P20 (Ano 2002)

Service Manual GB
P20
Valid from serial number: 364690AA-723983
Order number: 178826-040

Issued: 2002-04-29 ITS
© BT Industries AB
C-code T-code Valid from serial number
364690AA-
Version Date Order number
2002-04-29 178826-040
2 © BT Industries AB Service Manual P20 Approved by:

Contents
Valid from serial number T-code C-code/Section
364690AA-
Order number Date Version
178826-040 2002-04-29
Contents 1
Technical data ....................................................... 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 .................... 5 - 1
Tools .............................................................................. 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 Approved by: 1–3

Contents
C-code/Section T-code Valid from serial number
364690AA-
2002-04-29 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

Hydraulic chart and list of symbols 1
Adjusting the pressure limit valve 2
1–4 Service Manual P20 Approved by:

Contents
364690AA-
178826-040 2002-04-29
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 12

Contents
364690AA-
2002-04-29 178826-040

Technical data
364690AA- 662 M4
178826-040 2002-04-29 001
Technical data 2
Model P20-6 P20-8
Drive motor
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 >= 1Mohm >= 1Mohm
and motor casing
Weight, kg 14 17
Broms
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
Transmission/drive gear
Type 2-stage angle trans- 2-stage angle trans-
mission mission
Gear ratio 19,14:1 19,14:1
Oil volume, litre 1.0 1.0
Oil type Hypoid olja Hypoid olja
at normal temperature SAE 80W/90 SAE 80W/90
at temperature < -15oC SAE 75W SAE 75W
Service Manual P20 Approved by: L-G Andersson 2–1

Technical data
M4 662 364690AA-
001 2002-04-29 178826-040
Model P20-6 P20-8

Wheels
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)
Hydraulic system
Output, kW 2.2 2.2
Duty cycle,% 10 10
Minimum carbon brush length, mm 12 12
Minimum commutator thickness/diameter, 4.7 4.7
mm
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: Hydraulic oil Hydraulic oil
at normal temperature ISO-L-HM32 ISO-L-HM32
at temperature < -15oC ISO-L-HV32 ISO-L-HV32
Fuses
Drive motor circuits, A 125 125
Pump motor circuits, A 125 125
Control circuits, A 7,5 7,5
2–2 Service Manual P20 Approved by: L-G Andersson

Technical data
364690AA- 662 M4
178826-040 2002-04-29 001
Model P20-6 P20-8

Battery compartment, Batteries
Dimensions LxWxH, mm 193x642x450-510 193x642x450-510
Capacity, Ah 240-320 240-320
Weigh, kg 210-250 210-250
Driving speed
Without load, km/t 6,0 8,0
Without load, m/s 1.7 2.22
With rated load, km/t 6,0 7.2
With rated load, m/s 1,7 2.0
Lift/lowering speed
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
Power consumption
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
Incline climbing ability
With rated load 9% 9%
Measurement, L2
Medium 660 660
Lång 1008 1008
Turning radius WA 1960 1960
Lift height 205 205
Weight
Truck without battery, Medium 420 440

Technical data
M4 662 364690AA-
001 2002-04-29 178826-040

Introduction Maintenance
364690AA- 662 P1
178826-040 2000-06-01 001
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 oper-
ator may adapt them to local conditions, but it is important that the
intervals comply with BT’s minimum requirements.
The service intervals are based on the running times and can be
adapted to most normal 8 hour shifts. The service interval may be
shortened if the truck is used more frequently or in more demanding
situations, e.g cold store, dusty or corrosive situations. The following
running times have been used when calculating the intervals:
- Day time: 08.00-17.00 (20 hr./week)
- 2-shifts: 06.00-14.00, 14.00-22.00 (40 hr./week)
- 3-shifts: 06.00-14.00, 14.00-22.00,22.00-06.00
(60 hr./week)
Ensure the truck is given a regular maintenance service after every
500 driving hours. The truck’s safety, efficiency and service life is
dependent on the service and maintenance it is given.
Only use BT approved spare parts when service and repair work are
carried out.
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 electri-
cal 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 cov-
ers on the drive unit or electrical system

P1 662 364690AA-
001 2000-06-01 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 leak-
age. 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.

