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Service Manual SPE125/160/125L/160L Valid from serial number: 711956-
Order number: 218367-040 Issued: 2004-04-05 ITS
© BT Europe AB
en
Issue date
Resp.
Changes
2004-04-05
ITS
Completely new issue
© BT Europe AB
Service Manual SPE125/160/125L/160L
Approved by: L-G Andersson
Table of Contents Valid from serial number 711956Order number 218367-040
T-code 789, 791 Date 2004-04-05
1- Table of Contents Presentation of the truck – M2
2-1
Intended application of the truck ...................
2
Forbidden application of the truck.................
2
Truck data.....................................................
3
Truck dimensions .........................................
4
Identification plate.........................................
6
Capacity plate...............................................
6
Addition and information plate ......................
6
Capacity plate for double pallet handling ......
7
Main components .........................................
8
Warning and information plates ...................
10
Technical data – M4
3-1
General tightening torques ...........................
Installation and maintenance instructions – P1
5
4-1
Truck installation...........................................
1 4.1.1 Lifting the truck ................................................... 1 4.1.2 Battery installation .............................................. 2 4.1.3 Putting into service ............................................. 2
Introduction, maintenance ............................
4 4.2.1 Safety rules during maintenance work ............... 4
Cleaning and washing ..................................
6 4.3.1 External cleaning ................................................ 6 4.3.2 Cleaning the motor compartment ....................... 6 4.3.3 Electric components ........................................... 6
Safe lifting..................................................... © BT Europe AB
Service Manual SPE125/160/125L/160LApproved by: L-G Andersson
7
1- 1
Table of Contents T-code 789, 791 Date 2004-04-05
Valid from serial number 711956Order number 218367-040
Maintenance schedule – P2
5-1
Lubrication chart ...........................................
7
Oil and grease specification – P3
6-1
Tools – P4
7-1
Super Seal connectors .................................
1
AMP connectors ...........................................
2 7.2.1 AMP Connectors, 040 series .............................. 3
Molex connectors..........................................
3
Other tools ....................................................
4
Electric drive motor – 1760
8-1
Included components....................................
1
Disassembly/assembly of the truck motor.....
3 8.2.1 Disassembly ....................................................... 3 8.2.2 Assembly ............................................................ 3
Service/repairs..............................................
4 8.3.1 Disassembly of the motor ................................... 4 8.3.2 Motor installation ................................................. 5 8.3.3 Cleaning .............................................................. 5
Technical data ..............................................
Drive unit/gear – 2550
6
9-1
Included components....................................
1 9.1.1 Technical data .................................................... 3
Leakage from top cover ................................ Replacing the drive axle jointing ring ............
3
3 9.3.1 Disassembly ....................................................... 4 9.3.2 Assembly ............................................................ 4
1- 2
© BT Europe AB
Service Manual SPE125/160/125L/160L Approved by: L-G Andersson
Table of Contents Valid from serial number 711956Order number 218367-040
T-code 789, 791 Date 2004-04-05
Electromagnetic brake – 3370
10-1
Main components of the brake......................
1
Maintenance .................................................
2 10.2.1 Basic adjustment of the play .............................. 2 10.2.2 Brake disc replacement ...................................... 3
Electrical systems – 5000
11-1
Electrical equipment overview ......................
1
Equipment list and electrical diagram ........... 11.2.1 Electrical wiring diagram 1 of 8 11.2.2 Electrical wiring diagram 2 of 8 11.2.3 Electrical wiring diagram 3 of 8 11.2.4 Electrical wiring diagram 4 of 8 11.2.5 Electrical wiring diagram 5 of 8 11.2.6 Electrical wiring diagram 6 of 8 11.2.7 Electrical wiring diagram 7 of 8 11.2.8 Electrical wiring diagram 8 of 8
3 .......................... 7 .......................... 8 .......................... 9 ........................ 10 ........................ 11 ........................ 12 ........................ 13 ........................ 14
Functional description..................................
15 11.3.1 Description of steering system ......................... 22
Speed limitation ...........................................
23
Hour meter and battery condition.................
24
Diagnostic and troubleshooting ...................
26 11.6.1 Fault codes ....................................................... 26 11.6.2 Fault code history ............................................. 26 11.6.3 List of fault codes ............................................. 27 11.6.4 Transistor regulator troubleshooting and error codes 35 11.6.5 Built-in Test Function ....................................... 38 11.6.6 Display test mode ............................................. 43
Part numbers ...............................................
44
Parameters ..................................................
45 45 45 46 46 47 47
11.8.1 General ............................................................ 11.8.2 Viewing parameters -CAN key not connected . 11.8.3 Viewing parameters -CAN key connected ....... 11.8.4 Setting Driver parameters ................................ 11.8.5 Setting Service parameters .............................. 11.8.6 Summary of driver parameters ......................... © BT Europe AB
Service Manual SPE125/160/125L/160LApproved by: L-G Andersson
1- 3
Table of Contents T-code 789, 791 Date 2004-04-05
Valid from serial number 711956Order number 218367-040
11.8.7 Description of driver parameters ...................... 11.8.8 Summary of service parameters ...................... 11.8.9 Description of service parameters .................... 11.8.10 “Option” Parameters .......................................
49 50 52 59
Technical specifications – Curtis 1243.........
67
Hydraulic system – 6000
12-1
Hydraulic diagram......................................... 12.1.1 SPE125L/160L ................................................... 12.1.2 SPE125/160 ....................................................... 12.1.3 Main components ............................................... 12.1.4 Description .........................................................
