 2002-04-29

Valid from serial number 364690AAOrder number 178826-040

Approved by: L-G Andersson

Tools Valid from serial number 364690AAOrder number 178826 -040

T-code 662 Date 2000-06-01

C-code/Section P4 Version 001

Tools

6

Super Seal connectors 1

3 3 2 Figure

Number

Application

159232

Tool for application of pins/ sleeves

159229

Tool for release of lock (1)

159230

Tool for application of secondary locking 2-pole (2)

159231

Tool for application of secondary locking 4-pole (2)

159228

Tool for removal of pins/sleeves (3)

Service Manual P20

Approved by: L-G Andersson

6–1

Tools C-code/Section P4 Version 001

T-code 662 Date 2000-06-01

Valid from serial number 364690AAOrder number 178826 -040

AMP connectors

Figure

2

6–2

Number

Application

31-151080

Tool for removal of pins/sleeves

1=163787 2=163788

Tool for application of sleeves

1=163789 2=163790 3=163791

Tool for application of pins 1: For 0.2-0.5 mm2 2: For 0.5-1.0 mm2 3: For 1.5-2.5 mm2

1

Service Manual P20

Approved by: L-G Andersson

Tools Valid from serial number 364690AAOrder number 178826 -040

T-code 662 Date 2000-06-01

C-code/Section P4 Version 001

Other tools Figure

Number

Application

156263

Service instrument (CAN)

1=163793 2=163792

Service instrument for program modification

1=155619-001 2=166161 3=166473

1= Service instrument for Curtis transistor panel 2= Cable for Curtis 1243 and 1207A 3= Cable for Curtis 1207

When ordering 155619-001 both cables are received

Service Manual P20

Approved by: L-G Andersson

6–3

Tools C-code/Section P4 Version 001

Figure

6–4

T-code 662 Date 2000-06-01

Valid from serial number 364690AAOrder number 178826 -040

Number

Application

08-13022

Puller, drive gear

Service Manual P20

Approved by: L-G Andersson

Electric drive motor Valid from serial number 364690AAOrder number 178826-040

T-code 662 Date 2002-04-29

C-code/Section 1760 Version 001

Electric drive motor

7

Component parts 16 21 19

14

20

18

13

17 10

15

12 11

8

9

7 6 5 4 3 1 2

Pos

Description

Note

1

Screw

M6x25

2

Bearing shield

3

Locking ring

4

Bearing

5

Carbon brush bridge

6

Screw

M5x12

7

Screw

M5x20

8

Carbon brush

9

Rotor

Service Manual P20

Approved by: L-G Andersson

7–1

Electric drive motor C-code/Section 1760 Version 001

7–2

T-code 662 Date 2002-04-29

Pos

Description

10

Key

11

Plug

12

Stator

13

Cable

14

Cable

15

Bearing shield

16

Screw

17

Seal

18

Bearing

19

Washer

20

Locking ring

21

Locking ring

Service Manual P20

Valid from serial number 364690AAOrder number 178826-040

Note

M6x25

Approved by: L-G Andersson

Electric drive motor Valid from serial number 364690AAOrder number 178826-040

T-code 662 Date 2002-04-29

C-code/Section 1760 Version 001

Dismantling/assembling of motor from truck Dismantling • Switch off the truck and pull out the battery plug.

• Remove the covers for the motor compartment.

• Release the cables for the motor and tiller arm.

• Unscrew the four nuts for the attachment of the motor to the drive gear.

• Loosen the cables for the key switch and emergency switch. Pull out all the cables from the cover’s cable duct.

• Loosen the cover over the motor compartment and the tiller arm’s mounting from the motor. Remove the cover over the motor compartment together with the tiller arm.

• Carefully lift the motor straight up, without damaging the sealing surfaces to the drive gear and place the motor on a clean surface.

• Protect the drive gear from impurities by covering over its opening in an appropriate manner, e.g. with a piece of plastic.

The requisite service and repair of the motor can now be carried out.

Assembling • Assembling is carried out in the reverse order.

• Carefully lift down the motor in the drive gear to avoid damaging the seals and gear wheels.

• Tighten the nuts on the studs to the prescribed torque, 26.6 Nm. • Fit and adjust the brakes as per the instructions. Screw tight the cover and tiller arm, and connect the cables that were previously removed. Check that the polarity is correct.

• The function of the brakes should be checked before the truck is moved.

Service Manual P20

Approved by: L-G Andersson

7–3

Electric drive motor C-code/Section 1760 Version 001

T-code 662 Date 2002-04-29

Valid from serial number 364690AAOrder number 178826-040

Service/Repairs Dismantling of motor 16 21 19

14

20

18

13

17 10

15

12 11

8

9

7 6 5 4 3 1 2

• Release the brake disc’s companion flange by first removing the locking ring together with the washer in the end of the rotor shaft.

The companion flange can now be lifted off. It may be necessary to unclamp it with an appropriate tool.

• Remove the four plugs that cover the carbon brushes, move the springs on the carbon brushes to one side and pull out the carbon brushes.

• Dismantle the commutator end’s bearing shield (2) together with the carbon brush bridge (5) and carbon brushes (8) by unscrewing the eight screws (1). Now put down the motor with a firm resting point against the edge of the bearing shield, and carefully tap on the rotor shaft’s end with a rubber mallet.

• Dismantle the drive end’s bearing shield (15) together with the rotor (9). Make sure not to damage the motor windings when the rotor is removed from the motor housing.

7–4

Service Manual P20

Approved by: L-G Andersson

Electric drive motor Valid from serial number 364690AAOrder number 178826-040

T-code 662 Date 2002-04-29

C-code/Section 1760 Version 001

• After dismantling the motor’s bearing shields and removing the rotor from the motor housing, the gear wheel in the rotor’s drive end is removed. This is done by unscrewing the nuts on the gear wheel and then pulling the gear wheel off with a puller. Note that the gear wheel is locked with Loctite to the rotor shaft.

• Now release the inner locking ring together with the underlying washer. Pull out the rotor shaft from the bearing (18).

• Release the outer locking ring together with its washer, and remove the bearing from the bearing shield.

• Remove the bearing shield’s seal (17) and carefully clean the bearing shield.

• Fit a new seal in the bearing shield.

Assembling of motor Assemble the motor in the reverse order.

• Carefully check that the rotor can move freely in the direction of rotation and that the carbon brushes are flush with the commutator.

• Check the motor’s insulation resistance (between respective winding and the motor housing). For a new motor this should lie between 2 - 3 Mohm. When a used motor has been exposed to impurities an insulation resistance down to approx. 1 Mohm is acceptable.

• Fit a new O-ring in the drive shaft end’s bearing shield and a new seal on the collar of the bearing shield.

Cleaning An extremely critical factor to ensure correct functioning of the motor is that it is kept as clean as possible. The motor and the motor compartment must be regularly checked for dust, oil, and other impurities.

A vacuum cleaner with an appropriate nozzle can be used to clean the motor if the motor windings and inner compartment are dry Compressed air can be used in combination with a vacuum cleaner. In which case the compressed air must be clean and dry.

A cloth of non-fluffing material should be used if the windings have a coating. The cloth can also be moistened with a grease-dissolving, organic and volatile detergent that does not damage the windings. Use detergent sparingly to avoid it penetrating into the parts of the motor.

Residual detergent should be removed with an appropriate solvent, if it leaves a greasy surface.

If the parts of the motor are heavily fouled it may be necessary to use a solvent that is sprayed onto the parts. It is important that the detergent is applied in a way to prevent dirt from penetrating into the parts of the motor, especially for the rotor.

Service Manual P20

Approved by: L-G Andersson

7–5

Electric drive motor C-code/Section 1760 Version 001

T-code 662 Date 2002-04-29

Valid from serial number 364690AAOrder number 178826-040

One method of cleaning the rotor is to dip it in solvent. If this is done then the rotor must always be dried with the application of heat. There must be adequate ventilation during the drying process, and the drying should continue until a number of measurements of the insulation resistance provide equivalent and approved results.

