BT Service Training Manual - RR Version

TRAINING MATERIAL RR M
Valid for machine No. 337423-

Date: 2000-05-29
Ver: 001
Part number: 179395-040
© BT Products AB
TABLE OF CONTENTS RR M
0 SYMBOLS
HYDRAULIC SYMBOLS 0-1
HYDRAULIC SYMBOLS cont´d 0-2
ELECTRICAL SYMBOLS 0-3
ELECTRICAL SYMBOLS cont´d 0-4
COLOR / LINE SYMBOLS 0-5
1 IGNITION
SYSTEM OVERVIEW, IGNITION ON 1-1/2
KEY SWITCH OFF, BATTERY CONNECTED, CAN BUS 1-3
KEY SWITCH ON, BATTERY CONNECTED 1-4
KEY SWITCH ON 1-5
2 TRACTION
BRAKE RELEASE 2-1
DRIVE FORK DIR. 2-2
DRIVE STEER WHEEL DIR. 2-3
TRACTION SLOW DOWN 2-4
SPEED SENSOR SIGNALS 2-5
3 STEERING 3-1
STEERING 3-2
STEER TACHO INPUT 3-3
STEER TEST PULSE
4 BRAKE
BRAKE RELEASE 4-1
BRAKE APPLIED 4-2
BRAKE PERFORMANCE 4-3
PARKING BRAKE EMERGENCY RELEASE 4-4
5 HYDRAULIC
SYSTEM OVERVIEW 5-1/3
FORK LIFT 5-4/5
FORK LOWERING 5-6/7
MAST REACH OUT 5-8/9
MAST REACH IN 5-10/11
MAST SAFETY REACH IN 5-12
FORK TILT UP 5-13
FORK TILT DOWN 5-14
FORK SIDE SHIFT RIGHT 5-15
FORK SIDE SHIFT LEFT 5-16
SPARE 1 AND 2 5-17/18
FORK EMERGENCY LOWERING 5-19
MAST EMERGENCY REACH IN 5-20
LIFT LIMIT 5-21
© BT Products AB Page i
TABLE OF CONTENTS RR M
6 MISCELLANEOUS
BATTERY INDICATOR 6-1
PROGRAMMING CLOCK, DISPLAY ERROR 6-2
PROGRAMING DRIVERS PARAMETER 6-3
PARAMETER SETTING 6-4/7
MAIN CARD A5 6-8
DISPLAY 6-19
INPUT CIRCUIT PRINCIPLE MAIN CARD 6-10
OUTPUT CIRCUIT PRINCIPLE MAIN CARD 6-11
© BT Products AB Page ii
Type: RR M Date: 2000-05-29
Machine no: 337423- Version: 001

0. SYMBOLS
HYDRAULIC SYMBOLS
Single-acting hydraulic cylinder Pressure relief valve
Filter Directional control valve 3/2,

three ports, two distinct
positions
Reservoir (tank) Directional control valve 4/3,

four ports, three distinct
positions
Non-return valve Working line
Non-return valve, spring loaded Pilot (control) line
One-way restrictor valve Working line with junction
Gate-valve (emergency lowering)

Working line without junction
© BT Products AB Page 0-1


0. SYMBOLS
HYDRAULIC SYMBOLS cont´d
Enclosure of two or more

functions contained in one unit
Electric motor and two pumps

with fixed displacement on the
M same shaft, one direction of flow


0. SYMBOLS
ELECTRICAL SYMBOLS
Key switch, normally open Variable resistor
Switch, normally open Lamp
Capacitive proximity switch, Fuse

normally open
Push-button switch (non locking) Contactor

normally open
Push-button switch, Valve (coil)

normally closed
Emergency stop Brake (coil)
Proximity switch, operated on Battery

the approach of a magnet, 24 V
normally open


0. SYMBOLS
ELECTRICAL SYMBOLS cont´d
Motor, general
A1 A2 D.C series motor,

armature winding
M
D1 D2 Series winding
D.C series motor

D1 A2
M
Horn


0. SYMBOLS
COLOR / LINE SYMBOLS
Input LED, not active Output LED, active

Analog level
Input LED, active Not active line

Two level signal on/off 0.25mm = signal line
0.51mm = power line
Input LED, active Active line, positive

Two level signal on/off Two level signal (on/off)
Pulsing function 50-50% duty 0.25mm = signal line
0.51mm = power line
Input LED, active Active line, negative