Main lift chain system – 7120
1- 4
© BT Europe AB
1 1 2 3 4
13-1
General .........................................................
1
Checking the chain setting............................
1
Chain inspection ........................................... 13.3.1 Noise .................................................................. 13.3.2 Surface rust ........................................................ 13.3.3 Rusty links .......................................................... 13.3.4 Stiff links ............................................................. 13.3.5 Bolt rotation ........................................................ 13.3.6 Loose bolts ......................................................... 13.3.7 Outline wear ....................................................... 13.3.8 Stretching ........................................................... 13.3.9 Damage .............................................................. 13.3.10 Damaged discs ................................................. 13.3.11 Damaged bolts ................................................. 13.3.12 Dirty chain ........................................................
1 1 1 1 2 2 2 3 4 5 5 5 6
Cleaning .......................................................
6
Lubrication ....................................................
6
Service Manual SPE125/160/125L/160L Approved by: L-G Andersson
Table of Contents Valid from serial number 711956Order number 218367-040
T-code 789, 791 Date 2004-04-05
Control/computer equipment – 8700
14-1
General.........................................................
1
Connection ...................................................
1
Layout........................................................... 14.3.1 Main program screen ......................................... 14.3.2 Nodes ................................................................. 14.3.3 Icons ................................................................... 14.3.4 Tool buttons and menu bar ................................ 14.3.5 Information window ............................................ 14.3.6 Status bar ...........................................................
2 2 2 3 4 4 4
Connection function .....................................
4
Disconnection function .................................
5
Downloading program function ..................... 14.6.1 Normal downloading (truck with key) ................. 14.6.2 Normal downloading (truck with keypad) ........... 14.6.3 Emergency downloading (truck with keypad) ..... 14.6.4 Downloading in old versions of logic card .......... 14.6.5 Emergency downloading (truck with keypad) .....
5 5 6 6 7 7
Truck report function.....................................
8
Parameters function .....................................
9
Diagnostics function ....................................
11 11 12 13 14
14.9.1 Representation of signal colours ...................... 14.9.2 “Tiller arm” tab .................................................. 14.9.3 “Drive Controller” tab ........................................ 14.9.4 “EPS” tab (only OL 20 / 25) ..............................
Other menu functions ..................................
© BT Europe AB
14.10.1 Save to file ..................................................... 14.10.2 Download from file ......................................... 14.10.3 Reset CAN adapter ........................................ 14.10.4 Delete error code log ...................................... 14.10.5 Reset hour meter ........................................... 14.10.6 Read error code log ....................................... 14.10.7 Adjust date and time ...................................... 14.10.8 Adjusting the hour meter on older cards ........ 14.10.9 Help ................................................................ 14.10.10 Exit ...............................................................
16 16 16 16 16 16 16 16 17 17 17
Specifications ..............................................
17
Service Manual SPE125/160/125L/160LApproved by: L-G Andersson
1- 5
Table of Contents T-code 789, 791 Date 2004-04-05
Valid from serial number 711956Order number 218367-040
Installation ................................................... 14.12.1 Installation on a PC with Windows® 95/98 ..... 14.12.2 Installation on a PC with Windows XP/2000 .. 14.12.3 Installation on a PC with Windows NT ........... 14.12.4 In case of communication problems with CAN 14.12.5 To uninstall .....................................................
1- 6
© BT Europe AB
Service Manual SPE125/160/125L/160L Approved by: L-G Andersson
18 18 18 24 24 24
Presentation of the truck – M2 Valid from serial number 711956Order number 218367-040
T-code 789, 791 Date 2004-04-05
2- Presentation of the truck – M2 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. Best advantage can be taken of the truck’s properties by the operator standing on the ergonomically designed platform as this provides the operator with a clear view over the truck and load, allowing work to be carried out with ease and safety. The truck is also equipped with protective gates to protect the operator when driving standing on the platform. When the gates are retracted the truck’s maximum speed is always 6 km/h. When the gates are raised and the operator is standing on the platform the truck’s maximum speed is 8 km/h. The tiller arm is specially designed to provide the best possible operator ergonomy, having all the controls and buttons within easy reach without the operator needing to release the handle. The tiller arm is also equipped with a display showing running time and battery status among other things. The display is also used when the operator wishes to change any of the operator parameters with which the truck can be programmed. The truck is equipped with BT’s patented PowerTrak system, which means that the drive wheel pressure is adjusted according to the weight of the load and the wear on the drive wheel. This reduces the wear and tear on the drive wheel and ensures safer load handling. The truck has a 24V electrical system and the speed is regulated by means of a transistor controller to provide gentle control of acceleration and speed while driving. The forks are lifted using a compact, yet powerful hydraulic unit. Lifting is controlled by a transistorised variable speed controller. The truck's proportional valve is used to adjust the lowering speed and fork positioning during stacking. The battery compartment is designed to allow the battery to be changed from either side as well as from above, which means the truck is well suited to most types of battery changing situations.
© BT Europe AB
Service Manual SPE125/160/125L/160LApproved by: L-G Andersson
2- 1
Presentation of the truck – M2 Intended application of the truck T-code 789, 791 Date 2004-04-05
Valid from serial number 711956Order number 218367-040
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.
The truck’s maximum speed is 8 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.
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.
2.1 Intended application of the truck The truck is solely designed and manufactured to handle goods. The trucks should be fitted with the appropriate accessories relevant to the application.