364690AA- 662 P1
178826-040 2000-06-01 001
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 concen-
tration
• 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 chap-
ter Maintenance and lubrication chart.
Cleaning the motor compartment

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

P1 662 364690AA-
001 2000-06-01 178826-040
Electrical components
• Blow electric motors down using compressed air
• Clean the electrical panels, electronic boards, contactors, connec-
tions, solenoid valves, etc. using a damp cloth and a cleaning agent
NOTE!
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 cor-
ner 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.

Preventive maintenance
364690AA- 662 P2
178826-040 2002-04-29 001
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. Work to carry out
No. 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) I/L
0380.4 Check the lift limit switch l
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 I/T1 I/T
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 T2
1700.5 Check for abnormal noise in bearing l

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2550 Drive gear
2550.1 Check for leakage I3 I
2550.2 Check the oil level I
2550.3 Check for abnormal noise I
2550.4 Check the attachment and clearance in I
steering bearing
2550.5 Change the oil in the drive gear L4 L
3100. Brake
3100.1 Clean C
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 I
3500.2 Check the drive wheel for wear and the tight- I/T
ening torque on bolts
3500.3 Check that the support wheel turns and I
rotates freely
3500.4 Check for wear on the support wheel I
4110 Tiller arm
4110.1 Check the mountings I
4110.2 Check the power in the gas damper I
5000 Electrical functions
5000.1 Check the operation of the brake micros- I I/L
witch in the upper and lower brake positions.
Lubricate the switch head.
5000.2 Check the function of the collision safety I
switch
5000.3 Check the function of the gate switches I I

364690AA- 662 P2
178826-040 2002-04-29 001

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 I
5000.7 Check the function of the driver’s control I I
5000.8 Check the error code log and operating I I
times
5110 Battery
5110.1 Check the electrolyte level, 10-15 mm over M
the cell plates
5110.2 Check connections to battery, truck and I
charger
5110.3 Check that the cell and pole guards are I
undamaged
5110.4 Check the fluid density and temperature M
5110.5 Remove overflow fluid from the battery C
trough
5110.6 Check the battery locking I I
5400 Power system
5400.1 Cleaning and checking of mounting in chas- C/ C/T
sis 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 T1 I
5700.2 Check all segments on the display I

P2 662 364690AA-
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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 I
damaged mountings
6100.4 Check that the oil level is correct I
6100.5 Change the oil and clean the filter L5 L
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 I
the PowerTrak spring
6680.2 Grease in the contact pressure spring’s C/L
guides
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 eve-
ry 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 speci-
fied above.

364690AA- 662 P2
178826-040 2002-04-29 001
5000 5000
6680
4110
5110
5700
5000
0380
5400
6600
3100
1700
6100
0560
0000
2550
5000
3500

P2 662 364690AA-
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Lubrication schedule
Pos. Service point Interval/Operating hours Type of
No. 80 h 500 1000 h 3000 h lubricant
0380 Lubricating nipples (Option) L E
2550 Drive gear O4 C O C
6100 Hydraulic system O5 O B
L = Lubrication C = Check O = Oil change
4 = The oil is changed for the first time after 80 h/1 month, and then eve-
ry 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

Oil and grease specifica tion
364690AA- 662 P3
178826-040 2002-04-29 001
Oil and grease specifica tion 5
Pos. Type of lubri- Specification Application

cant > -15° C < -15o C
A Grease BT 26777 BT 26777 Bearings and bushes
(Spray) (Spray)
B Hydraulic oil ISO-L-HM32 ISO-L-VG 32 Hydraulic system
C Transmission oil Hypoid oil SAE Hypoid oil SAE Gears
80W/90 75W
D Grease Staburags Staburags Guide bearing
NBU 8EP NBU 8EP
E Grease BT 73942XX5 BT 73942XX5 Lubricating nipples,
TOTAL N3942 TOTAL N3942 Contact pressure spring

Oil and grease specifica tion
P3 662 364690AA-
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Tools
364690AA- 662 P4
178826 -040 2000-06-01 001
Tools 6
Super Seal connectors
3
3
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)

Tools
P4 662 364690AA-
001 2000-06-01 178826 -040
AMP connectors

31-151080 Tool for removal of pins/sleeves
1=163787 Tool for application of sleeves

2=163788
1
2
1=163789 Tool for application of pins
2=163790 1: For 0.2-0.5 mm2
3=163791 2: For 0.5-1.0 mm2
3: For 1.5-2.5 mm2