Analog level Two level signal (on/off)
0.25mm = signal line
0.51mm = power line
Output LED, not active Active line, positive

Two level signal (on/off)
Pulsing function 50-50% duty
0.51mm = power line
Output LED, active Active line, positive

Two level signal on/off Analog level 0-100%
0.51mm = power line
Output LED, active Direction of signal

Two level signal 50-50% duty In/output
NOTE! Not dir. of current


1. IGNITION
SYSTEM OVERVIEW, IGNITION ON, DRIVER ON THE SEAT
G1 48V
X1 X1
+ -
26
F63
1
X42 40
2
MAIN CONTACTOR K10
F62
72
71
76
23
31
S1 34
804
INP MAIN CONTACTOR 808
INP BATTERY MONITOR 602

101 INP SETUP SELECT
S2 35
102 INP SETUP UP
S3
OUT MAIN CONTACTOR

36
103 INP SETUP DOWN
F60 21
805 + 48VDC
24
807 INP KEY
S23 43
110 INP LEFT FOOT SWITCH
S17 S21 22
809 INP +48VDC SUPPLY OUTPUTS
S26 45
104 INP DRIVE FORK DIR CREEP
46
105 INP STEER WHEEL DIR CREEP
S89 49
203 INP SEAT SWITCH
27
507 POT FEED 7-7,5VDC
50
R1 501 SPEED REFERENCE VALUE 3,7-1,7 VDC
28
508 POT GND
29
810 +15VDC
30
811 GND
58
210 INP STEER WHEEL ANGLE A
59
S66 211 INP STEER WHEEL ANGLE B
57
209 INP STEER WHEEL REF 180 DEG
S65 806
40
902 GND
25
901 +48VDC STEER SERVO
F61 60
903 OUT + STEER MOTOR
M6 61
904 GND FOR STEER MOTOR
62
509 INP STEERING WHEEL TACHO +
U1 129
511 GND FOR TACHO
S131
64
802 OUT PARKING BRAKE
Y1
51
R2 502 INP BRAKE REFERENCE VALUE 1,7-4,1 VDC
82
R11 503 INP JOYSTICK FORK 0,66-3,7-6,6 VDC
83
R12 504 INP JOYSTICK REACH CARRIAGE
84
R13 505 INP JOYSTICK TILT
85
R14 506 INP JOYSTICK SPARE 1
86
R15 510 INP JOYSTICK SPARE 2
202 OUT DATA COLLECT LIFT
208 OUT DATA COLLECT DRIVE
S56 80
207 INP REACH LOW SPEED IN
S46 106 303 INP SPEED REDUCTION, LIFT
S32 98 301 INP LIFT LIMIT
S33
S31
100
79
205 INP OVERRIDE A5
206 INP SPEED REDUCTION
PWR
M12
107
307 OUT POWER FAN ELECTRIC PANEL
S18 54
H1
E10
M10


1. IGNITION
SYSTEM OVERVIEW, IGNITION ON, DRIVER ON THE SEAT
121
SERIE + 405 1 SERIE +
122
SERIE - 406 2 SERIE -
RS 485 125
TX + 407 3 RX +
TX - 408
126
4 RX - A6
X41
117 117
OUT CAN +15VDC 401 118 1
118
OUT CAN GND 402 119 119 2
OUT/INP CAN H 403 120 3

120
OUT/INP CAN L 404 4
R100
R102 S132
88
OUT FORK LOWER 803
Y10
89
OUT FORK LIFT 701
S133
5
90
E1 160A F3 B+
REACH CARRIAGE IN 702 40
Y12 D1
6
B-
REACH CARRIAGE OUT 703
91
A2/E2
M
Y13
92
M3
TILT DOWN 704 119
Y14 J2-1
93 120
TILT UP 705
Y15 J2-8
94
SPARE 1A 706
Y16
A2 J2-16
22
95
SPARE 1B 707
Y17 2 125A F1 8
96 M1 U B+
SPARE 2A 708 3 40
B-
Y18 V
4
97 W 14
SPARE 2B 709 7
Y19 117
12 11 B1
118 4
13 10
119 3
10 12
120 5
11 13
6
A1 1 22
U11


1. IGNITION
KEY SWITCH OFF, BATTERY CONNECTED

CONTROLLER AREA NETWORK (CAN BUS)
u
M1
2
A1 B- B- A2 E1
~ v
3
B+ M3
B+ M
w 4 11 10 13 12 J2-16 J2-1 J2-8 A2/E2
- D1
22
R101
CAN +15V 117
CAN Gnd 118
CAN H 119
CAN L 120
R100
401 402 403 404