2.2 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- 2
© BT Europe AB
Service Manual SPE125/160/125L/160L Approved by: L-G Andersson
Presentation of the truck – M2 Truck data Valid from serial number 711956Order number 218367-040
T-code 789, 791 Date 2004-04-05
2.3 Truck data The table provides information regarding some technical data, which is of value with daily use of the truck.
Table 1: Truck data Truck type
SPE125/ 125L
SPE160/160L
Rated capacity, kg
1250
1600
Lift height, mm
2350-5400
2350-5400
Travel speed without load (800kg) with gates Transporting position (Lh < 1,5 m), km/h
7
7
Travel speed without gates Transporting position (Lh < 1,5 m), km/h
6
6
Travel speed Stacking position (Lh >1,5 m), km/h
5
5
Gradient with rated load, %
8
8
Weight without battery, kg
980
1130
Weight with battery, kg (Ah) *
1230
1390
Turning radius (Wa), mm (Small battery space, fork length 1150 mm, mast DX)
1755
1755
Continuous noise level, dB A
33V / Can be caused by fully-charged battery and energy return feed to the battery during heavy reverse braking
C43
Traction transistor regulator thermal cutback
Driving may be too intensive Defective Traction transistor regulator [A1]
C47
Battery under voltage warning -pump transistor regulator
Pump transistor regulator[A3] has detected battery voltage < 17V / Battery parameter not correctly adjusted. See “# 21 - Battery size” on page 54 for setting of parameter #21 Battery due for charging
C48
Battery overvoltage -pump transistor regulato
Pump transistor regulator[A3] has detected battery voltage > 33V
C49
Pump transistor regulator thermal cutback
Lifting may be too intensive Defective pump transistor regulator [A3]
C60
Pressure sensor error, Lift system
Voltage at i/p [B4:INP.PRESSURE LIFT] outside range +0,3V to +7,7V / Check pressure sensor [B4] wiring and function Defective pressure sensor [B4]
C61
Pressure sensor error powertrak
Voltage at i/p [B5:INP.PRESSURE PT] outside range +0,3V to +7,7V / Check pressure sensor [B5] wiring and function Defective pressure sensor [B5]
C62
Powertrak error
Unexpected pressure level in Powertrak system / Check wiring & connections to Powertrak related components [Y58], [Y59], [B4] & [B5] Mechanical failure in powertrak valves
C63
Powertrak valve output error
Valve defective [Y59] or fault in o/p from traction transistor regulator [A1:OUT.POWERTRAK FILL UP VALVE]
C64
Powertrak valve output error
Valve defective [Y58] or fault in o/p from traction transistor regulator [A1:OUT.POWERTRAK DRAIN VALVE]
11- 28
© BT Europe AB
Service Manual SPE125/160/125L/160L Approved by: L-G Andersson
Electrical systems – 5000 Diagnostic and troubleshooting Valid from serial number 711956Order number 218367-040
T-code 789, 791 Date 2004-04-05
Table 21: List of fault codes Code
Description
Possible cause / Hint or Solution
C 70
Pump motor field circuit open
Shunt field open [M3], harness broken, pump transistor regulator defective [A3]./ Check wiring and connections to shunt field [M3]
C 71
M minus error - Pump transistor regulator [A3]
Problem with switch transistor in armature circuit inside Pump transistor regulator [A3] Defective Pump transistor regulator [A3].
C 72
Current sensor error Pump transistor regulator [A3]
Armature current sensor fault in pump transistor regulator [A3] Defective pump transistor regulator [A3]
C73
CAN timeout error -Pump transistor regulator [A3]
Pump transistor regulator [A3] reports unexpected loss of data flow from tiller head [A2]./ Check CAN bus signal cables and connections.[A3, A2] Restart the truck
C74
Data not received - Pump transistor regulator [A3]
Data from [A3] not received by [A2] Broken CAN wire / Check CAN bus signal cables and connections.[A3, A2] Restart the truck
C75
Transmission to Pump transistor controller[A3] failed
Data from [A2] not received by [A3] Broken CAN wire Defective Pump transistor regulator [A3] /Check CAN bus signal cables and connections.[A3, A2] Restart the truck
C76
Pump transistor regulator [A3] incompatible with the type of truck
Incorrect type of pump transistor regulator is fitted / Check correct transistor regulator type is fitted
C77
Lift potentiometer [R14] connection error
Analogue potentiometer control not detected. / Check wiring & connections between potentiometer [R14] & [A2]
C80
Steer servo - Reference sensor current error
Steer servo reference current < 0,1A Supply fault to home reference sensor [S65] Defective home reference sensor [S65] / Check wiring to sensor
C81
Steer servo - Reference sensor supply error
Sensor supply from Defective home reference sensor [S65] / Check supply voltage is 12V between wires 95-97 / Check Wiring to sensor Check condition of [F50]
C82
Steer servo - drive current warning
Steer servo drive current is exceeding 80% of maximum. Steering activity may be too intensive See also code E132
© BT Europe AB
Service Manual SPE125/160/125L/160LApproved by: L-G Andersson
11- 29
Electrical systems – 5000 Diagnostic and troubleshooting T-code 789, 791 Date 2004-04-05
Valid from serial number 711956Order number 218367-040
Table 21: List of fault codes Code
Description
Possible cause / Hint or Solution
E90
Extra I/0 (0) CAN communication error
Data from extra I/0 box (0) not received by [A2] / Check CAN bus cables and connections. [A2] Restart the truck
E91
Extra I/0 (1) CAN communication error
Data from extra I/0 box (1) not received by [A2] / Check CAN bus cables and connections. [A2] Restart the truck
E92
Configuration error Extra I/0 (0)
Faulty configuration of option in extra I/0 box (0) / Check allocation of outputs in I/0 extension box (0).