Tools
364690AA- 662 P4
178826 -040 2000-06-01 001
Other tools
156263 Service instrument (CAN)
1=163793 Service instrument for

2=163792 program modification
1=155619-001 1= Service instrument for Curtis

2=166161 transistor panel
3=166473 2= Cable for Curtis 1243 and
1207A
When ordering 3= Cable for Curtis 1207
155619-001 both
cables are
received

Tools
P4 662 364690AA-
001 2000-06-01 178826 -040

08-13022 Puller, drive gear

Electric drive motor
364690AA- 662 1760
178826-040 2002-04-29 001
Electric drive motor 7

Component parts
16
21
20
14 19
18
13 17
15 10
12
11 8
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

1760 662 364690AA-
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10 Key
11 Plug
12 Stator
13 Cable
14 Cable
15 Bearing shield
16 Screw M6x25
17 Seal
18 Bearing
19 Washer
20 Locking ring
21 Locking ring

364690AA- 662 1760
178826-040 2002-04-29 001
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 com-
partment together with the tiller arm.
• Carefully lift the motor straight up, without damaging the sealing sur-
faces 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 cov-
er and tiller arm, and connect the cables that were previously re-
moved. Check that the polarity is correct.
• The function of the brakes should be checked before the truck is
moved.

1760 662 364690AA-
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Service/Repairs
Dismantling of motor
16
21
20
14 19
18
13 17
15 10
12
11 8
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.

364690AA- 662 1760
178826-040 2002-04-29 001
• 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 re-
moved. 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 bear-
ing 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 rota-
tion and that the carbon brushes are flush with the commutator.
• Check the motor’s insulation resistance (between respective wind-
ing 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 compart-
ment 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 Com-
pressed 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.

1760 662 364690AA-
001 2002-04-29 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
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 car- 11 11
bon brush (mm)
Minimum commutator 47 60
diameter (mm)
Resistance, shunt field 0,49 0,498
winding Ω at 26 C°
Resistance, armature 0,0156 0,0161
winding,Ω at 26C°
Insulation resistance >= 1Mohm >= 1Mohm
between windings and
motor housing
Weight (kg) 14 17

Drive unit/gear
364690AA- 662 2550
178826-040 2000-06-01 001
Drive unit/gear 8
3
4
5
6
01
7
8
24
9
25 27
10 26
11
28
13
12 14
32
31
30
15 29
19
18
17
16
20 23
21 22

Drive unit/gear
2550 662 364690AA-
001 2000-06-01 178826-040
Component parts

01 Drive gear complete
2 Air valve
3 Cover
4 Dip stick
5 Washer
6 Gasket
7 Nut Tightening torque 70 Nm
Locked with punch mark
8 Washer
9 Gear wheel Primary gear
10 Conical roller bearing
11 Shims
12 Screw Top cover and gear housing
Tightening torque 26.6 Nm
Lock with Loctite 242
13 Shims
15 Pinion/ Crown gear Cog clearance 0.09-0.15 mm
Pretension bearing with 2-5/100
Stamped size on pinion adjusted
with shims
17 Shims
19 Shims
20 Screw Bottom cover and gear housing

Drive unit/gear
364690AA- 662 2550
178826-040 2000-06-01 001

21 Screw Bottom cover and gear housing
22 Cover
23 Gasket
24 Gear wheel Motor gear
25 Washer
27 Screw Motor and gear housing
28 Nut Tightening torque 26.6 Nm
30 Shims
31 Seal
32 Drive shaft
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

Drive unit/gear
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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).

Drive unit/gear
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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.

Drive unit/gear
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Electro magnetic brake
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Electro magnetic brake 9

Main components of the brake
9 1
8
2
6
4
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

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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 readjust-
ment 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.

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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 refit-
ted.
• 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.

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Steering system
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Steering system 10
Component parts, tiller arm
Serial number 364690AA-432919AA
1
8
9
10 11
12
14 13
16
15
18 17
19
20
21
22
23
Service Manual P20 Approved by: L-G Andersson 10 – 1

Steering system
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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 4
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 S 10
10 – 2 Service Manual P20 Approved by: L-G Andersson

Steering system
364690AA- 662 4000
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Serial number 432920AA-

1
9 10
11
13 12
15
14
17 16
18
19
20
21
22

Steering system
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001 2002-04-29 178826-040

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 4
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 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.