1 2 3 4
A5
808 In K10
Service Key 805 +48v
out K10 804

807 in S17
809 +48v supply outputs
R100 120ohm 0.6w

R101 120ohm 0.6w
A5
A1
A2
Service Key


1. IGNITION
KEY SWITCH OFF, BATTERY CONNECTED
K10
F1 F2
u B+ B- B+ B- E1
2
M1
~ -
v M3
3 M
D1
w 4 1 A1 J2-16 A2 A2/E2
F62
10A
40
F60 23 A5 0v 902
10A 808 In K10
21 Power
805 +48v
31
out K10 804
24
807 in S17
K10
S17 S21
22
809 +48v for outputs


1. IGNITION
KEY SWITCH ON
K10
F1 F2
u B+ B- B+ B- E1
2
M1 A1 A2
~ -
v M3
3 M
D1
w 4 1 J2-16 A2/E2
F62
10A
40
F60 23 A5 0v 902
10A 808 In K10
21 Power
805 +48v
31
out K10 804
24
807 in S17
K10
S17 S21
22
809 +48v for outputs


2. TRACTION
BRAKE RELEASE
F60 F62
10A 10A
23 A5
808 +48v
21 40
805 +48v 0v 902
24
807 in S17
S17 S21
22
809 In +48v for outputs
45
104 In Drive fork first, & Creep
S26
46
105 In Drive steer wheel, & Creep
S131 S89
64 49
203 In Seat switch
S23
43
110 In Left foot switch
27
507 feed out 7v to 7.5v
1.7 V 51
R2 502 In Brake pot voltage
28
508 0v for Pots & steering
3.7 V 50
R1 501 In speed pot voltage
Y1
64
Out parking brake 802


2. TRACTION
DRIVE FORK DIR.
From K10
F60
10A F2
21 A5
S17
805 +48v
M1
~ B1
U11
24 u w
807 in S17
v
S21
22
809 In +48v for outputs 2 3 4 14 11 10 12 13
12 V Supply.
45
S26
46
105 In Drive steer wheel, & Creep u v w 7 4 3 5 6
S89 49
203 In Seat switch
B+ B-
S23 43
110 In left foot switch
Out CAN +12v 401
117
12
A1
Out CAN Gnd 402 118
13
119
Out CAN H 403 10
Out CAN L 404 120

11 1
22
27
51
28 In 48 volt
50
R1 501 In speed pot voltage 3.7v - 1.7v
Y1
64
40
0v 902
Actions
Traction pulse control AC.
Variable Frequency


2. TRACTION
DRIVE STEER WHEEL DIR
From K10
F60
10A F2
21 A5
S17
805 +48v
M1
~ B1
U11
24 u w
807 in S17
v
S21
22
809 In +48v for outputs 2 3 4 14 11 10 12 13
12 V Supply.
45
S26
46
S89 49
203 In Seat switch
B+ B-
S23 43
Out CAN +12v 401
117
12
A1
Out CAN Gnd 402 118
13
119
Out CAN H 403 10
Out CAN L 404 120

11 1
22
27
51
28 In 48 volt
50
R1 501 In speed pot voltage 3.7v - 1,7v
Y1
64
40
0v 902


2. TRACTION
TRACTION SLOW DOWN
From K10
F60
10A F2
21
805 +48v A5
S17
u
M1
~ B1
U11
24 w
807 in S17
v
S21
22
809 In +48v for outputs 2 3 4 14 11 10 12 13
12 V Supply.
45
S26
46
S89 49
203 In Seat switch
B+ B-
S23 43
Out CAN +12v 401
117
12
A1
Out CAN Gnd 402 118
13
119
Out CAN H 403 10
Out CAN L 404 120

11 1
22
27
51
28 In 48 volt
50
R1 501 In speed pot voltage 3.7v - 1.7v
Y1
64
40
0v 902