Technical data

7–6

Type of machine

P20/6

P20/8

Type

TSL140S-DS30

TSL140B-DS40

Output (kW)

1,4

1,7

Intermittence

S2 60 min.

S2 60 min.

Minimum length of carbon brush (mm)

11

11

Minimum commutator diameter (mm)

47

60

Resistance, shunt field winding Ω at 26 C°

0,49

0,498

Resistance, armature winding,Ω at 26C°

0,0156

0,0161

Insulation resistance between windings and motor housing

>= 1Mohm

>= 1Mohm

Weight (kg)

14

17

Service Manual P20

Approved by: L-G Andersson

Drive unit/gear Valid from serial number 364690AAOrder number 178826-040

T-code 662 Date 2000-06-01

C-code/Section 2550 Version 001

Drive unit/gear

8

2 3 4 5

6

01

7 8

24

9 27

25 26

10 11

28

13 12 14 32 29

15

18

16

30

31

19

17 20

23 21

Service Manual P20

22

Approved by: L-G Andersson

8–1

Drive unit/gear C-code/Section 2550 Version 001

T-code 662 Date 2000-06-01

Valid from serial number 364690AAOrder number 178826-040

Component parts

8–2

Pos

Description

01

Drive gear complete

2

Air valve

3

Cover

4

Dip stick

5

Washer

6

Gasket

7

Nut

8

Washer

9

Gear wheel

10

Conical roller bearing

11

Shims

12

Screw

13

Shims

14

Conical roller bearing

15

Pinion/ Crown gear

Cog clearance 0.09-0.15 mm Pretension bearing with 2-5/100 Stamped size on pinion adjusted with shims

16

Nut

Tightening torque 300 Nm Locked with punch mark

17

Shims

18

Conical roller bearing

19

Shims

20

Screw

Service Manual P20

Note

Tightening torque 70 Nm Locked with punch mark

Primary gear

Top cover and gear housing Tightening torque 26.6 Nm Lock with Loctite 242

Bottom cover and gear housing Tightening torque 26.6 Nm Lock with Loctite 242

Approved by: L-G Andersson

Drive unit/gear Valid from serial number 364690AAOrder number 178826-040

T-code 662 Date 2000-06-01

C-code/Section 2550 Version 001

Pos

Description

Note

21

Screw

Bottom cover and gear housing Tightening torque 26.6 Nm Lock with Loctite 242

22

Cover

23

Gasket

24

Gear wheel

25

Washer

26

Nut

Tightening torque 30 Nm Locked with punch mark Lock with Loctite 603

27

Screw

Motor and gear housing

28

Nut

Tightening torque 26.6 Nm Lock with Loctite 242

29

Conical roller bearing

30

Shims

31

Seal

32

Drive shaft

Motor gear

Technical data Type of truck

W18/20 P20

Type of gear

2-step angle gear

Gear ratio

14,20:1

Oil volume, litres

1,75

Oil type

Hypoid oil

Viscosity, normal temperature

SAE 80W90

Viscosity, <-15°C

SAE 75W

Service Manual P20

Approved by: L-G Andersson

8–3

Drive unit/gear C-code/Section 2550 Version 001

T-code 662 Date 2000-06-01

Valid from serial number 364690AAOrder number 178826-040

Leakage from top cover Dismantling • Lift up the truck, and block up to ensure that it is stable.

• Unscrew the drive wheel.

• Unscrew the M8 nuts (28), that hold the gear and motor, with a box wrench. Support the gear so that it does not drop.

• Release the M8 bolts (12), that hold the cover (3), with a 6 mm hex socket wrench.

• Change the gasket (6).

Assembling is carried out in the reverse order • Tighten the four M8 bolts and the four M8 nuts to a torque of 26.6 Nm Lock with Loctite 242.

• Tighten the drive gear’s 5 bolts to a torque of 65 Nm.

Changing of the drive shaft’s sealing ring The drive shaft’s sealing ring can be changed with the gear mounted in the truck.

Follow the instructions below if oil is leaking from the drive shaft.

Dismantling • Unscrew the drive wheel 1).

• Remove the lower cover and drain off the oil (22).

• Release the drive shaft nut. Remove the nut and washer (16,17).

• Carefully tap out the drive shaft with a brass drift and hammer (32).

• Pull off the bearing from the drive shaft with tool 08-13022 (29).

• Check that the bearing washers are not damaged. If they have been damaged by the puller tool, measure the total thickness of the shim washers and change them before assembling (30).

• Remove the sealing ring from the drive shaft (31).

8–4

Service Manual P20

Approved by: L-G Andersson

Drive unit/gear Valid from serial number 364690AAOrder number 178826-040

T-code 662 Date 2000-06-01

C-code/Section 2550 Version 001

Assembling Assembling of the gear after changing the drive shaft’s sealing ring is carried out in the reverse order to dismantling.

Pay special attention to the following during assembling: • Fill the sealing ring with grease after fitting it on the drive shaft.

• Make sure that only undamaged shim washers with the same total thickness as the originals are put on the drive shaft.

• Press the bearing on the drive shaft and make sure not to damage the bearing’s shim washers.

• When fitting the drive shaft with bearing, shim washers and seal, make sure that the shaft keys correspond with the crown gear’s keys and that the bearing and seal are correctly positioned in the gear housing before the shaft is pressed in completely.

• Put the distance ring on the drive shaft end, and put on the shaft nut.

Always use a new nut. Tighten the shaft nut to a torque of 300 Nm and lock it with a punch mark in the middle. The drive shaft nut should be lubricated before it is put on the shaft.

• Change the gasket before fitting the bottom cover. Make sure that it is not damaged. Fit the cover and tighten the bolts to a torque of 26.6 Nm. The bolts should be lubricated before they are fitted. Fill up with oil in accordance with the instructions for replenishing the oil.

Fit the drive gear and tighten the bolts to a torque of 65 Nm.

Service Manual P20

Approved by: L-G Andersson

8–5

Drive unit/gear C-code/Section 2550 Version 001

8–6

Service Manual P20

T-code 662 Date 2000-06-01

Valid from serial number 364690AAOrder number 178826-040

Approved by: L-G Andersson

Electro magnetic brake Valid from serial number 364690AAOrder number 178826-040

T-code 662 Date 2000-06-01

C-code/Section 3370 Version 001

Electro magnetic brake

9

Main components of the brake 9

1

8 2

7

3

6 4

5

Pos No

Description

1

Magnetic coil

2

Electrical wire

3

Pressure plate

4

Pressure springs

5

Friction plate

6

Adjustment locking nut

7

Brake disc

8

Mounting bolts

9

Hub

Service Manual P20

Approved by: L-G Andersson

9–1

Electro magnetic brake C-code/Section 3370 Version 001

T-code 662 Date 2000-06-01

Valid from serial number 364690AAOrder number 178826-040

Maintenance Basically the brake is maintenance free in normal work environments.

However it is recommended according to the preventive maintenance schedule to check the brake disc for wear and the gap between the magnetic coil housing and the pressure plate on a regular basis.

Basic Adjustment of gap 9,5 Nm

0,3

The nominal gap between the coil housing and the pressure plate, in applied position, shall be 0.3 mm. The maximum gap before readjustment is necessary is 0.8 mm.

Adjustment procedure: • Loosen the tension of the three mounting bolts .

• Turn the lock nuts anti-clockwise and tighten the bolts slightly while checking the gap on three points with a 0.3 mm feeler gauge.

• Tighten the mounting bolts 9,5 Nm and recheck the gap with the feeler gauge.

9–2

Service Manual P20

Approved by: L-G Andersson

Electro magnetic brake Valid from serial number 364690AAOrder number 178826-040

T-code 662 Date 2000-06-01

C-code/Section 3370 Version 001

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

• Disconnect the electrical wires of the brake.

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

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

• 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 chapter “Basic Adjustment of gap”.

• Reconnect the electrical wiring.