E93
Configuration error Extra I/0 (1)
Faulty configuration of option in extra I/0 box (1) / Check allocation of outputs in I/0 extension box (1).
E100
Steer servo - configuration error
Presence of steer servo and parameter #38 setting do not match/ Ensure parameter #38 is set correctly
E101
Traction transistor regulator [A1] incompatible with the type of truck
Incorrect type of traction transistor regulator is fitted / Check correct transistor regulator type is fitted
E104
Brake switch transistor output in Traction transistor regulator [A1] shorted
Defective Traction transistor regulator [A1] / Check cables and magnetic coil to the brake [Y1]
E106
Digital output fault or field current limit
Attempting to drive more current than specified from outputs. OR problem regulating field current. Internal Traction transistor regulator fault. [A1]
E107
Main contactor not activated [K10]
Problem with main contactor tips or cabling (open circuit). Contactor control wire not connected. Contactor drive output in controller faulty (off) / Check main contactor tips. Check control wires to main contactor. Check contactor drive output goes low. [A1]
E108
Main contactor tips welded or open circuit in coil.[K10]
Main contactor tips welded. Contactor drive output in controller faulty (on) / Check main contactor tips Check contactor drive output goes high. [A1]
E110
Fault in armature current reading
Possible defect in the transistor regulator [A1]. Can be caused by excessive moisture inside regulator. / Restart the truck
E112
Steer servo- wheel position error
Error when comparing actual wheel position (reference sensor signal) with steer servo’s calculated position. / Check reference sensor[S65] functions correctly Check steer servo pinion is not loose and in contact with drive unit’s gear ring Restart the truck
11- 30
© BT Europe AB
Service Manual SPE125/160/125L/160L Approved by: L-G Andersson
Electrical systems – 5000 Diagnostic and troubleshooting Valid from serial number 711956Order number 218367-040
T-code 789, 791 Date 2004-04-05
Table 21: List of fault codes Code
Description
Possible cause / Hint or Solution
E113
Unspecified steer servo fault
Control system has detected a fault condition but is unable to ascertain the exact cause. / Restart the truck
E114
Steer servo phase error [A5, M6]
Loss of motor phase to steer servo motor. / Check internal motor cable connections in steer servo[A5, M6]
E115
Steer servo initialisation error [A5]
Faulty Servo [A5] Internal logical fault Wrong parameters / Restart the truck
E116
Steer servo checksum error [A5]
Can occur after new firmware has been loaded into truck / Restart the truck
E117
Steer servo communication error
Shall not occur under normal conditions./ Contact support organisation
E118
Command mode error
Shall not occur under normal conditions./ Contact support organisation
E119
Steer servo error during homing operation (Time out)
Home position (steering straight) not achieved within preset time. Home reference sensor [S65] not adjusted correctly Faulty reference sensor / Check reference sensor gap is adjusted correctly, check wiring to sensor
E120
Steer servo- potentiometer error
Comparison of voltages between IN_0 & IN_1 is out of range. / Check potentiometer inputs
E121
Steer servo error -steering angle value check
Restart the truck Check that sum of voltages between wire nos. 92-94 and 93-94 ≈ 5V Re calibrate steering (See “# 36 - Calibrate” on page 55)
E122
Steer servo -reference supply out of range
Defective steer servo [A5] / Check voltage between wire nos. 91-94 = 4,5 to 5,5 V
E123
Steer servo - Hall sensor fault
Intermittent contacts inside steer servo Defective steer servo [A5] / Check internal connections from Hall sensors to main circuit board in steer servo [A5]
E124
Steer servo - overvoltage [A5]
May occur when performing heavy reverse braking on newly charged battery (Voltage exceeded 39V) / Restart the truck
E125
Steer servo - internal short circuit [A5, M6]
Defective steer servo [A5,M6] / Check wiring for short-circuit Restart the truck
E126
Steer servo - current offset error [A5, M6]
Defective steer servo [A5,M6] / Restart the truck
© BT Europe AB
Service Manual SPE125/160/125L/160LApproved by: L-G Andersson
11- 31
Electrical systems – 5000 Diagnostic and troubleshooting T-code 789, 791 Date 2004-04-05
Valid from serial number 711956Order number 218367-040
Table 21: List of fault codes Code
Description
Possible cause / Hint or Solution
E127
Steer servo - temperature error[A5, M6]
Steer servo internal temperature outside range -40 to +85º C Steering activity may be too intensive Defective steer servo [A5,M6] / Restart the truck (See also code C35)
E128
Not applicable in this truck
-
E129
Steer servo - supply undervoltage
Battery charge too low Intermittent connection in servo supply circuit [A5] Steer servo fuse [F52] faulty or blown. / Check condition of Fuse [F52] Charge battery
E130
Steer servo - analogue steer signal input fault
Faulty steer angle potentiometer [R2] Intermittent connection in potentiometer circuit [R2,A5] / Check wiring to potentiometer [R2] Move tiller handle in all directions to ensure no wiring problems exist.