2. TRACTION
SPEED SENSOR SIGNALS
FORK DIRECTION, SLOW SPEED FORK DIRECTION, FULL SPEED

+50V +50V
+40V +40V
+30V +30V
+20V +20V
+10V +10V
0V 0V
+20V +20V
+10V +10V
0V 0V
-10V -10V
-20V -20V
0ms 30ms 0ms 30ms
STEER WHEEL DIRECTION, SLOW SPEED STEER WHEEL DIRECTION, FULL SPEED
+50V +50V
+40V +40V
+30V +30V
+20V +20V
+10V +10V
0V 0V
+20V +20V
+10V +10V
0V 0V
-10V -10V
-20V -20V
0ms 30ms 0ms 30ms
CHAN. A
CHAN. B


3. STEERING
STEERING
A5
29
810 +15
30
811 0 volt
58 210 In Steer angle A
59 211 In Steer angle B

S66
22 48 Volt
57
209 In Steer reference 180 deg
40 S65
40 902 0 volt
F61 30A
1 25
901 +48v Steering
60
903 Out +Steer Motor
M6
61
904 Out - Steer Motor
62
509 In Steer Tacho
U1
28
508 In Steer Tacho
122 405 SERIE +

SERIE +, 1
121
SERIE -, 2 406 SERIE -
125
RX +, 3 407 TX +
126
RX -, 4 408 TX -
A6


3. STEERING
STEER TACHO INPUT
+5V
+4V
+3V
+2V
+1V
0V
-1V
-2V
-3V
-4V
-5V
250 rpm CCW 0 rpm CW 250 rpm


3. STEERING
STEER GENERATOR TEST PULSE, STEER MOTOR OUTPUT
STEER TACHO TESTPULSE

+50V +50V
+40V +40V
+30V +30V
+20V +20V
+10V +10V
0V 0V
-10V -10V
-20V -20V
-30V -30V
-40V -40V
-50V -50V
0ms 1ms 0ms 100ms
STEER MOTOR OUTPUT
NEUTRAL CCW, FULL SPEED
+50V +50V
+40V +40V
+30V +30V
+20V +20V
+10V +10V
0V 0V
-10V -10V
-20V -20V
-30V -30V
-40V -40V
-50V -50V
0ms 200ms 0ms 200ms
AVERAGE VOLTAGE AT: AVERAGE VOLTAGE AT:

TERMINAL 903 (M+) ~24V 903 TERMINAL 903 (M+) ~47,5V 903
TERMINAL 904 (M-) ~24V 904 TERMINAL 904 (M-) ~0,5V 904


4. BRAKE
BRAKE RELEASE
F60 F62
10A 10A
23 A5
808 +48v
21 40
805 +48v 0v 902
24
807 in S17
S17 S21
22
45
S26
46
S131 S89
64 49
203 In Seat switch
S23
43
27
1.7 V 51
28
3.7 V - 1.7V 50
Y1
64


4. BRAKE
BRAKE APPLIED
4,1 V 100%
90% A5
R2 502 REFERENCE
0-60%
VALUE
1,7 V
F60 F62
10A 10A
23 A5
808 +48v
21 40
805 +48v 0v 902
24
807 in S17
S17 S21
22
45
S26
46
S131 S89
64 49
203 In Seat switch
S23
43
27
1.7 V - 4.1V 51
28
3.7 V 50
Y1
64


4. BRAKE
BRAKE PERFORMANCE
Brake performance without support arm brakes
Electro mechanical brake

Brake Force
Regenerative motor brake
0% 25% 50% 75% 100%

Brake Pedal Stroke


4. BRAKE
PARKING BRAKE EMERGENCY RELEASE
F60 F62
10A 10A
23 A5
808 +48v
21 40
805 +48v 0v 902
24
807 in S17
S17 S21
22
45
S26
46
S131 S89
64 49
203 In Seat switch
S23
43
27
51
28
50
Y1
64


5. HYDRAULIC
SYSTEM OVERVIEW
13
3 1 2
1 2
1 2 11 13 12
11 12
11
Duplex Duplex Triplex

HiLo Tele HiLo
4 5 6
C1 C2
14
B1 B2
H A B B1 A1 B2 A2
15
Y13 Y14 Y17
30
Y10/2 Y10/3
16
18
Y12 17 Y15 Y16
P R
25
24
26
M3


5. HYDRAULIC
SYSTEM OVERVIEW
13
3 5 6
1 2 C1 C2
7
11 12
4 14 A1
A2
Y17 Y16
B1 B2
H A B B1 A1 B2 A2
15
Y13 Y14 Y19
30
Y10/2 Y10/3
16
18
Y12 17 Y15 Y18
P R
25
24
26
M3