Service Manual P20

Approved by: L-G Andersson

9–3

Electro magnetic brake C-code/Section 3370 Version 001

9–4

Service Manual P20

T-code 662 Date 2000-06-01

Valid from serial number 364690AAOrder number 178826-040

Approved by: L-G Andersson

Steering system Valid from serial number 364690AAOrder number 178826-040

T-code 662 Date 2002-04-29

C-code/Section 4000 Version 001

Steering system

10

Component parts, tiller arm Serial number 364690AA-432919AA 1 2 3

4

5 6

7

8

9 10

14

12

13

16 18

11

15

17

19 20 21 22 23

Service Manual P20

Approved by: L-G Andersson

10 – 1

Steering system C-code/Section 4000 Version 001

T-code 662 Date 2002-04-29

Valid from serial number 364690AAOrder number 178826-040

Serial number 364690AA-432919AA

10 – 2

Pos

Description

Note

1

Screw

4

2

Washer

3

Handle

4

Screw

4

5

Washer

2

6

Cable holder

7

Nut

8

Gas damper

9

Bracket

10

Stop screw

11

Screw

12

Ball joint

13

Screw

14

Distance

15

Bush

2

16

Damper

2

17

Axle

18

Cam

19

Distance

20

Screw

21

Distance

22

Distance

23

Switch

Service Manual P20

4

S 10

Approved by: L-G Andersson

Steering system Valid from serial number 364690AAOrder number 178826-040

T-code 662 Date 2002-04-29

C-code/Section 4000 Version 001

Serial number 432920AA1 2 3

4

5 6

8

7 9

13

11

12

15 17

10

14

16

18 19 20 21 22

Service Manual P20

Approved by: L-G Andersson

10 – 3

Steering system C-code/Section 4000 Version 001

T-code 662 Date 2002-04-29

Valid from serial number 364690AAOrder number 178826-040

Serial number 432920AA-

Pos

Description

Note

1

Screw

4

2

Washer

3

Handle

4

Screw

4

5

Washer

2

6

Cable holder

7

Gas damper

8

Bracket

9

Stop screw

10

Screw

11

Ball joint

12

Screw

13

Distance

14

Bush

2

15

Damper

2

16

Axle

17

Cam

18

Distance

19

Screw

20

Distance

21

Distance

22

Switch

4

S 10

Adjustments Adjusting of brake microswitch Switch (23) is always adjusted to its lowest position.

• Unscrew the screws (13, 20) that hold the switch and the distance.

• Press down the switch and tighten the screws.

• Check that the switch is actuated by the cam (18) in the arm’s top and bottom position.

10 – 4

Service Manual P20

Approved by: L-G Andersson

Steering system Valid from serial number 364690AAOrder number 178826-040

T-code 662 Date 2002-04-29

C-code/Section 4000 Version 001

Tiller arm handle 28 29

27 26 24 25

14 23 22

17 18

21

16

20

19

15 14 14

30 31 10 9 8

32

35

14

12 11

13

33 34 5

7

6

4

1

2 3

Pos

Description

1

Screw

2

Cover

3

Handle

4

Electronic circuit board

5

Screw

6

Display card

7

Top cover

8

Pushbutton

9

Signal switch

10

Signal button

11

Display glass

12

Arm

13

Pushbutton

14

Plate

15

Spring

Service Manual P20

Note Keyboard option

Option

Lift/Lower

Approved by: L-G Andersson

10 – 5

Steering system C-code/Section 4000 Version 001

T-code 662 Date 2002-04-29

Valid from serial number 364690AAOrder number 178826-040

Pos

Description

Note

16

Pushbutton

Not used

17

Arm

18

Holder

19

Spring

20

Control switch

21

Axle

22

Sliding bearing

23

Control stop

24

Arm

25

Spring holder

26

Spring

27

Spring holder

28

Sliding bearing

29

Control switch

30

Button for safe reversing

31

Arm

32

Spring

33

Lower cover

34

Screw

M4x40

35

Screw

2xM5x45 - 2xM5x60

Dismantling/Assembling • Dismantle cover (2), (keyboard option).

• Remove the screws (35), hold top cover firm (7).

• Disconnect the cable connected to the electronic circuit board (4).

• Remove the screws (34).

• Carefully lift off the lower cover (33), and place a finger between the lower cover (33) and button (30) to hold the button (30) in place.

Assembling is carried out in the reverse order.

NOTE! Static electricity!

Risk of static discharge that can damage the electronics.

Make sure to take the necessary precautions before working with the electronics.

10 – 6

Service Manual P20

Approved by: L-G Andersson

Steering system Valid from serial number 364690AAOrder number 178826-040

T-code 662 Date 2002-04-29

C-code/Section 4000 Version 001

Change from ignition key to keyboard (2) • Connect the CAN-key to the truck.

• Enter parameter mode (P).

• Change parameter 39 to value = 3 or 4.

• Set the required PIN-code by using parameter 10.

• Switch off the truck.

• Dismantle the cover(2) on the tiller arm.

• Fit the keyboard.

• Remove the ignition key, fit the strap.

• Fit the cover in the key hole.

• Start the truck using the chosen PIN-code.

Change from keyboard to ignition key (2) • Connect the CAN-key to the truck.

• Enter parameter mode (P).

• Change parameter 39 to value = 1 or 2.

• Switch off the truck.

• Remove the keyboard (2) on the tiller arm.

• Fit the cover.

• Remove the strap.

• Remove the cover.

• Fit the ignition key.

• Start the truck.

Changing of signal button/switch (9, 10) • Dismantle the button as per the diagram.

• Disconnect the connection for the switch on the electronic circuit board (4).

• Press out the switch from its mounting.

Assembling is carried out in the reverse order.

Service Manual P20

Approved by: L-G Andersson

10 – 7

Steering system C-code/Section 4000 Version 001

T-code 662 Date 2002-04-29

Valid from serial number 364690AAOrder number 178826-040

Changing of lift/lowering button (13) • Remove the button by placing a screwdriver in the hole (A) as per the diagram below.

A

A

• Unscrew the holder (18) so that the arm (12) comes loose.

Assembling is carried out in the reverse order.

Changing of pushbutton (16) • Press the button by hand sideways.

• Place a screwdriver as per the diagram and carefully pry the button loose.

• Unscrew the button’s holder and arm.

Assembling is carried out in the reverse order.