E131
Steer servo - analogue steer signal input 0 fault
Faulty steer angle potentiometer [R2] Intermittent connection in potentiometer circuit [R2,A5:INP.A_IN0] / Check 0,4 to 4.8V between wires 94-93, check wiring to potentiometer [R2] Move tiller handle in all directions to ensure no wiring problems exist.
E132
Steer servo - current limit reached
Output current to steer motor exceeding 80% of maximum for longer than 5 seconds. Steered portion of drive unit not moving freely./ Check for free movement of drive wheel on floor. Check steering drive train is free of dirt or other foreign objects.(See also code C82)
E133
Steer servo - analogue steer signal input 1 fault
Faulty steer angle potentiometer [R2] Intermittent connection in potentiometer circuit [R2,A5:INP.A_IN1] / Check 0,4 to 4.8V between wires 94-92 , check wiring to potentiometer [R2] Move tiller handle in all directions to ensure no wiring problems exist.
E134
Steer servo - analogue steer signal input short circuit
Faulty steer angle potentiometer [R2] or wiring short circuit between [A5:INP.A_IN1 and INP.A_IN0] / Check wiring to potentiometer [R2], Move tiller handle in all directions to ensure no wiring problems exist.
11- 32
© BT Europe AB
Service Manual SPE125/160/125L/160L Approved by: L-G Andersson
Electrical systems – 5000 Diagnostic and troubleshooting Valid from serial number 711956Order number 218367-040
T-code 789, 791 Date 2004-04-05
Table 21: List of fault codes Code
Description
Possible cause / Hint or Solution
E135
Steer servo - offset value error
Voltage difference between [A5:INP.A_IN1 and INP.A_IN0] is too great Requires re calibration / Re calibrate steering (parameter #36) See “# 36 - Calibrate” on page 55
E136
Steer servo - steer angle potentiometer error
Calibrated neutral position value is out of range. Defective potentiometer [R2] / Ensure potentiometer is fitted correctly. Re calibrate steering (parameter #36). See “# 36 - Calibrate” on page 55
E137
Steer servo - checksum error on received data
Faulty wiring / Check CAN bus signal cables and connections.[A5, A2] Restart the truck
E138
CAN data not received
Data from traction transistor regulator not received by [A2] Faulty wiring / Check CAN bus signal cables and connections.[A1, A2] Restart the truck
E139
Steer servo - data transmission to servo failed
Faulty wiring / Check CAN bus signal cables and connections.[A5, A2] Restart the truck
E140
Checksum error
Faulty internal micro controller [A2], faulty software
E141
Software problem
Faulty internal micro controller [A2], faulty software / New software may need loading via CAN
E150
Data not received - Traction transistor controller
Traction transistor regulator [A1] does not answer, bad connections or faulty Traction transistor regulator [A1].
E151
Transmission to traction transistor regulator failed
Broken CAN-wire. Traction transistor regulator [A1] defective
E157
Bus off error
CAN-bus problem, wiring harness or hardware problem.[A2] / Check CAN wiring
E159
Over-run error
CAN-bus problem, wiring harness or hardware problem.[A2] / Check CAN wiring
E160
Error -safety switch against collision
Error in Hall sensor for safety switch against collision “belly button”/ Check switch is not activated.
E200
Drive motor field circuit open
Shunt field open [M1], harness broken, Traction transistor regulator defective [A1]. / Check wiring and connections to shunt field [M1]
© BT Europe AB
Service Manual SPE125/160/125L/160LApproved by: L-G Andersson
11- 33
Electrical systems – 5000 Diagnostic and troubleshooting T-code 789, 791 Date 2004-04-05
Valid from serial number 711956Order number 218367-040
Table 21: List of fault codes Code
Description
Possible cause / Hint or Solution
E201
M minus error
Problem with switch transistor in armature circuit inside Traction transistor regulator [A1] Defective Traction transistor regulator [A1].
E202
Current sensor error - traction transistor regulator [A1]
Armature current sensor fault in Traction transistor regulator [A1]. Defective Traction transistor regulator [A1].
E214
CAN-timeout error - traction transistor regulator [A1]
Traction transistor regulator reports unexpected loss of data flow from tiller head [A2]./ Check CAN bus signal cables and connections
11- 34
© BT Europe AB
Service Manual SPE125/160/125L/160L Approved by: L-G Andersson
Electrical systems – 5000 Diagnostic and troubleshooting Valid from serial number 711956Order number 218367-040
T-code 789, 791 Date 2004-04-05
11.6.4 Transistor regulator troubleshooting and error codes
STATUS MODEL
VOLTAGE
SERIAL
CURRENT
General Curtis 1243 is a regulator [A1] & [A3] 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.
STATUS MODEL
VOLTAGE
SERIAL
CURRENT
Transistor regulator errors The table below depicts the error codes that may be shown by the STATUS LED or read using the hand-held terminal.
Table 22: Transistor regulator error code STATUS LED
Hand-held 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.
¤¤
© BT Europe AB
Service Manual SPE125/160/125L/160LApproved by: L-G Andersson
11- 35
Electrical systems – 5000 Diagnostic and troubleshooting T-code 789, 791 Date 2004-04-05
Valid from serial number 711956Order number 218367-040
Table 22: Transistor regulator error code STATUS LED
Hand-held terminal display
Explanation
Possible cause
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 current. Internal controller fault.
3,3
¤¤¤ ¤¤¤
FIELD OPEN
Open field winding
Shunt field open, harness broken, motor controller defect.