Steering system
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Tiller arm handle

28
29
27 26
24 14
25 14
23 22
17
21 18
20 16
19 15
14
30 14
31 13
12
10 11
32 9
8
35 33
34
5 6 7
4
1 2
3

1 Screw
2 Cover Keyboard option
3 Handle
4 Electronic circuit board
5 Screw
6 Display card
7 Top cover
8 Pushbutton Option
9 Signal switch
10 Signal button
11 Display glass
12 Arm
13 Pushbutton Lift/Lower
14 Plate
15 Spring

Steering system
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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.

Steering system
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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.

Steering system
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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.
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.


Electrical systems
364690AA- 662 5000
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Electrical systems 11
Electrical parts
S10
S17 S21
S19
Y1
S31
Y41
X5
M3
X1
F50
F51
F1
Y41
R1
K10
F3
K30 M1
A1
H1
S19
Service Manual P20 Approved by: Joakim Carleborn 11 – 1

Electrical systems
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A7
11 – 2 Service Manual P20 Approved by: Joakim Carleborn

Electrical systems
364690AA- 662 5000
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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 24 V
H1 Horn
K10 Contactor Main contactor

K30 Contactor Pump motor
M1 Motor Drive motor

M3 Motor Pump motor
R1 PTC-resistor Power supply 15 Ohm
S1 Switch Option
S2 Switch Option
S3 Switch Option

Electrical systems
5000 662 364690AA-
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Symbol Description Function Notes

S4 Switch Option
S5 Switch Option
S6 Switch Option
S10 Switch Travel brake Brake lever
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 Option
Y1 Brake
Y41 Magnetic valve Fork lowering
X1 Connector Battery
X41 Connection point CAN-communication

KEY ELECTRONIC CARD TILLER ARM
S17
22 S20
2 24 V DC SAFETY REVERSING
1 2
X41
1 1 2 3 4 SPEED REFERENCE VALUE
R H1 P1
20
S 2 P
EMERGENCY SWITCH Y S34
FORK LIFT
S21 3
24
1 2 S18 S18
Y1 S41
X21 HORN HORN
FORK DOWN
21
X22
S19 2 S59 S53 S31 3
F50 F51
K10 A1 K30 A1 2 2
S10 X11
Y41 A2 A2 3 3 3
X12
64
45
49
31
63
31
65
58
38
364690AA-
57
39
66
119
120
118
178826-040
IO O IO BIO BI O HO PWM AI AI I
3
5
8
4
9
2
3
1
2
4
Order number
15
16
11
10
14
12
13
F
Tx
Tx
EXTERNAL
Service Manual P20

GNO
EQUIPMENT
24 V DC
CAN LOW
CAN HIGH
OUT. PUMP
OUT. HORN
INP. BRAKE
POWER ON
INP. ANALOG
OUT. BRAKE B
OUT. BRAKE A
INP. LIFT LIMIT
Valid from serial number
OUT. MAIN CON

INP. PLATFORM UP
AI=Analog In PWM=PWM Out
OUT. MAGNET VALVE

Electrical systems
INP. GATES WALK/RIDE

I=Digital In BI=Brake In
INP. MAN ON PLATFORM
OUT. MAGNET VALVE PWM

O=Digital Out BIO=Brake In or Out
IO=Digital In or Out
HO=Horn Out
662
Electrical wiring diagram

Date
M
S2
S1
MOTOR CONTROLLER
CURTIS
T-code
F1
3 S19 MAN ON PLATFORM HIGH
6
2002-04-29
M1 S59 PLATFORM UP LOW

F3 K30
K10 1 R1 9 10 A1 A2 S53 GATES WALK LOW
PTC 15 OHM A
MAIN 1 2 S53 GATES RIDE HIGH
A1
CONTACTOR 4
2 N3 S31 LIFT LIMIT NORMAL HIGH
S1 S2 5 S31 LIFT LIMIT TOP LOW
G1 24V
X1 X1 40 A2
BENÄMNING/TITEL
Approved by: Joakim Carleborn

ELSCHEMA
RITN. NR/DRG. No
WIRING DIAGRAM
001
5000
178311
Version
C-code/Section
11 – 5
Electrical systems
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Electrical wiring diagram 1(5)

X10
X10
X10
D1/E1
A2/E2

Electrical systems
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Electrical systems
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S21
X5
X5
X5
X5

Electrical systems
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Electrical systems
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Electrical systems
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Functional description
Starting the truck

• Battery connector plugged in.
• S21 closed.
• S17 on.
A1 Driving without using platform and gates,

B- speed ≤ 6 km/h
S1
T1
Ish S2
• S59 open.
- M-
A2
+ • S10 closed.
Shunt
A
Ia A1
T2
• L1 activated in any direction.
K10 B+
Driving from platform without using gates,

speed ≤ 6 km/h
• S 19 closed.
• S10 closed .
Driving from platform and using gates,

speed ≤ 8 km/h
• S 19 closed.
• S 53 closed.
• S10 closed .