5. HYDRAULIC
SYSTEM OVERVIEW
13
3
1 2 4 5 6 7
11 12 C2 A1
C1 C2
C1 A2
Y18
Y19
14 B1 B2
B1 B2
H A B B1 A1 B2 A2
15
Y13 Y14 Y17
30
Y10/2 Y10/3
16
18
Y12 17 Y15 Y16
P R
25
24
26
M3


5. HYDRAULIC
FORK LIFT
Triplex Duplex
HiLo HiLo
3
13
3
1 2
1 2
11 13 12
11
Triplex Duplex
HiLo Tele
3 13
1 2
1 2
12 11 12
11
18
Y10/2 Y10/3
88
40
89 18
M3
P1
F1


5. HYDRAULIC
FORK LIFT
From K10
F60
10A
21
805 +48v A5
S17
24 D1 E1
807 in S17
S21 M3
22
809 In +48v for outputs -
S89
49
203 In Seat switch A2/E2
27
82
R11 503 In joystick forks
3.7 V- 6 V 6
28 M
40
83 B-
R12 504 In joystick reach carriage
3.7 V
5
B+ A2
S46 106
303 In Reduced Lift Speed
119
Out CAN H 403 J2-1
Out CAN L 404 120

J2-8 J2-16
From R13 84 505 In joystick tilt 22
From R14 85 506 In joystick spare 1

In 48 volt
89
Out Fork Lift 701
Y10
Out Fork Lower 803 88
40
0v 902
Actions
Hydraulic pulse control AC
Variable Frequency


5. HYDRAULIC
FORK LOWER
Triplex Duplex
HiLo HiLo
3
13
3
1 2
1 2
11 13 12
11
Triplex Duplex
HiLo Tele
3 13
1 2
1 2
12 11 12
11
Y10/2 Y10/3
88
40
89 18
M3
P1
F1


5. HYDRAULIC
FORK LOWER
From K10
F60
10A
21
805 +48v A5
S17
24 D1 E1
807 in S17
S21 M3
22
S89
49
203 In Seat switch
A2/E2
27
82
3.7 V- 0.7 V 6
28
508 0v for Pots & steering M
40
83 B-
3.7 V
5
B+ A2
S46 106
Out CAN H 403 119
J2-1
Out CAN L 404 120
J2-8 J2-16

In 48 volt
89
Out Fork Lift 701
Y10
RV1 88
Out Fork Lower 803
40
0v 902


5. HYDRAULIC
MAST REACH OUT
40 91
A B
15
Y13
16
18
Y12
17
P R
40 90
P1 M3
F1


5. HYDRAULIC
MAST REACH OUT
From K10
F60
10A
21
805 +48v A5
S17
24 D1 E1
807 in S17
S21 M3
22
S89
49
27
82
6
28 M
40
83 B-
3.75 V- 0.7 V
5
B+ A2
S56 80
207 In reach carriage low speed in
Out CAN H 403 119
J2-1
Out CAN L 404 120
J2-8 J2-16
From R13 84 22
505 In joystick tilt

In 48 volt
702 90
Out Reach In
Y12
Out Reach out 703 91

Y13
40
0v 902


5. HYDRAULIC
MAST REACH IN
40 91
A B
15
Y13
16
18
Y12
17
P R
40 90
P1 M3
F1


5. HYDRAULIC
MAST REACH IN
From K10
F60
10A
21
805 +48v A5
S17
24 D1 E1
807 in S17
S21 M3
22
S89
49
27
82
6
28 M
40
83 B-
3.75 V- 6 V
5
B+ A2
S56 80
207 In reach carriage low speed in
Out CAN H 403 119
J2-1
Out CAN L 404 120
J2-8 J2-16

In 48 volt
702 90
Out Reach In
Y12

Y13
40
0v 902


5. HYDRAULIC
MAST SAFETY REACH IN
40 91
A B
15
Y13
16
18
Y12
17
P R
40 90
P1 M3
F1


5. HYDRAULIC
FORK TILT UP
5
5 6
C1 C2
14 C1 C2
B1 B2 14 A1
A2
Y17 Y16
5
B1 B2
C1 C2
40 95 94 40
14
B1 B2 40 92
B1 A1
Y14
18
Y15
P R
40 93
P1 M3
F1


5. HYDRAULIC
FORK TILT DOWN
5
5 6
C1 C2
14 C1 C2
B1 B2 14 A1
A2
5 Y17 Y16
B1 B2
C1 C2
40 95 94 40
14
B1 B2 40 92
B1 A1
Y14
18
Y15
P R
40 93
P1 M3
F1