4,1
¤¤¤¤ ¤
LOW BATTERY VOLTAGE
Low battery voltage
1. Battery voltage 33 volts
4,3
¤¤¤¤ ¤¤¤
THERMAL CUTBACK
Over-/under-temperature reduction
1. Temp. >85oC or < - 25oC 2. Truck overloaded 3. Wrong installation of transistor regulator 4. Operation under extreme conditions
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© BT Europe AB
Service Manual SPE125/160/125L/160L Approved by: L-G Andersson
Electrical systems – 5000 Diagnostic and troubleshooting Valid from serial number 711956Order number 218367-040
T-code 789, 791 Date 2004-04-05
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.
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Service Manual SPE125/160/125L/160LApproved by: L-G Andersson
11- 37
Electrical systems – 5000 Diagnostic and troubleshooting T-code 789, 791 Date 2004-04-05
Valid from serial number 711956Order number 218367-040
11.6.5 Built-in Test Function The truck’s control system provides a number of useful built-in test functions • Connect CAN-key in X41 and press
[A17].
• Battery status is shown. • Press Horn S18 repeatedly to choose Built-in Test mode. NOTE! All truck functions operate as normal in this mode. Care should be taken when operating the truck and reading the display at the same time!
Table 23: Built-in test modes Flashing symbol
Displayed data
Unit
Speed reference value sent to traction transistor controller.
-
Lift / lower command value sent to pump transistor controller.
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© BT Europe AB
Main control card signals [A2) See Table 26:
-
Inputs / outputs traction transistor regulator & pump transistor regulator. See Table 24: & Table 25:
-
Battery voltage
V
Armature current to traction motor [M1]
A
Field current to traction motor [M1]
A
Service Manual SPE125/160/125L/160L Approved by: L-G Andersson
Electrical systems – 5000 Diagnostic and troubleshooting Valid from serial number 711956Order number 218367-040
T-code 789, 791 Date 2004-04-05
Table 23: Built-in test modes Flashing symbol
© BT Europe AB
Displayed data
Unit
Armature PWM to traction motor [M1]
%
Armature current to pump motor [M3]
A
Field current to pump motor [M3]
A
Armature PWM to pump motor [M3]
%
Signal from pressure sensor [B4] (Hydraulic pressure in lift circuit)
bar
Signal from pressure sensor [B5] (Hydraulic pressure in powertrak circuit)
bar
Maximum lift pressure setting.
bar
Service Manual SPE125/160/125L/160LApproved by: L-G Andersson
11- 39
Electrical systems – 5000 Diagnostic and troubleshooting T-code 789, 791 Date 2004-04-05
Valid from serial number 711956Order number 218367-040
Digital inputs/outputs test mode In the digital inputs/outputs mode, the operation of both inputs and outputs can be checked by checking the individual segments of the main display as given in the following tables.
Table 24: Transistor regulator inputs Function
Segment
Tiller arm in drive pos.[S10], input A1:INP.TILLER ARM IN DRIVE POS: Platform not folded up switch [S59], input A1:PLATFORM NOT FOLDED UP Man on platform switch [S19], input A1:INP.MAN ON PLATFORM Gates up switch [S53], input A1:GATES UP
Gates down switch [S56], input A1:GATES DOWN Support arms at top switch [S31], input A3:INP.SUPPORT ARM AT TOP (SPE125L/160L) Support arms at bottom switch [S90], input A3:INP.SUPPORT ARM AT BOTTOM (SPE125L/160L) Forks < 1800mm [S33/2] magnetic switch , input A3:LIFT LIMIT 800 kg. Travel speed = 7.0 km/h (Declines linearly to 7.0 km/h at maximum load)
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Service Manual SPE125/160/125L/160LApproved by: L-G Andersson
12- 5
Hydraulic system – 6000 Hydraulic diagram T-code 789, 791 Date 2004-04-05
Valid from serial number 711956Order number 218367-040
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12- 6
© BT Europe AB
Service Manual SPE125/160/125L/160L Approved by: L-G Andersson
Main lift chain system – 7120 General Valid from serial number 711956Order number 218367-040
T-code 789, 791 Date 2004-04-05
13- Main lift chain system – 7120 13.1 General Applies to all machines with a mast.
13.2 Checking the chain setting The lift chains must be adjusted at regular periods due to stretching, see below. The chain setting is checked during servicing as set out in the maintenance schedule. Any adjustment is made with the chain mounting bolts. Adjust the fork height according to C code 7100, 7420, 7700 and 7800 as applicable.
13.3 Chain inspection The chains are exposed to two types of wear, outline wear and stretching. Wear to the bolts and disc holes is caused by stretching. The chains are also affected by the environment they are used in.
13.3.1 Noise If lubrication has been insufficient there will be metallic friction on the chain and this will result in noise. The chain should be replaced.
13.3.2 Surface rust Surface rust is easy to recognize as the chain will be reddish brown. Deep-seated rust has generally started and the chain has impaired strength. The chain should be replaced
13.3.3 Rusty links Fretting corrosion results in a reddish brown powder being visible by the outer discs. It can also appear as if the chain is bleeding when lubricated. The chain should be replaced.
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Service Manual SPE125/160/125L/160LApproved by: L-G Andersson
13- 1
Main lift chain system – 7120 Chain inspection T-code 789, 791 Date 2004-04-05
Valid from serial number 711956Order number 218367-040
13.3.4 Stiff links If it is not possible to pull out the chain to its normal position this can be because of link rust or seizing. The chain should be replaced.