10 – 8

Service Manual P20

Approved by: L-G Andersson

Electrical systems Valid from serial number 364690AAOrder number 178826-040

T-code 662 Date 2002-04-29

C-code/Section 5000 Version 001

Electrical systems

11

Electrical parts S10 S17

S21 S19

Y1 S31 Y41 X5 M3

X1 F50 F51 F1

Y41

R1 K10 F3 M1

K30 A1 H1

S19

Service Manual P20

Approved by: Joakim Carleborn

11 – 1

Electrical systems C-code/Section 5000 Version 001

T-code 662 Date 2002-04-29

Valid from serial number 364690AAOrder number 178826-040

A7

11 – 2

Service Manual P20

Approved by: Joakim Carleborn

Electrical systems Valid from serial number 364690AAOrder number 178826-040

T-code 662 Date 2002-04-29

C-code/Section 5000 Version 001

List of symbols and electrical wiring diagram Symbol

Description

Function

Notes

A1

Transistor regulator

A5

Electronic card

A6

Display

A7

Keypad

PIN-number login

Option

F1

Fuse

Drive motor circuit

125 A

F3

Fuse

Pump motor circuit

125 A

F 50

Fuse

Operating circuit A5

7,5 A

F 51

Fuse

Operating circuit A1

7,5 A

F 52

Fuse

Optional equipment

Option

G1

Battery

H1

Horn

K10

Contactor

Main contactor

K30

Contactor

Pump motor

M1

Motor

Drive motor

M3

Motor

Pump motor

R1

PTC-resistor

Power supply

S1

Switch

Option

S2

Switch

Option

S3

Switch

Option

24 V

Service Manual P20

15 Ohm

Approved by: Joakim Carleborn

11 – 3

Electrical systems C-code/Section 5000 Version 001

T-code 662 Date 2002-04-29

Symbol

Description

S4

Switch

Option

S5

Switch

Option

S6

Switch

Option

S10

Switch

Travel brake

S17

Switch

Key

S18

Switch

Horn button

S19

Switch

Man on platform

S20

Switch

Safety reversing

S21

Switch

Emergency switch off

S31

Switch

Lift height limiter

S34

Switch

Fork lifting

S41

Switch

Fork lowering

S53

Switch

Gates

S59

Switch

Platform in upper position

Y1

Brake

Y41

Magnetic valve

Fork lowering

X1

Connector

Battery

X41

Connection point

CAN-communication

11 – 4

Function

Valid from serial number 364690AAOrder number 178826-040

Service Manual P20

Notes

Brake lever

Option

Approved by: Joakim Carleborn

20

F

R1

MAIN CONTACTOR 2

K10 1

EXTERNAL EQUIPMENT

Y41

IO

O

A2

K10 A1

IO

X22

X21

BIO

X12

S10 X11

Y1

BI

9 1

O

A2

K30 A1

3

HO

Y

H1

1

PWM

2 P

P1

AI

3

3

S19 2

AI

S59

I

3

2

S53

S31

3

2

1

2 3 4

3

S18 HORN S41 FORK DOWN

S34 FORK LIFT S18 HORN

SPEED REFERENCE VALUE

S20 2 24 V DC SAFETY REVERSING

X1 40

K30 2

A2

N3

A1

10

S1

A1 A

M1

S2

A2

5

4

S19 S59 S53 S53 S31 S31

Approved by: Joakim Carleborn

WIRING DIAGRAM

ELSCHEMA

BENÄMNING/TITEL

MAN ON PLATFORM PLATFORM UP GATES WALK GATES RIDE LIFT LIMIT NORMAL LIFT LIMIT TOP

178311

RITN. NR/DRG. No

HIGH LOW LOW HIGH HIGH LOW

T-code 662 Date 2002-04-29

X1

G1 24V

PTC 15 OHM

F3

F1

HO=Horn Out

IO=Digital In or Out

BI=Brake In BIO=Brake In or Out

O=Digital Out

PWM=PWM Out

I=Digital In

AI=Analog In

2

OUT. MAGNET VALVE

F51

2

24

S

R

X41

4

OUT. MAIN CON

F50

1

EMERGENCY SWITCH S21

2

3

OUT. BRAKE B

21

ELECTRONIC CARD TILLER ARM

Valid from serial number 364690AAOrder number 178826-040

6

1

MOTOR CONTROLLER CURTIS

22

5

OUT. BRAKE A

38

12

INP. BRAKE

64

6 OUT. PUMP

31

7 OUT. HORN

57

9 OUT. MAGNET VALVE PWM

31

10 INP. ANALOG

45

11 INP. MAN ON PLATFORM

39

13 INP. PLATFORM UP

63

14 INP. GATES WALK/RIDE

65

15 INP. LIFT LIMIT

M

16 24 V DC

66

1 CAN HIGH

58

8 CAN LOW

S2

Service Manual P20 S1

4 POWER ON

49

3 Tx

119

1 Tx

120

2 GNO

118

KEY S17

Electrical systems C-code/Section 5000 Version 001

Electrical wiring diagram

Serial number 364690AA-432919AA

11 – 5

Electrical systems C-code/Section 5000 Version 001

T-code 662 Date 2002-04-29

Valid from serial number 364690AAOrder number 178826-040

Electrical wiring diagram 1(5)

A2/E2

D1/E1

X10

X10

X10

Serial number 432920AA-

11 – 6

Service Manual P20

Approved by: Joakim Carleborn

Electrical systems Valid from serial number 364690AAOrder number 178826-040

T-code 662 Date 2002-04-29

C-code/Section 5000 Version 001

Electrical wiring diagram 2(5) Serial number 432920AA-

Service Manual P20

Approved by: Joakim Carleborn

11 – 7

Electrical systems C-code/Section 5000 Version 001

T-code 662 Date 2002-04-29

Valid from serial number 364690AAOrder number 178826-040

Electrical wiring diagram 3(5)

11 – 8

X5

X5

X5

X5

S21

Serial number 432920AA-

Service Manual P20

Approved by: Joakim Carleborn

Electrical systems Valid from serial number 364690AAOrder number 178826-040

T-code 662 Date 2002-04-29

C-code/Section 5000 Version 001

Electrical wiring diagram 4(5) Serial number 432920AA-

Service Manual P20

Approved by: Joakim Carleborn

11 – 9

Electrical systems C-code/Section 5000 Version 001

T-code 662 Date 2002-04-29

Valid from serial number 364690AAOrder number 178826-040

Electrical wiring diagram 5(5) Serial number 432920AA-

11 – 10

Service Manual P20

Approved by: Joakim Carleborn

Electrical systems Valid from serial number 364690AAOrder number 178826-040

T-code 662 Date 2002-04-29

C-code/Section 5000 Version 001

Functional description Starting the truck • Battery connector plugged in.

• S21 closed.

• S17 on.

Driving without using platform and gates, speed ≤ 6 km/h

A1 BS1 T1

Ish

Ia

• S59 open.

MShunt

+

S2 A2

• S10 closed.

A A1

T2

K10

• L1 activated in any direction.

B+

Driving from platform without using gates, speed ≤ 6 km/h • S 19 closed.

• S10 closed .

• L1 activated in any direction.

Driving from platform and using gates, speed ≤ 8 km/h • S 19 closed.

• S 53 closed.

• S10 closed .

• L1 activated in any direction.

Service Manual P20

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11 – 11

Electrical systems C-code/Section 5000 Version 001

T-code 662 Date 2002-04-29

Valid from serial number 364690AAOrder number 178826-040

Neutral speed reduction • L1 to neutral position, motor starts to work as generator. Brake energy comes back to battery.

• Load sensor P1 determines speed reduction force.

• Y1 will be applied when the truck comes to a stand still even if the tiller is in drive position.

Picture 3 Energy back to the battery.

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

A1 BS1

T1 Ish

S2

MShunt

+ Ia

A2

A A1

T2 K10

B+

T

Neutral speed reduction in slopes If the driver release the speed leaver (L1) in a slope and the truck doesn’t come to a stop within a certain time the electrical brake will be applied by the system.

Braking The brake is always applied when the truck is started with the tiller in it’s upper or lower position (S10 open). The brake is released in the same moment as the conditions for driving are fulfilled and the truck starts to move.

Conditions to brake the truck.: • S10 open or S19 open

11 – 12

Service Manual P20

Approved by: Joakim Carleborn

Electrical systems Valid from serial number 364690AAOrder number 178826-040

T-code 662 Date 2002-04-29

C-code/Section 5000 Version 001

Lifting the forks • S34.

• S31 closed.

• Battery status ok (if battery capacity >20% left).

Lowering the forks • S41activated.

Horn • S18 activated.

Hour meter A

• Press S18 and turn S17 to on at the same time.

• Press S18 until you read H= hour meters.

• You have now choosen H= hourmeters the symbol “B” will be highlighted.

E

D

C

B

• You can now choose type of hourmeter by pressing L1.

1(A)= Key time.

2(b)= Drive motor time.

3(c)= Pump motor time.

4(d)= Activity time.

5(s)= Time to service.

Service Manual P20

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11 – 13

Electrical systems C-code/Section 5000 Version 001

T-code 662 Date 2002-04-29

Valid from serial number 364690AAOrder number 178826-040

Fault codes A

• Press S18 and turn S17 to on at the same time.

• Press S18 until you read E= fault codes.

• By choose E the symbol “E” will be highlighted to indicate what’s currently shown on display.

E

D

C

B

• The last 50 fault codes will be stored. The latest fault will be shown first. The display first show the error code and then wich hour the fault occured.

• The fault codes are devided into two groups C = caution and E = error.

• The C will not be stored. It’s only a caution and will be highlighted on display as long as the fault exists.

• If you for example only have one fault registerd in memory the second empty place will be shown like this: Fault : E - - - and time : ----.

11 – 14

Code

C19

Description

Default parameter warning.

Possible fault reason

Parameter area is probably corrupt.

Default values have been down loaded, i.e special parameter settings must be restored.

Code

C20

Description

Butterfly warning

Possible fault reason

Problem with butterfly sensor.