Electrical systems
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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
B-
S1
T1
Ish S2
- M-
A2
+
Shunt
A
Ia A1
T2
K10 B+
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

Electrical systems
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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 high-
lighted.
• You can now choose type of hourmeter by pressing L1.
E D C B
1(A)= Key time.
2(b)= Drive motor time.
3(c)= Pump motor time.
4(d)= Activity time.
5(s)= Time to service.

Electrical systems
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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 :
----.
Code C19
Description Default parameter warning.
Possible fault Parameter area is probably corrupt.
reason Default values have been down loaded, i.e special
parameter settings must be restored.
Code C20
Description Butterfly warning
Possible fault Problem with butterfly sensor.
reason Butterfly may have been activated during start up
or faulty sensor.
Code C28
Description Emergency switch warning
Possible fault Emergency switch activated
reason No voltage supply to motor controller.
Harness problem.

Electrical systems
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Code C29
Description Service time warning
Possible fault Time to make service
reason Service counter not reset after latest service
Code C31
Description Pressure switch warning
Possible fault A problem with the pressure switch. Check that
reason the voltage is approximately 24 V between the
cables 24 and 40 connected to the pressure sen-
sor.
Check the voltage between cable 40 and 63 con-
nected 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 Battery voltage < 17 volts
reason Battery parameter not correct adjusted
Time to charge battery
Code C42
Description Battery overvoltage warning
Possible fault Battery voltage > 33 volts
reason Fully-charged battery and energy return feed to
the battery during motor braking.
Code C43
Description Power amplifier thermal cutback
Possible fault Too intensive driving
reason Defect motor controller

Electrical systems
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Code E101
Description Motor controller does not correspond with the
type of truck
Possible fault Check that the right type of motor controller is fit-
reason ted
Code E104
Description Brake switch transistor shorted
Possible fault Defect motor controller
reason Check the cables and magnetic coil to the brake
Code E106
Description Digital output or exceeding the field current limit.
Possible fault Attempt to drive more current than specified from
reason outputs.
Problem to regulate field currrent.
Internal controller fault.
Code E107
Description Contactor off
Possible fault Problem with main contactor tips or cabling (open
reason circuit).
Contactor control wire not connected.
Contactor drive output in controller faulty (off).
Code E108
Description Contactor welded
Possible fault Main contactor tips welded.
reason Contactor drive output in controller faulty (on).

Electrical systems
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Code E110
Description System error
Possible fault Possible defect in the motor controller.
reason Restart the truck.
Code E140
Description Checksum error
Possible fault Internal microcontroller fault (tiller head), faulty
reason software or pcb.
Code E141
Description Software problem
Possible fault Internal microcontroller fault (tiller head), faulty
reason software or pcb.
Code E150
Description Drive communication error
Possible fault Broken CAN-cable.
reason Motor controller broken.
Code E151
Description Drive communication Tx error
Possible fault Motor controller does not answer, bad connections
reason or faulty motor controller.
Code E157
Description Bus off error
Possible fault CAN-bus problem, harness or hardware problem.
reason

Electrical systems
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001 2002-04-29 178826-040
Code E159
Description Over flow error
Possible fault CAN-bus problem, harness or hardware problem.
reason
Code E160
Description Error in safety reversing
Possible fault Critical sensor element faulty
reason
Code E200
Description Field open
Possible fault Shuntfield open, harness broken, motor controller
reason defect.
Code E201
Description M minus error
Possible fault Problem with switch transistor in armature circuit
reason inside motor controller.
Code E202
Description Power amplifier sensor error
Possible fault Armature current sensor fault in motor controller.
reason
Code E214
Description Power amplifier CAN-timeout
Possible fault Motor controller reports unexpected loss of data
reason flow from tiller head.