13.3.5 Bolt rotation Bolt rotation can be a phenomenon of stiff links. The fault is easy to see when comparing with a new chain. The chain should be replaced .
13.3.6 Loose bolts If a bolt is loose it will protrude from the side of the chain, which is due to a stiff link or bolt rotation. The chain should be replaced.
13- 2
© BT Europe AB
Service Manual SPE125/160/125L/160L Approved by: L-G Andersson
Main lift chain system – 7120 Chain inspection Valid from serial number 711956Order number 218367-040
T-code 789, 791 Date 2004-04-05
13.3.7 Outline wear P
H2
H3
P = Pitch H2 = Nominal disc height. H3 = Minimum disc height. A new lift chain has a specific nominal disc height, defined as H2 in the figure. As the truck is used the lift chain wears radically, on the side that runs over the chain sprocket. The minimum disc height is define as H3 in the figure and denotes the minimum permitted value of the disc height. Maximal permitted outline wear is 5% of the height H2. If a lift chain reaches the maximum level of wear, the chain should be replaced.
The nominal and minimum disc heights for respective lift chains are stated in the table in the chapter “Stretching”.
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Service Manual SPE125/160/125L/160LApproved by: L-G Andersson
13- 3
Main lift chain system – 7120 Chain inspection T-code 789, 791 Date 2004-04-05
Valid from serial number 711956Order number 218367-040
13.3.8 Stretching The amount of stretch on a lift chain is measured on the part of the chain that runs over the chain sprocket. The amount of stretch may, at the most, be 2% on the most worn section of the chain. Measurement is suitably made over 300-1000 mm of the chain. The nominal and maximum permitted chain lengths for lift chains are stated in the table below.
Table 38: Stretching Type of chain
Nominal disc height H2 ( mm)
Minimum disc height H3 (mm)
Pitch P (mm)
Nominal chain length for 20/30/ 50 discs (mm)
Maximum permitted chain length for 20/ 30/50 discs (mm)
3/4”, 2x3
17.8
16.9
19.05
381/572/953
389/583/972
3/4”, 3x4
17.8
16.9
19.05
381/572/953
389/583/972
3/4”, 4x6
17.8
16.9
19.05
381/572/953
389/583/972
1”, 4x4
23,6
22,4
25,4
508/762/1270
518/777/1295
1”, 6x6
23,6
22,4
25,4
508/762/1270
518/777/1295
Wear to the bolts and around the holes on the discs are a reason why the chain stretches. The chain should be replaced if stretching is more than 2%.
13- 4
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Service Manual SPE125/160/125L/160L Approved by: L-G Andersson
Main lift chain system – 7120 Chain inspection Valid from serial number 711956Order number 218367-040
T-code 789, 791 Date 2004-04-05
13.3.9 Damage The chain should be replaced if damaged in any way.
13.3.10 Damaged discs If a disc has broken on the chain, this can be due to overloading or corrosion. The chain should be replaced.
13.3.11 Damaged bolts It can be difficult to discover whether a bolt has broken. It can appear as bolt rotation and/or that the outer disc is loose. The chain should be replaced.
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13- 5
Main lift chain system – 7120 Cleaning T-code 789, 791 Date 2004-04-05
Valid from serial number 711956Order number 218367-040
13.3.12 Dirty chain If a chain is very dirty it is first and foremost recommended that it is replaced. It can also be dismantled and cleaned as set out in the chapter “Cleaning”.
13.4 Cleaning If a chain is very dirty it is recommended that it is replaced. Dirty chains should be cleaned before they are lubricated, e.g. by washing with solvent such as diesel or petrol. The chain should be blown dry using compressed air and lubricated directly after cleaning NOTE! Exercise care with degreasing agent as these can contain abrasives.
13.5 Lubrication Mineral and synthetic oils can be used to relubricate Rexnord chains. NOTE! Lubricant must not contain substances such as molybdenum disulphide, PTFE or the like.
A lift chain should be offloaded from the weight of the fork carriage (hanging free) when lubricated. • Lubrication intervals: - 500 hours with normal operations - 100 hours when driving in rugged environments such as cold stores and corrosive environments. The chains are sprayed with lubricant. Note the entire chain must be lubricated, even the fastening bolts. It is especially important that the part of the chain which runs over the chain sprocket is well lubricated.
13- 6
© BT Europe AB
Service Manual SPE125/160/125L/160L Approved by: L-G Andersson
Main lift chain system – 7120 Lubrication Valid from serial number 711956Order number 218367-040
T-code 789, 791 Date 2004-04-05
The lubricate must comply with the viscosity demands at respective temperatures as set out in the table below. The following lubricants are recommended:
Table 39: Recommended Product Ambient temperature
Viscosity class
Recommended Products*
> - 40°C < - 30°C
VG 15
Klüberoil 4UH 1-15, Klüber Lubrication
> - 30°C < + 5°C
VG 68
> + 5°C < + 45°C
VG 150
>+ 45°C .
14.10.5 Reset hour meter To reset the truck’s hour meter, start the truck in drive mode and then select < Tools | Reset hour meters >.
14.10.6 Read error code log To show the truck’s error code log, select < Tools | Read error log >.
14.10.7 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! This does not apply to trucks without a real-time clock. 14- 16
© BT Europe AB
Service Manual SPE125/160/125L/160L Approved by: L-G Andersson
Control/computer equipment – 8700 Specifications Valid from serial number 711956Order number 218367-040
T-code 789, 791 Date 2004-04-05
14.10.8 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.