5. HYDRAULIC
FORK SIDE SHIFT RIGHT
5 6
C1 C2
14 A1
A2
Y17 Y16
B1 B2
40 95 94 40
40 92
B1 A1
Y14
18
Y15
P R
40 93
P1 M3
F1


5. HYDRAULIC
FORK SIDE SHIFT LEFT
5 6
C1 C2
14 A1
A2
Y17 Y16
B1 B2
40 95 94 40
40 92
B1 A1
Y14
18
Y15
P R
40 93
P1 M3
F1


5. HYDRAULIC
SPARE 1 AND 2
6 7 6 7
C2 A1 C2 A1
C1 A2 C1 A2
Y18 Y18
B1 B2 Y19 B1 B2 Y19
40 95 40 95
40 95
B1 A1
Y17
18
Y16
P R
40 94
P1 M3
F1


5. HYDRAULIC
SPARE 1 AND 2
6 7 6 7
C2 A1 C2 A1
C1 A2 C1 A2
Y18 Y18
B1 B2 Y19 B1 B2 Y19
40 95 40 95
40 95
B1 A1
Y17
18
Y16
P R
40 94
P1 M3
F1


5. HYDRAULIC
FORK EMERGENCY LOWERING
From K10
F60
10A
21
805 +48v A5
S17
24 D1 E1
807 in S17
S21 M3
22
S89
49
203 In Seat switch
A2/E2
27
82
R11 503 In joystick forks 0.7 Volt
6
28
508 0v for Pots & steering M
40
83 B-
5
B+ A2
S46 106
Out CAN H 403 119
J2-1
Out CAN L 404 120
J2-8 J2-16

In 48 volt
89
Out Fork Lift 701
Y10
Out Fork Lower 803 88
40
0v 902
S132 48V 9.V
R102


5. HYDRAULIC
MAST EMERGENCY REACH IN
From K10
F60
10A
21
805 +48v A5
S17
24 D1 E1
807 in S17
S21 M3
22
S89
49
27
82
6
28 M
40
83 B-
5
B+ A2
S46 106
Out CAN H 403 119
J2-1
Out CAN L 404 120
J2-8 J2-16
From R14 85
506 In joystick spare 1

In 48 volt
702 90
Out Reach In
Y12

Y13
40
0v 902
S133


5. HYDRAULIC
LIFT LIMIT
22
S32
A5
S33
98
205 In Lift limit override
100
301 In lift limit special
height


6. MISC.
BATTERY INDICATOR
48 V
1 SHUNT WIRE 40
LOAD
A2
72
410 BATT IND. CURRENT
71
409 BATT IND. - / CURRENT -
70
408 BATT IND. +
A3
1 121
+1 101 +
122
-2 102 -
1/2 123
RX+ 3 103 TX+
124
RX- 4 104 TX-
0


6. MISC.
PROGRAMMING CLOCK, DISPLAYING ERROR, PARAMETER

AND TIMER
PRESS ( I ) IN NORMAL MODE (RETURNS AUTOM. AFTER 10 SEC. IDLE)
+1
( II )
SETTING THE HOURS 0-23
( III )
-1
(I)
+1
( II )
SETTING THE MINUTES 0-59

( III )
-1
(I)
+1
( II )
DISPLAY ERROR HISTORY 0-50
( III )
DATE ( III ) TIME ( III )
(I)
+1
( II )
SERVICE TIME
DISPLAY SAVED PARAMETERS 1-42 ( II )
PUMP MOTOR TIME
( II )
DRIVE MOTOR TIME
( II )
(I)
KEY TIME
( II )
TOTAL MOVEMENT
( II )
DISPLAY IGNITION TIME


6. MISC.
PROGRAMING DRIVERS PARAMETERS
START UP TRUCK, SELECT DRIVER, TURN OF.

PRESS ( I ) AND HOLD DURING POWER UP.
A
+1
( II )
01. STEERING SENSITIVITY (I) 1-6 (I) STORED
( III )
-1
( II ) ( III )
+5
( II )
02. DRIVE MOTOR MAX SPEED (I) 10-100 (I) STORED
( III )
-5
( II ) ( III )
+5
( II )
03. DRIVE MOTOR ACCELERATION (I) 10-100 (I) STORED
( III )
-5
( II ) ( III )
+5
( II )
04. DRIVE MOTOR PLUG BRAKE (I) 0-100 (I) STORED
( III )
-5
( II ) ( III )
+5
( II )
05. DRIVE MOTOR AUTO PLUG BRAKE (I) 35-100 (I) STORED
( III )
-5
FOLLOW “B”
WITHOUT PROGRAMING POSSIBILITY