Butterfly may have been activated during start up or faulty sensor.

Code

C28

Description

Emergency switch warning

Possible fault reason

Emergency switch activated No voltage supply to motor controller.

Harness problem.

Service Manual P20

Approved by: Joakim Carleborn

Electrical systems Valid from serial number 364690AAOrder number 178826-040

T-code 662 Date 2002-04-29

C-code/Section 5000 Version 001

Code

C29

Description

Service time warning

Possible fault reason

Time to make service Service counter not reset after latest service

Code

C31

Description

Pressure switch warning

Possible fault reason

A problem with the pressure switch. Check that the voltage is approximately 24 V between the cables 24 and 40 connected to the pressure sensor.

Check the voltage between cable 40 and 63 connected to the pressure sensor. The output voltage should be 0.5 Volt (unloaded machine) - 5 Volt (max load)

Code

C41

Description

Battery undervoltage warning

Possible fault reason

Battery voltage < 17 volts Battery parameter not correct adjusted Time to charge battery

Code

C42

Description

Battery overvoltage warning

Possible fault reason

Battery voltage > 33 volts Fully-charged battery and energy return feed to the battery during motor braking.

Code

C43

Description

Power amplifier thermal cutback

Possible fault reason

Too intensive driving Defect motor controller

Service Manual P20

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11 – 15

Electrical systems C-code/Section 5000 Version 001

11 – 16

T-code 662 Date 2002-04-29

Valid from serial number 364690AAOrder number 178826-040

Code

E101

Description

Motor controller does not correspond with the type of truck

Possible fault reason

Check that the right type of motor controller is fitted

Code

E104

Description

Brake switch transistor shorted

Possible fault reason

Defect motor controller Check the cables and magnetic coil to the brake

Code

E106

Description

Digital output or exceeding the field current limit.

Possible fault reason

Attempt to drive more current than specified from outputs.

Problem to regulate field currrent.

Internal controller fault.

Code

E107

Description

Contactor off

Possible fault reason

Problem with main contactor tips or cabling (open circuit).

Contactor control wire not connected.

Contactor drive output in controller faulty (off).

Code

E108

Description

Contactor welded

Possible fault reason

Main contactor tips welded.

Contactor drive output in controller faulty (on).

Service Manual P20

Approved by: Joakim Carleborn

Electrical systems Valid from serial number 364690AAOrder number 178826-040

T-code 662 Date 2002-04-29

C-code/Section 5000 Version 001

Code

E110

Description

System error

Possible fault reason

Possible defect in the motor controller.

Restart the truck.

Code

E140

Description

Checksum error

Possible fault reason

Internal microcontroller fault (tiller head), faulty software or pcb.

Code

E141

Description

Software problem

Possible fault reason

Internal microcontroller fault (tiller head), faulty software or pcb.

Code

E150

Description

Drive communication error

Possible fault reason

Broken CAN-cable.

Motor controller broken.

Code

E151

Description

Drive communication Tx error

Possible fault reason

Motor controller does not answer, bad connections or faulty motor controller.

Code

E157

Description

Bus off error

Possible fault reason

CAN-bus problem, harness or hardware problem.

Service Manual P20

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11 – 17

Electrical systems C-code/Section 5000 Version 001

11 – 18

T-code 662 Date 2002-04-29

Valid from serial number 364690AAOrder number 178826-040

Code

E159

Description

Over flow error

Possible fault reason

CAN-bus problem, harness or hardware problem.

Code

E160

Description

Error in safety reversing

Possible fault reason

Critical sensor element faulty

Code

E200

Description

Field open

Possible fault reason

Shuntfield open, harness broken, motor controller defect.

Code

E201

Description

M minus error

Possible fault reason

Problem with switch transistor in armature circuit inside motor controller.

Code

E202

Description

Power amplifier sensor error

Possible fault reason

Armature current sensor fault in motor controller.

Code

E214

Description

Power amplifier CAN-timeout

Possible fault reason

Motor controller reports unexpected loss of data flow from tiller head.

Service Manual P20

Approved by: Joakim Carleborn

Electrical systems Valid from serial number 364690AAOrder number 178826-040

T-code 662 Date 2002-04-29

C-code/Section 5000 Version 001

Parameters A

• Press S18 and turn S17 to on at the same time.

• Press S18 until you read P= parameters.

• You have now choosen P=parameters the symbol “C” on display will be highlighted to indicate what’s currently shown on display.

E

D

C

B

• Scroll to the parameter you want to change or look at by pressing the L1 up or down.

• Press S18 ones to get access to the parameter.

• Set parameter value by pressing L1 up or down.

• Press S18 ones to confirm change.

• Turn S17 to off.

You have now completed a parameter change and the next time you start the truck the new parameter setting will be valid.

NOTE !

Truck handling.

Modifying specific truck parameters will change the driving characteristics of the truck.

Do not change any parameters without the necesarry know-how.

Service Manual P20

Approved by: Joakim Carleborn

11 – 19

Electrical systems C-code/Section 5000 Version 001

T-code 662 Date 2002-04-29

Valid from serial number 364690AAOrder number 178826-040

Driver parameters Serial number 364690AA-432919AA

Parameter

Name

Unit

Min

Max

Step

Std

Description

02

Speed

%

10

100

5

100

10 :low Speed 100: full Speed

03

Acceleration

10

100

5

80

10 :low acceleration 100: full acceleration

04

Neutral speed reduction

5

100

5

70

Defines motor speed reduction force when lever goes to neutral position.

5: low reduction force 100: full reduction force

05

Logg off

0

20

1

0

The time until the truck will be switched off when a key pad is used. Time is counted from when the latest power consumer is used.

1min

Parameter description Parameter 2 The maximum speed can be adjusted.

Parameter 3 The lower value of the parameter the longer time it takes to accelerate the truck to top speed.

Parameter 4 Defines motor brake force when lever (L1) goes to neutral position.The lower value of parameter the longer time to reduce speed.

Parameter 5 The time until the truck will be switched off when a key pad is used.

Time is counted from when the latest power consumer is used.

11 – 20

Service Manual P20

Approved by: Joakim Carleborn

Electrical systems Valid from serial number 364690AAOrder number 178826-040

T-code 662 Date 2002-04-29

C-code/Section 5000 Version 001

Driver parameters Serial number 432920AA-

Parameter

Name

Unit

Min

Max

Step

Std

Description

1

Speed, low Speed

%

10

100

5

100

10:low Speed 100:highest Speed

02

Speed, high speed

%

10

100

5

100

10:low Speed 100:highest Speed.

03

Acceleration

10

100

5

75

10:low acceleration 100:full acceleration

04

Neutral speed reduction

5

100

5

80

Defines motor speed reduction force when lever goes to neutral position.

5: low reduction force 100: full reduction force

05

Logg off

0

20

1

0

The time until the truck will be switched off when a key pad is used.

Time is counted from when the latest power consumer is used.

1min

Parameter description Parameter 1 Possibility to adjust the speed in the low speed range (when the safety gates are not used).

Parameter 2 Possibility to adjust the speed in the high speed range (when the safety gates are used).

Parameter 3 The lower value of the parameter the longer time it takes to accelerate the truck to top speed.

Parameter 4 Defines motor brake force when lever (L1) goes to neutral position.The lower value of parameter the longer time to reduce speed.

Parameter 5 The time until the truck will be switched off when a key pad is used.

Time is counted from when the latest power consumer is used.

Service Manual P20

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11 – 21

Electrical systems C-code/Section 5000 Version 001

T-code 662 Date 2002-04-29

Valid from serial number 364690AAOrder number 178826-040

Service parameters • Connect CAN-key in X41.

• Choose parameter.

Parameter

Name

10

PIN-code

14

Unit Min

Max

Step

Std

Description

0

9999

1

0

Possibility to set up to 10 PIN - codes (10 different drivers)

Creep speed

-10

10

1

0

This defines how much output the controller gives when you reach the first speed sensor.

-10 : low speed when reaching first speed sensor.