Electrical systems
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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 charac-
teristics of the truck.
Do not change any parameters without the necesarry know-how.

Electrical systems
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001 2002-04-29 178826-040
Driver parameters
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 5 100 5 70 Defines motor speed
speed reduction force when
reduction lever goes to neutral
position.
5: low reduction force
100: full reduction
force
05 Logg off 1min 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.
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.

Electrical systems
364690AA- 662 5000
178826-040 2002-04-29 001
Driver parameters

1 Speed, low % 10 100 5 100 10:low Speed
Speed 100:highest Speed
02 Speed, high % 10 100 5 100 10:low Speed
speed 100:highest Speed.
03 Acceleration 10 100 5 75 10:low acceleration
100:full acceleration
04 Neutral speed 5 100 5 80 Defines motor speed
reduction reduction force when
lever goes to neutral
position.
5: low reduction force
100: full reduction force
05 Logg off 1min 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.
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.

Electrical systems
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001 2002-04-29 178826-040
Service parameters
• Connect CAN-key in X41.
• Choose parameter.

10 PIN-code 0 9999 1 0 Possibility to set up to 10
PIN - codes (10 different
drivers)
14 Creep speed -10 10 1 0 This defines how much out-
put the controller gives
when you reach the first
speed sensor.
-10 : low speed when reach-
ing first speed sensor.
10: high speed when reach-
ing first speed sensor
20 Hour meter 1 5 1 2 Select hour meter
selection
21 Battery size 1 20 1 8 Battery size selection
25 Service 1h 0 2000 50 100 Possible to set servicetimer
interval
28 - Serial n° Lift button 1 3 1 1 Button selector
432920AA- selection
39 Access code 1 4 1 1 State which level of authori-
zation the driver has to the
parameters
40 - Serial n° Display code 0 1 1 0 Defines what should be
364690AA- shown on display.
432919AA
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.

Electrical systems
364690AA- 662 5000
178826-040 2002-04-29 001
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.

Electrical systems
5000 662 364690AA-
001 2002-04-29 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.

Electrical systems
364690AA- 662 5000
178826-040 2002-04-29 001
Parameter 28 - Serial number 432920AA-

Using 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.
Flashing symbol Displayed data

A
B Speed reference value sent to Curtis.
C Digital inputs to Curtis and hallele-
ments. * See explanation below
BC Battery voltage (V)
E D C B
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).

Electrical systems
5000 662 364690AA-
001 2002-04-29 178826-040
• The most significant figure active (marked with arrow)

• Power amplifier inputs.
A T
Segment Function
A
B S53 , input A1:14
E D C B
C S31 , input A1:15
D S10 , input A1:12
$ E
F S19 , input A1:11
) %
*
G S10 , input A1:5
( & DP
'3
'
• The second most significant figure active (marked with arrow).

• Power amplifier outputs
Segment Function
A
B
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

Electrical systems
364690AA- 662 5000
178826-040 2002-04-29 001
• The third most significant figure active (marked with arrow) .

• Digital input from control sensors.
A
Segment Function
A
E D C B B
C
D Fork up
$
E Fork down
) %
* F Support arms up
G Support arms down
( &
DP
'3
'
• The fourth most significant figure active (marked with arrow).
A Segment Function
A Extra function 6
B Extra function 5
C Extra function 4
E D C B D Extra function 3
E Extra function 2
F Extra function 1
G
DP

Electrical systems
5000 662 364690AA-
001 2002-04-29 178826-040
Part numbers
A
• Press S18 and turn S17 to on at the same time.
• Press S18 until you read Pn= partnumbers.
• You have now choosen Pn= part numbers the symbol “D” on dis-
play will be highlighted to indicate what’s currently shown on dis-
E D C B play. In the start the Pn = part number complete unit will be shown.
• 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
MODEL VOLTAGE
SERIAL CURRENT
B+ M-
General
Curtis 1243 is a regulator for controlling shunt motors. Varying the volt-
age applied through the armature primarily controls the speed. The
voltage is varied through use of pulse-width modulation (PWM). This
A1
M A2
involves varying the “on” time of the MOS-FET transistors regulating
the armature current.
Switching of the rotational direction is achieved by switching the polari-
ty on the field winding (S1-S2). The regulator is fitted with a four-quad-
rant transistor bridge for the field winding and a single-quadrant transis-
tor bridge for the armature winding.
S1 S2