6. MISC.
PARAMETER SETTING
CONNECT CAN-TOOL TO X41
PRESS ( I ) DURING POWER UP
DRIVER NO:10
A
DRIVER NO:2
DRIVER NO:1
+1
( II )
01. STEERING SENSITIVITY (I) 1-6 (I) STORED (I) STORED
( III )
-1
( II ) ( III )
+5
( II )
02. DRIVE MOTOR MAX SPEED (I) 10-100 (I) STORED (I) STORED
( III )
-5
( II ) ( III )
+5
( II )
03. DRIVE MOTOR ACCELERATION (I) 10-100 (I) STORED (I) STORED
( III )
-5
( II ) ( III )
+5
( II )
04. DRIVE MOTOR PLUG BRAKE (I) 10-100 (I) STORED (I) STORED
( III )
-5
( II ) ( III )
+5
( II )
05. DRIVE MOTOR AUTO PLUG BRAKE (I) 35-100 (I) STORED (I) STORED
( III )
-5
( II ) ( III )
+1
( II )
(I) STORED B
10. PIN CODE (I) 000-3333 (I) STORED
( III )
-1


6. MISC.
PARAMETER SETTING
B
+5
( II )
11. DRIVE MOTOR SPEED REDUCTION (I) 10-100 (I) STORED
( III )
-5
( II ) ( III )
+5
( II )
12. MAST OUT/IN MOVEMENT SPEED (I) 10-100 (I) STORED
( III )
-5
( II ) ( III )
+5
( II )
13. EXTRA FUNCTION 1 SPEED (I) 10-100 (I) STORED
( III )
-5
( II ) ( III )
+5
( II )
14. EXTRA FUNCTION 2 SPEED (I) 10-100 (I) STORED
( III )
-5
( II ) ( III )
+5
( II )
15. EXTRA FUNCTION 1 FORCE (I) 10-100 (I) STORED
( III )
-5
( II ) ( III )
+5
( II )
16. EXTRA FUNCTION 2 FORCE (I) 10-100 (I) STORED
( III )
-5
( II ) ( III )
+1
( II )
20. TIME INDICATION (I) 1-5 (I) STORED
( III )
-1
D


6. MISC.
PARAMETER SETTING
D
+1
( II )
21. BATTERY SIZE (I) 1-20 (I) STORED
( III )
-1
( II ) ( III )
+1
( II )
23. TYPE OF MAST (I) 0/1 (I) STORED
( III )
-1
( II ) ( III )
+1
( II )
24.LEFT FOOT SWITCH (I) 1/0 (I) STORED
( III )
-1
( II ) ( III )
+50
( II )
25. SERVICE INTERVAL (I) 0-2000 (I) STORED
( III )
-50
( II ) ( III )
+5
( II )
26. TILT SPEED (I) 10-100 (I) STORED
( III )
-5
( II ) ( III )
+1
( II )
27. LIFT PRIORITY (I) 1/0 (I) STORED
( III )
-1
( II ) ( III )
+1
( II )
28. INDICATION SIGNAL (I) 1/0 (I) STORED
( III )
-1
E


6. MISC.
PARAMETER SETTING
E
+1
( II )
38. CALIBRATION POT/ REACH (I) 1/0 (I) STORED
( III )
-1
( II ) ( III )
+1
( II )
39. DIVERS ACCESS (I) 1-4 (I) STORED
( III )
-1
( II ) ( III )
+1
( II )
40. CLOCK YEAR (I) 0-99 (I) STORED
( III )
-1
( II ) ( III )
+1
( II )
41. CLOCK DAY (I) 1-31 (I) STORED
( III )
-1
( II ) ( III )
+1
( II )
42. CLOCK MONTH (I) 1-12 (I) STORED
( III )
-1
A


6. MISC.
MAIN CARD A5
170600-XXX


6. MISC.
DISPLAY
A B C D E
F G H I J K
A. PARKING BRAKE
B. DIRECTION INDICATOR
C. TIME DISPLAY
D. DISPLAY OF HOUR READING/ERROR CODES
E. OPERATOR IDENTIFICATION
F. DRIVE WHEEL INDICATOR
G. ERROR CODE CONTROL
H. WEIGHT INDICATION
I. PARAMETER CONTROL
K. BATTERY CONTROLLER