10: high speed when reaching first speed sensor

20

Hour meter selection

1

5

1

2

Select hour meter

21

Battery size

1

20

1

8

Battery size selection

25

Service interval

0

2000

50

100

Possible to set servicetimer

28 - Serial n° 432920AA-

Lift button selection

1

3

1

1

Button selector

39

Access code

1

4

1

1

State which level of authorization the driver has to the parameters

40 - Serial n° 364690AA432919AA

Display code

0

1

1

0

Defines what should be shown on display.

1h

Parameter description Parameter 10 10 drivers can have it’s own PIN-code to get access to the truck. Each driver have possibility to set all the driver parameters individual.

On delivery the PIN code is set to 1 and this only applies for driver no. 1 Code 0 is not accepted as a solitary code.

When you wish to start the truck enter your code and press the green button with the number 1.

To turn the truck to off press the red no.0 button.

When you have the CAN-key connected you can turn the truck on by just pressing the green no. 1 button. You turn it to off by pressing the red no. 0 button.

11 – 22

Service Manual P20

Approved by: Joakim Carleborn

Electrical systems Valid from serial number 364690AAOrder number 178826-040

T-code 662 Date 2002-04-29

C-code/Section 5000 Version 001

Parameter 14 Defines the speed you will get when you reach the first speed sensor.

Parameter 20 You choose wich hour meter you want to display.

1(A) = Key time.

2(b) =Activity time.

3(c) = Drive motor time.

4(d = Pump motor time.

5(s) = Time to service.

Parameter 21 You must give data about wich battery the truck is equipped with.

To adjust the disconnection point of the battery discharge indicator meassure according to : • Acid concentration when fully charged battery. To check quality of battery. Shall be between 1,27-1,29.

• When you get lift cut out (80 % discharged of battery capacity) you shall have close to 1,14 not less.

Service Manual P20

Approved by: Joakim Carleborn

11 – 23

Electrical systems C-code/Section 5000 Version 001

T-code 662 Date 2002-04-29

Valid from serial number 364690AAOrder number 178826-040

The acid concentration can vary depending of battery brand.

Value

Function

Battery (Ah)

1 2 3 4 5 6 7 8

320

9

↑

10 11

Less discharged

12 13

More discharged

14

↓

15 16 17 18 19 20

WARNING !

Control that you have correct parameter setting.

Otherwise the battery can be destroyed.

Parameter 25 With this parameter you can set a time limit to next service from 0 to 2000 hours in step of 50 hours. When it’s time for service you will get caution 29 (C29) on the display.

11 – 24

Service Manual P20

Approved by: Joakim Carleborn

Electrical systems Valid from serial number 364690AAOrder number 178826-040

T-code 662 Date 2002-04-29

C-code/Section 5000 Version 001

Parameter 28 - Serial number 432920AAUsing this parameter you can select which button is to be used for lift/ lower.

1 = Lower lift/lower button activated (default) 2 = Upper lift/lower button activated 3 = Both lift/lower buttons are activated

Parameter 39 This parameter can be adjusted like: 1 = Key connected, driver parameters open.

2 = Key connected, driver parameters must be opened with CAN-key.

3 = Key pad connected, driver parameters open.

4 = Key pad connected, driver parameters must be opened with CAN - key.

Parameter 40 - Serial number 364690AA-432919AA • Set parameter to value 1.

• Turn S17 to off and then on again.

• Press S18 to choose display mode.

Service indication - Serial number 432920AA• Connect CAN-key in X41 and start the Truck.

• Battery status is shown and symbol "D" is lit.

• Press S18 to choose display mode.

See table below.

A

E

D

C

B

Flashing symbol

Displayed data

B

Speed reference value sent to Curtis.

C

Digital inputs to Curtis and hallelements. * See explanation below

BC

Battery voltage (V)

D

Armature current (A)

BD

Field current (A)

CD

PWM Armature in %

BCD

Status Curtis

*They are displayed by high lighting segments of three of the figures (A).

Service Manual P20

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11 – 25

Electrical systems C-code/Section 5000 Version 001

T-code 662 Date 2002-04-29

Valid from serial number 364690AAOrder number 178826-040

• The most significant figure active (marked with arrow) • Power amplifier inputs.

A

T

Segment

Function

A

E

D

B

C

$ )

*

( '

B

S53 , input A1:14

C

S31 , input A1:15

D

S10 , input A1:12

E

% & '3

F

S19 , input A1:11

G

S10 , input A1:5

DP

• The second most significant figure active (marked with arrow).

• Power amplifier outputs

Segment

Function

A B

11 – 26

C

Y41 , output A1:2

D

Y1 , output A1:3

E

K10, output A1:4

F

H1 , output A1:7

G

Y1 , output A1:5

DP

K30 , output A1:6

Service Manual P20

Approved by: Joakim Carleborn

Electrical systems Valid from serial number 364690AAOrder number 178826-040

T-code 662 Date 2002-04-29

C-code/Section 5000 Version 001

• The third most significant figure active (marked with arrow) .

• Digital input from control sensors.

A

Segment

Function

A

E

D

C

B

B C

$ )

%

*

( '

& '3

D

Fork up

E

Fork down

F

Support arms up

G

Support arms down

DP

• The fourth most significant figure active (marked with arrow).

A

E

D

C

B

Segment

Function

A

Extra function 6

B

Extra function 5

C

Extra function 4

D

Extra function 3

E

Extra function 2

F

Extra function 1

G DP

Service Manual P20

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11 – 27

Electrical systems C-code/Section 5000 Version 001

T-code 662 Date 2002-04-29

Valid from serial number 364690AAOrder number 178826-040

Part numbers A

• Press S18 and turn S17 to on at the same time.

• Press S18 until you read Pn= partnumbers.

E

D

C

• You have now choosen Pn= part numbers the symbol “D” on display will be highlighted to indicate what’s currently shown on display. In the start the Pn = part number complete unit will be shown.

B

• By scrolling with the L1 you can get the following information: • SPn= Software part number.

• HPn= Hardware part number • HSn= Hardware serial number.

Transistor panel

STATUS

B+

A1

M-

M

A2

MODEL

VOLTAGE

SERIAL

CURRENT

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

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

S1

11 – 28

S2

Service Manual P20

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Electrical systems Valid from serial number 364690AAOrder number 178826-040

T-code 662 Date 2002-04-29

C-code/Section 5000 Version 001

Diagnostic and troubleshooting Error codes and troubleshooting

STATUS MODEL

VOLTAGE

SERIAL

CURRENT

The table below describes the error codes that may be shown by the STATUS LED or read using the handheld terminal.

STATUS LED Handheld terminal display

Explanation

Possible cause

LED off

-

No voltage or defective regulator

Burnt fuse, bad contact, not connected, defective regulator

LED on

-

Defective regulator

Defective regulator

1,1

¤¤

CURRENT SHUNT FAULT

Built-in current shunt defective

Armature current sensor fault in motor controller

1,2

¤ ¤¤

HW FAILSAFE

Power amplifier CAN-timeout

Motor controller reports unexpected loss of data flow from tiller head

1,3

¤ ¤¤¤

M- SHORTED

Internal M- short to B-

Problem with switch transistor in armature circuit inside motor controller

3,1

¤¤¤ ¤

CONT COIL/FLD SHORT

Too high current for contactor feeding or shorted field winding

Attempt to drive more current than specified from outputs.

Problem to regulate field currrent.

Internal controller fault

3,3

¤¤¤ ¤¤¤

FIELD OPEN

Open field winding

Shuntfield open, harness broken, motor controller defect

4,1

¤¤¤¤ ¤

LOW BATTERY VOLTAGE

Low battery voltage

1. Battery voltage <17 volts 2. Corroded battery terminals 3. Loose battery or regulator connections

4,2

¤¤¤¤ ¤¤

OVERVOLTAGE

Overvoltage

1. Battery voltage > 33 volts

Service Manual P20

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11 – 29

Electrical systems C-code/Section 5000 Version 001

T-code 662 Date 2002-04-29

Valid from serial number 364690AAOrder number 178826-040

STATUS LED Handheld terminal display

Explanation

Possible cause

4,3

Over-/under-temperature reduction

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

¤¤¤¤ ¤¤¤

THERMAL CUTBACK

Resetting errors To reset an error turn S17 to off and then on again.