Electrical systems
364690AA- 662 5000
178826-040 2002-04-29 001
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 ter- Explanation Possible cause

minal display
LED off - No voltage or Burnt fuse, bad contact, not con-
defective regulator nected, defective regulator
LED on - Defective regulator Defective regulator
1,1 ¤¤ CURRENT Built-in current Armature current sensor fault in motor
SHUNT FAULT shunt defective controller
1,2 ¤ ¤¤ HW FAILSAFE Power amplifier Motor controller reports unexpected
CAN-timeout loss of data flow from tiller head
1,3 ¤ ¤¤¤ M- SHORTED Internal M- short to Problem with switch transistor in
B- armature circuit inside motor control-
ler
3,1 ¤¤¤ ¤ CONT COIL/FLD Too high current Attempt to drive more current than
SHORT for contactor feed- specified from outputs.
ing or shorted field Problem to regulate field currrent.
winding Internal controller fault
3,3 ¤¤¤ ¤¤¤ FIELD OPEN Open field winding Shuntfield open, harness broken,
motor controller defect
4,1 ¤¤¤¤ ¤ LOW BATTERY Low battery volt- 1. Battery voltage <17 volts
VOLTAGE age 2. Corroded battery terminals
3. Loose battery or regulator connec-
tions
4,2 ¤¤¤¤ ¤¤ OVERVOLTAGE Overvoltage 1. Battery voltage > 33 volts

Electrical systems
5000 662 364690AA-
001 2002-04-29 178826-040
STATUS LED Handheld ter- Explanation Possible cause

minal display
4,3 ¤¤¤¤ ¤¤¤ THERMAL Over-/under-tem- 1. Temp. >85oC or < - 25oC
CUTBACK perature reduction 2. Truck overloaded
3. Wrong installation of transistor reg-
ulator
4. Operation under extreme condi-
tions
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 When battery voltage exceeds 16 V
VOLTAGE
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!
Remove all watches, jewellery and always use insulated tools only.

Electrical systems
364690AA- 662 5000
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Technical specifications –
Curtis 1243
Value Unit Explanation

Rated operating voltage 24 Volts
Overvoltage limit 33 Volts
Undervoltage limit 16 Volts Minimum operating voltage
Electrical insulation towards cold 500 V AC Minimum
body
PWM frequency 16 kHz
Max. current of armature wind-ing * 200 Amps for 2 minutes
100 Amps for 1 hour
Max. current of field winding 25 Amps for 2 minutes
20 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 Volts
<1; Low
Logic input current 15 mA
Operating temperature -40 to +50 °C
Overtemperature, reduction 85 °C
Undertemperature, reduction -25 °C
* During specific test conditions.

Electrical systems
5000 662 364690AA-
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Hydraulic/pneumatic system
364690AA- 662 6000
178826-040 2000-06-01 001
Hydraulic/pneumatic system 12
Hydraulic chart and list of symbols
n
1 2
Y41
5
M3
P 6
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 Pump motor
P Pump
T Tank 1.2 litre
Y41 Valve Lowering valve for the forks

Hydraulic/pneumatic system
6000 662 364690AA-
001 2000-06-01 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 ma-
chine cannot lift the load.

PowerTrak cylinder
364690AA- 662 6680
178826-040 2000-06-01 001
PowerTrak cylinder 13
Component parts
3
2
4

1 PowerTrak spring
2 PowerTrak cylinder
3 Spring guide 2
4 Drive unit

PowerTrak cylinder
6680 662 364690AA-
001 2000-06-01 178826-040
2
Dismantling of PowerTrak cylinder
3
Make sure that the truck is unloaded and that the forks are lowered.
• 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!
Risk of injury.
There is a risk of personal injury in conjunction with work on the Pow-
erTrak system.
49
Follow the instructions carefully.

Control/computer equipment
364690AA- 662 8700
178826-040 2002-02-01 001
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 parame-
ters 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

8700 662 364690AA-
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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.
14 – 2 Service Manual P20 Approved by: K-G Andersson

364690AA- 662 8700
178826-040 2002-02-01 001
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.

8700 662 364690AA-
001 2002-02-01 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.

364690AA- 662 8700
178826-040 2002-02-01 001
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.

8700 662 364690AA-
001 2002-02-01 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).