6. MISC.
INPUT CIRCUIT PRINCIPLE, A5 CARD
NORMAL INPUT CIRCUIT
+
IN R4
mP
R1
R3 C1
D1
The input is an "active high" input. The signal which comes from switches
etc. is positive. The LED D1 is connected to a pull-down resistor R1.
The voltage is divided by R4 / R3 for the uP. C1 is a filter capacitor.
HEIGHT SENSOR INPUT CIRCUIT
+15V
R1
+ D1
IN R2
mP
C1
R3
The speed / height sensors are "active low" type. The pulses which come
from the sensors are negative. Therefore the LED D1 is connected to a
pull-up resistor. When the input is deactivated, 15 volts are divided by
R2 / R3 for the uP.
C1 is a filter capacitor.


6. MISC.
OUTPUT CIRCUIT PRINCIPLE, A5 CARD
NORMAL OUTPUT CIRCUIT
+48V
OUT
R3
R2
R4
IC1
mP R1 D1 D2
T1 LOAD
<100 W
C1
R5
Activate the output:

The uP sends a short pulse (1) to IC1 which trigger T1 and the output is
activated. After the pulse, the uP reads the signal via R5 and check that the
level is high.The R5 holds the level high continously.
Deactivate the output:

The uP sets the IC1 low which deactivates T1 and the output is
deactivated. After the pulse the uP reads the signal via R5 and checks that
the signal is low. The uP holds the level low continously.
Open wire protection:

If the load is disconnected, the R3 feeds a high signal to the uP via R5, wich
detect a high signal when low is requested.
Short circuit protection:

If the output is shorted to negative the uP detect a low signal via R5 when
high is requested.
D1 is a free wheel diode.

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BT Service Training Manual - RR Version

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TRAINING MATERIAL RR M

Valid for machine No. 337423-

Part number: 179395-040

Machine no: 337423- Version: 001

Single-acting hydraulic cylinder Pressure relief valve

Filter Directional control valve 3/2,

Reservoir (tank) Directional control valve 4/3,

Non-return valve Working line

Non-return valve, spring loaded Pilot (control) line

One-way restrictor valve Working line with junction

Gate-valve (emergency lowering)

© BT Products AB Page 0-1

Machine no: 337423- Version: 001

HYDRAULIC SYMBOLS cont´d

Enclosure of two or more

Electric motor and two pumps

© BT Products AB Page 0-2

Machine no: 337423- Version: 001

Key switch, normally open Variable resistor

Switch, normally open Lamp

Capacitive proximity switch, Fuse

Push-button switch (non locking) Contactor

Push-button switch, Valve (coil)

Emergency stop Brake (coil)

Proximity switch, operated on Battery

© BT Products AB Page 0-3

Machine no: 337423- Version: 001

ELECTRICAL SYMBOLS cont´d

A1 A2 D.C series motor,

D.C series motor

© BT Products AB Page 0-4

Machine no: 337423- Version: 001

COLOR / LINE SYMBOLS

Input LED, not active Output LED, active

Input LED, active Not active line

Input LED, active Active line, positive

Input LED, active Active line, negative

Output LED, not active Active line, positive

Output LED, active Active line, positive

Output LED, active Direction of signal

NOTE! Not dir. of current

© BT Products AB Page 0-5

Machine no: 337423- Version: 001

SYSTEM OVERVIEW, IGNITION ON, DRIVER ON THE SEAT

MAIN CONTACTOR K10

INP BATTERY MONITOR 602

OUT MAIN CONTACTOR

© BT Products AB Page 1-1

Machine no: 337423- Version: 001

SYSTEM OVERVIEW, IGNITION ON, DRIVER ON THE SEAT

OUT/INP CAN H 403 120 3

© BT Products AB Page 1-2

Machine no: 337423- Version: 001

KEY SWITCH OFF, BATTERY CONNECTED

CAN Gnd 118

401 402 403 404

Service Key 805 +48v

out K10 804

809 +48v supply outputs

R100 120ohm 0.6w

© BT Products AB Page 1-3

Machine no: 337423- Version: 001

KEY SWITCH OFF, BATTERY CONNECTED

© BT Products AB Page 1-4