Error

Reset when

OVERVOLTAGE

Battery voltage falls below 33 V

THERMAL CUTBACK

The temperature is within allowed range

THROTTLE FAULT 1, 2

Error has been fixed

LOW BATTERY VOLTAGE

When battery voltage exceeds 16 V

Safety The regulator is a high-power component. When working on a battery operated vehicle, necessary precautions should be taken. This includes, but is not limited to, correct training, use of eye protectors, avoiding use of lose-fitting clothes, removal of watches and jewellery, and use of insulated tools only.

WARNING! Risk of short-circuiting.

Remove all watches, jewellery and always use insulated tools only.

11 – 30

Service Manual P20

Approved by: Joakim Carleborn

Electrical systems Valid from serial number 364690AAOrder number 178826-040

T-code 662 Date 2002-04-29

C-code/Section 5000 Version 001

Technical specifications – Curtis 1243 Value

Unit

Rated operating voltage

24

Volts

Overvoltage limit

33

Volts

Undervoltage limit

16

Volts

Minimum operating voltage

Electrical insulation towards cold body

500

V AC

Minimum

PWM frequency

16

kHz

Max. current of armature wind-ing *

200

Amps

for 2 minutes

100

Amps

for 1 hour

25

Amps

for 2 minutes

Max. current of field winding

20

Explanation

for 1 hour

Contactor voltage

24

Volts

Same as battery voltage

Contactor current

2

Amps

Max (current limit at 2.5 amps)

KSI input voltage, Min.

16.8

Volts

KSI input current

50

mA

Logic input voltage

>7.5; High <1; Low

Volts

Logic input current

15

mA

Operating temperature

-40 to +50

°C

Overtemperature, reduction

85

°C

Undertemperature, reduction

-25

°C

* During specific test conditions.

Service Manual P20

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11 – 31

Electrical systems C-code/Section 5000 Version 001

11 – 32

Service Manual P20

T-code 662 Date 2002-04-29

Valid from serial number 364690AAOrder number 178826-040

Approved by: Joakim Carleborn

Hydraulic/pneumatic system Valid from serial number 364690AAOrder number 178826-040

T-code 662 Date 2000-06-01

C-code/Section 6000 Version 001

Hydraulic/pneumatic system 12 Hydraulic chart and list of symbols n

2

1

A Y41

5

3 4

M3

P

6 T

List of Symbols Pos No

Description

Function

Remarks

1

Lift cylinders

Lifting the forks

2 pieces

2

Powertrakcylinder

Increase the pulling quality when loaded

3

Preasure relief valve

4

Flow control valve

5

Non-return valve

6

Filter

M3

Motor

P

Pump

T

Tank

Y41

Valve

Pump motor

1.2 litre Lowering valve for the forks Service Manual P20

Approved by: L-G Andersson

12 – 1

Hydraulic/pneumatic system C-code/Section 6000 Version 001

T-code 662 Date 2000-06-01

Valid from serial number 364690AAOrder number 178826-040

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 machine should be capable of lifting a load of between 2050-2100 kg.

1. Locking nut.

2. Adjuster screw, pressure limit.

Adjusting clockwise results in increased pressure.

Adjusting anticlockwise results in decreased pressure.

• Loosen the locking nut (1) using a 13 mm spanner.

• Place a load of 2000 kg on the forks and check that the machine can lift it.

• If the machine lifts 2000 kg, place a further 100 kg on the forks.

Check whether the machine can lift the load.

• If the machine lifts 2100 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.

12 – 2

Service Manual P20

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PowerTrak cylinder Valid from serial number 364690AAOrder number 178826-040

T-code 662 Date 2000-06-01

C-code/Section 6680 Version 001

PowerTrak cylinder

13

Component parts 3

2 4

1

Pos

Description

1

PowerTrak spring

2

PowerTrak cylinder

3

Spring guide

4

Drive unit

Service Manual P20

Note

2

Approved by: L-G Andersson

13 – 1

PowerTrak cylinder C-code/Section 6680 Version 001

T-code 662 Date 2000-06-01

Valid from serial number 364690AAOrder number 178826-040

Dismantling of PowerTrak cylinder

1 2

Make sure that the truck is unloaded and that the forks are lowered.

3

• Turn the key to neutral and pull out the battery plug.

• Dismantle top covers and head.

• Release the hydraulic hose (1).

4

• Carefully unscrew the screws (2) to the clamp (3) that holds the spring guides.

• Lift out the PowerTrak cylinder (4).

Assembling is carried out in the reverse order The measurement between washer and screw head should be 49 mm.

WARNING!

49

13 – 2

Risk of injury.

There is a risk of personal injury in conjunction with work on the PowerTrak system.

Follow the instructions carefully.

Service Manual P20

Approved by: L-G Andersson

Control/computer equipment Valid from serial number 364690AAOrder number 178826-040

T-code 662 Date 2002-02-01

C-code/Section 8700 Version 001

Control/computer equipment

14

User Manual for TruckCom 3.2

General TruckCom is a communication program which communicates with trucks equipped with CAN (Controller Area Network) communication. It enables functions such as downloading programs, adjusting parameters and displaying measuring data etc. to be carried out.

This Manual is valid for program number 182145-001.

The program is a Windows program run under Windows® 95/98.

Connection A CAN interface of the CPC-PP type is needed to connect it to the truck, with attendant cable. The interface is connected to the printer port on a PC, and the cable is connected between the interface and truck’s CAN connection.

The CAN interface is supplied with power from the truck electronics and is protected from any high voltages in the truck if a fault should occur.

Service Manual P20

Approved by: K-G Andersson

14 – 1

Control/computer equipment C-code/Section 8700 Version 001

T-code 662 Date 2002-02-01

Valid from serial number 364690AAOrder number 178826-040

Layout Main window A main window opens when the program is started, consisting of menu bar, tool buttons, workspace, log window and status window.

Nodes The nodes detected on the bus are shown in the node window. The current node status and input component/information is show with different icons.

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Service Manual P20

Approved by: K-G Andersson

Control/computer equipment Valid from serial number 364690AAOrder number 178826-040

T-code 662 Date 2002-02-01

C-code/Section 8700 Version 001

Icons

Icon

Description Node OK is shown when contact is made with a node and no errors have been reported.

Node not connected is shown when there is no contact with a node in the network.

Node not OK is shown when an error has been reported by a node. Click on node to obtain more information.

Program version is shown when information is available on which software is installed. Click to obtain more information.

Information is shown when a node has information on, for example, error codes.

Truck report

Parameters is shown when a node has information on a parameter.

Diagnostics

Exit

Tool buttons Search for units, disconnect from PC, download, truck report, parameters, diagnostics, information and exit.

Service Manual P20

Approved by: K-G Andersson

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Control/computer equipment C-code/Section 8700 Version 001

T-code 662 Date 2002-02-01

Valid from serial number 364690AAOrder number 178826-040

Information window The right section of the main window contains a status window where different messages are shown.

To see previous messages, use the scroll arrows in the right margin.

Status bar There is a status bar at the bottom of the main window, which shows variable status when the program is run.

REC

MACHINE

The following are shown from the left: Help text "pop-up" via the mouse cursor, connected/not connected to network, truck type connected, initiation result of CAN interface and the present time.

Function Connection To connect the PC the network, select the "Scan units" function. This can be done with the menu <Nodes | Scan units> or with the tool button [Scan nodes].

This should also be done when the truck is supplied with voltage and in normal drive mode.

The program will now run a check and installation of the CAN interface.

A diagnosis will also be carried out to check which units are connected in the system. The result of this diagnosis is shown in the Node window.

Disconnection Select the Disconnect function to disconnect from the network. This can be done with the menu <Nodes | Set PC off-Line > or with the tool button [Set PC off-Line].

The CAN interface is then reset and the CAN cable can be disconnected if so required.

The objective is to enable connection to another truck without having to close the program.