364690AA- 662 8700
178826-040 2002-02-01 001
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] [ERROR LOG]
REPORT DATE-TIME=1999-12-09 07:42:14 01=55 99-12-09 06:11
CPC-PP SERIAL No=8002008 02=55 99-12-08 20:54
MACHINE NUMBER=392179 03=55 99-12-08 14:26
CUSTOMER=CUSTOMER 1 04=231 99-12-08 14:16
TECHNICIAN=NONAME 05=55 99-12-08 14:11
COMPANY=COMPANY 1 .
NOTES=Test report .
.
[CAN NODES] 50=55 99-12-08 14:40
MAIN CARD=125
FORK CARD=-1 [DRIVER PARAMETERS]
TRUCK TRACKER=-1 1=3
ACC LIFT CONTROLLER=0 2=100
ACC DRIVE CONTROLLER=0 3=100
CURTIS LIFT CONTROLLER=-1 .
.
[MAIN CARD CONFIGURATION] .
SOFTWARE=169942-001 100=0
HARDWARE=169937-001
SERIAL NO=12112
[TRUCK PARAMETERS]
[HOUR METERS] 11=100
A IGNITION TIME=1 12=80
B TOTAL MOVEMENT=0 13=10
C DRIVE MOTOR TIME=0
D PUMP MOTOR TIME=0
S SERVICE TIME=9
The contents of certain rows can vary according to truck type.
8700 662 364690AA-
001 2002-02-01 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.

364690AA- 662 8700
178826-040 2002-02-01 001
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.

8700 662 364690AA-
001 2002-02-01 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.

364690AA- 662 8700
178826-040 2002-02-01 001
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.

8700 662 364690AA-
001 2002-02-01 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
0
Operating temperature 0-60 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 > .

P20 (Ano 2002)

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Order number: 178826-040

2 © BT Industries AB Service Manual P20 Approved by:

Technical data ....................................................... 2 - 1

Introduction Maintenance ........................... 3 - 1

Preventive maintenance ............................... 4 - 1

Oil and grease specifica tion .................... 5 - 1

Electric drive motor .......................................... 7 - 1

Drive unit/gear ....................................................... 8 - 1

Service Manual P20 Approved by: 1–3

Electro magnetic brake .................................. 9 - 1

Steering system ................................................. 10 - 1

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

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

1–4 Service Manual P20 Approved by:

PowerTrak cylinder ......................................... 13 - 1

Control/computer equipment ................ 14 - 1

Service Manual P20 Approved by: 1–5

1–6 Service Manual P20 Approved by:

Service Manual P20 Approved by: L-G Andersson 2–1

Model P20-6 P20-8

2–2 Service Manual P20 Approved by: L-G Andersson

Model P20-6 P20-8

Service Manual P20 Approved by: L-G Andersson 2–3

2–4 Service Manual P20 Approved by: L-G Andersson

Safety regulations with

Service Manual P20 Approved by: 3–1

• Relieve the system pressure slowly before starting work on the

3–2 Service Manual P20 Approved by:

Cleaning and washing

Cleaning the motor compartment

Service Manual P20 Approved by: 3–3

3–4 Service Manual P20 Approved by:

Service Manual P20 Approved by: L-G Andersson 4–1

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

4–2 Service Manual P20 Approved by: L-G Andersson

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

Service Manual P20 Approved by: L-G Andersson 4–3

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

4–4 Service Manual P20 Approved by: L-G Andersson

Service Manual P20 Approved by: L-G Andersson 4–5

4–6 Service Manual P20 Approved by: L-G Andersson

Oil and grease specifica tion 5

Pos. Type of lubri- Specification Application

Service Manual P20 Approved by: L-G Andersson 5–1

5–2 Service Manual P20 Approved by: L-G Andersson

Figure Number Application

159229 Tool for release of lock (1)

159230 Tool for application of secondary

159231 Tool for application of secondary

159228 Tool for removal of pins/sleeves

Service Manual P20 Approved by: L-G Andersson 6–1

Figure Number Application

1=163787 Tool for application of sleeves

6–2 Service Manual P20 Approved by: L-G Andersson

1=163793 Service instrument for

1=155619-001 1= Service instrument for Curtis

Service Manual P20 Approved by: L-G Andersson 6–3

Figure Number Application

6–4 Service Manual P20 Approved by: L-G Andersson

Electric drive motor 7

Pos Description Note

Service Manual P20 Approved by: L-G Andersson 7–1