14.10.9 Help About TruckCom To see program information, select or tool button [About].
14.10.10 Exit To exit the program, select or the tool button [Exit].
14.11 Specifications Table 40: Can interface specification
© BT Europe AB
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
Service Manual SPE125/160/125L/160LApproved by: L-G Andersson
C
14- 17
Control/computer equipment – 8700 Installation T-code 789, 791 Date 2004-04-05
Valid from serial number 711956Order number 218367-040
14.12 Installation Note The program must be installed from the hard disk.
Note The software application in the computer can be damaged, which is why the PC installation should be performed by someone with the required knowledge. BT does not accept any responsibility for any errors that occur during the installation.
Note All references to PC operating system actions, menus and commands are based on the English language version of Windows®.
14.12.1 Installation on a PC with Windows® 95/98 If a previous version of the TruckCom application has been installed on the PC, it will be necessary to edit the System.ini file. Start the Msconfig.exe application by selecting the Start button, selecting Run and then typing msconfig. Click on System.ini and open the folder (386Enh). Unmark the option at Device=C:\Windows\Cpcppvd.vxd. Save the change and close the application. Now continue with installation The software application is supplied on a CD or via a network. Start installation by running X:\SETUP.EXE, where X:\ is the drive on which the installation application can be found. Then follow the on-screen instructions.
14.12.2 Installation on a PC with Windows XP/2000 To make the application work, it is necessary to first enter a value in the Windows® Registry and then make a few changes in the Windows® Control panel. Due to the built-in Windows® security, this must be done manually. The instructions below provide step-by-step guidance to enable these changes and make the interface operate under Windows XP and Windows 2000. The changes can be made either before or after TruckCom is installed. • Open the Registry Editor. To do this, select the Start button, then Run, type regedit and hit Enter.
14- 18
© BT Europe AB
Service Manual SPE125/160/125L/160L Approved by: L-G Andersson
Control/computer equipment – 8700 Installation Valid from serial number 711956Order number 218367-040
T-code 789, 791 Date 2004-04-05
• Mark the Enum folder which can be found under HKEY_LOCAL_MACHINE\SYSTEM\CurrentControlSet inside the Registry Editor.
Select the Edit option, then Find and type PortName to search for the correct folder. NOTE! The location of the folder differs between different computers (some may be .. \Enum\Root\.., while others could be ...\Enum\ACPI\... etc.). Thus be sure to search for the correct folder.
When the folder is found, check that LPTx (x=1, 2, 3, 4) is displayed in the PortName data field and that the folder name is Device Parameters. Right-click with the mouse in the right box to enter a new value of the DWORD type and with the name
EnableConnectInterruptIoctl.
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Service Manual SPE125/160/125L/160LApproved by: L-G Andersson
14- 19
Control/computer equipment – 8700 Installation T-code 789, 791 Date 2004-04-05
Valid from serial number 711956Order number 218367-040
Change the value in data field 1 by right-clicking on the name and selecting Modify.
14- 20
© BT Europe AB
Service Manual SPE125/160/125L/160L Approved by: L-G Andersson
Control/computer equipment – 8700 Installation Valid from serial number 711956Order number 218367-040
T-code 789, 791 Date 2004-04-05
EnableConnectInterruptIoctl
The Device Parameters folder should look like the one in the picture.
The Registry change is now complete. Close the Registry Editor. Changes in Windows® Control Panel Select the Start button. Choose Settings, then Control Panel and double-click on System, then select Hardware. Click on Device Manager and open Ports (Com & LPT).
© BT Europe AB
Service Manual SPE125/160/125L/160LApproved by: L-G Andersson
14- 21
Control/computer equipment – 8700 Installation T-code 789, 791 Date 2004-04-05
14- 22
© BT Europe AB
Valid from serial number 711956Order number 218367-040
Service Manual SPE125/160/125L/160L Approved by: L-G Andersson
Control/computer equipment – 8700 Installation Valid from serial number 711956Order number 218367-040
T-code 789, 791 Date 2004-04-05
Double-click on the LPT port to be changed, and select the Port Settings tab. Check the "Use any Interrupt assigned to the port" option and click on OK.
The software application is supplied on a CD or via a network. Start installation by running X:\SETUP.EXE, where X:\ is the drive on which the installation application can be found. Then follow the on-screen instructions.
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Control/computer equipment – 8700 Installation T-code 789, 791 Date 2004-04-05
Valid from serial number 711956Order number 218367-040
14.12.3 Installation on a PC with Windows NT The software application is supplied on a CD or via a network. Start installation by running X:\SETUP.EXE, where X:\ is the drive on which the installation application can be found. Then follow the on-screen instructions.
14.12.4 In case of communication problems with CAN Make sure the computer settings for the printer port in the BIOS Setup are as follows: Port address: 0378 IRQ:
7
Mode:
Output only
For detailed information on how to change the Setup settings, refer to the User's Guide supplied with the computer.
14.12.5 To uninstall To uninstall TruckCom under Windows®, select the Start button, Settings, Control Panel, Add/Remove Programs. To uninstall you must then select the TruckCom Program and click Change/Remove.
14- 24
© BT Europe AB
Service Manual SPE125/160/125L/160L Approved by: L-G Andersson
Control/computer equipment – 8700 Installation Valid from serial number 711956Order number 218367-040
T-code 789, 791 Date 2004-04-05
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© BT Europe AB SE-595 81 Mjölby Sweden www.bt-industries.com