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Service Manual P20

Approved by: K-G Andersson

Control/computer equipment Valid from serial number 364690AAOrder number 178826-040

T-code 662 Date 2002-02-01

C-code/Section 8700 Version 001

Downloading program To download a new program to one of the nodes, select the Download function. This can be done with the menu <Tools | Download software... > or with the tool button [Download].

Type 123456

Normal downloading Select Open.. to open the file to be downloaded into a node. The file name, file type and version number are shown in the window for “file information”. If it is file for a controller, indicate which type of controller is to receive the file. Start downloading by selecting Start... and by restarting the truck by turning the key off and on twice.

Restart must be made within 20 seconds from when the Start button has been activated.

Close the download window when the download is ready, and then disconnect the PC from the network. A new connection can now be made to verify the new program.

Downloading in old versions of logic card To download to older versions of electronic cards which do not support restart with key, the button Old card... should be used instead of Start...

Downloading is carried out in the same way, except that restart is done by using the battery lug instead of the key.

Service Manual P20

Approved by: K-G Andersson

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Control/computer equipment C-code/Section 8700 Version 001

T-code 662 Date 2002-02-01

Valid from serial number 364690AAOrder number 178826-040

Emergency downloading E141 will be shown in the truck’s display when starting, if for any reason there is no program in the electronics card (interrupted downloading).

Communication with the truck via the PC will then be minimised. Use “E141” to download the program in the card.

P24: If there is no program a counter will be shown in the display, which continuously counts up.

NOTE! The logic cards for P24 can only be upgraded with the same basic programs when they have been programmed. It is therefor not possible to change basic programs (other machine type).

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Service Manual P20

Approved by: K-G Andersson

Control/computer equipment Valid from serial number 364690AAOrder number 178826-040

T-code 662 Date 2002-02-01

C-code/Section 8700 Version 001

Truck report It is possible to generate a report to a file or disk with the truck’s configuration and status. Select menu <Tools | Generate truck report...> or with the tool button Truck report. Save the report in Report.file.

NAME

Example of information generated in the truck report: [GENERAL] REPORT DATE-TIME=1999-12-09 07:42:14 CPC-PP SERIAL No=8002008 MACHINE NUMBER=392179 CUSTOMER=CUSTOMER 1 TECHNICIAN=NONAME COMPANY=COMPANY 1 NOTES=Test report [CAN NODES] MAIN CARD=125 FORK CARD=-1 TRUCK TRACKER=-1 ACC LIFT CONTROLLER=0 ACC DRIVE CONTROLLER=0 CURTIS LIFT CONTROLLER=-1 [MAIN CARD CONFIGURATION] SOFTWARE=169942-001 HARDWARE=169937-001 SERIAL NO=12112 [HOUR METERS] A IGNITION TIME=1 B TOTAL MOVEMENT=0 C DRIVE MOTOR TIME=0 D PUMP MOTOR TIME=0 S SERVICE TIME=9

[ERROR LOG] 01=55 99-12-09 06:11 02=55 99-12-08 20:54 03=55 99-12-08 14:26 04=231 99-12-08 14:16 05=55 99-12-08 14:11 . . .

50=55 99-12-08 14:40 [DRIVER PARAMETERS] 1=3 2=100 3=100 . . .

100=0 [TRUCK PARAMETERS] 11=100 12=80 13=10

The contents of certain rows can vary according to truck type.

Service Manual P20

Approved by: K-G Andersson

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Control/computer equipment C-code/Section 8700 Version 001

T-code 662 Date 2002-02-01

Valid from serial number 364690AAOrder number 178826-040

Parameters To change the truck parameters, select the Parameter function. This can be done with the menu <Tools | Change parameters > or with the tool button [Parameters].

NOTE! P24 trucks must be in normal mode, i.e. not in parameter mode.

This must therefore be done when the truck is in parameter mode.

When the truck is in normal drive mode the parameter window is locked and no information can be changed. Nevertheless, it is possible to unlock the window by restarting the truck in parameter mode and then selecting Unlock... without closing the window first.

The parameter numbers follow the description in the respective truck Service Manuals.

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Service Manual P20

Approved by: K-G Andersson

Control/computer equipment Valid from serial number 364690AAOrder number 178826-040

T-code 662 Date 2002-02-01

C-code/Section 8700 Version 001

Diagnostics To access diagnostics, select the Diagnostic function. This can be done with the menu <Tools | Diagnostic...> or with the tool button [Diagnostic].

NOTE! If the value “---” is shown in a field, or a red status LED lights up, the communication has been interrupted for some reason and error data will not be able to be shown.

Analogue Several analogue values will be shown on the Analogue side: Inputs, outputs and the drive/lift converter values. The input/output values are read directly from the in/out directory in the main card and are then shown as voltages and number of revolutions.

NOT P24 “Cmd” is the requested number of revolutions from the main card sent to the drive/lift converters via the CAN bus.

“Actual” is the number of revolutions the drive/lift converters have detected and sent back to the main card.

Service Manual P20

Approved by: K-G Andersson

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Control/computer equipment C-code/Section 8700 Version 001

T-code 662 Date 2002-02-01

Valid from serial number 364690AAOrder number 178826-040

Temperature The actual temperatures of the electronic units and motors are shown.

The values are shown in degrees Celsius.

NOTE! Certain trucks only have temperature sensors in one electronic unit and motor.

Digital The digital inputs are read directly from the input directory on the main card. It is assumed that the input is activated if the colour of the LED is green. If the LED is white/transparent the input is not activated.

The digital outputs are read directly from the out-directory on the main card and are shown with red LEDs.

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Service Manual P20

Approved by: K-G Andersson

Control/computer equipment Valid from serial number 364690AAOrder number 178826-040

T-code 662 Date 2002-02-01

C-code/Section 8700 Version 001

Other functions Save to file The truck parameters can be saved in the PC for downloading at a later date.

Select <File | Save to file | Parameters >. All parameters in the nodes which are connected to the bus will be scanned in and saved in a file.

If only the hour meters are needed, select <File | Save to file | Hour meters >.

Download from file A set of parameters can be downloaded from the PC to the truck. Select <File | Load from file | Parameters >. The parameters in the file will be copied to the nodes connected to the bus. If only the hour meter settings are needed, select <File | Load from file | Hour meters >.

Reset CAN adapter If problems should occur when resetting the CAN adapter connected to the PC, this can normally be done manually by making sure that the adapter is supplied with voltage and then selecting <Nodes | Reset CPC-PP >.

Delete error code log To delete the truck’s error code log, start the truck in parameter mode and then select < Tools | Erase error log >.

Reset hour meter To reset the truck’s hour meter, start the truck in drive mode and then select < Tools | Reset hour meters >.

Read error code log To show the truck’s error code log, select < Tools | Read error log >.

Adjust date and time To quickly adjust the truck’s data and time, select < Tools | Adjust date & time >. The time given in the PC will now be downloaded into the truck.

NOTE! Not trucks which do not have real time clock (P24):

Adjusting the hour meter on older cards To adjust the hour meter on trucks with older cards, select < Tools | Adjust Hour meters >. The time in the PC will then be downloaded to the truck.

Service Manual P20

Approved by: K-G Andersson

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Control/computer equipment C-code/Section 8700 Version 001

T-code 662 Date 2002-02-01

Valid from serial number 364690AAOrder number 178826-040

Help About TruckCom To see program information, select <Help | About TruckCom... > or tool button [About].

Exit To exit the program, select <File | Exit > or the tool button [Exit].

Specifications CAN interface Description

Value

Unit

Power consumption

40-120

mA

Supply voltage

11-28

V

Transfer rate

125

kbit/s

Storage temperature

-20-80

0C

Operating temperature

0-60

0

C

Installation The program is delivered on disks or over the network, and the installation is started by running A:\SETUP.EXE. Follow the instructions shown on the screen.

Make sure that the computer settings for the printer port in setup (BIOS) are as follows: Port address: 0378 IRQ:

7

Mode:

Output only

For information on how the settings in setup are changed, see the user manual from the computer manufacturer.

To uninstall If you wish to uninstall TruckCom this can be done from Windows < Setup| Control Panel| Add/delete program > .

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Service Manual P20

Approved by: K-G Andersson