DOOSAN Forklift Truck & Electric All Models Workshop Manual

Specifications Systems Operation Testing & Adjusting MicroController Control System Models : B13T-2, B15T-2, B18T-2 (48V: P/N A154600, P/N A154240) (36V: P/N A154600, P/N A154701) for Electric Lift Trucks SB2077E03 Jan 2002

MicroController Control Systems Specifications Important Safety Information Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skill and tools to perform these functions properly. Improper operation, Iubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operater or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information. Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons. The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “WARNING” as shown below. The meaning of this safety alert symbol is as follows : Attention! Become Alert! Your Safety is Involved. The message that appears under the warning, explaining the hazard, can be either written or pictorially presented. Operations that may cause product damage are identified by NOTICE labels on the product and in this publication. DAEWOO cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this pulication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating technique not specifically recommended by DAEWOO is used, you must satisfy yourself that it is safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication, maintenance or repair procedures you choose. The information, specifications, and illustrations in this publication are on the basis of information available at the time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service given to the product. Obtain the complete and most current information before starting any job. DAEWOO dealers have the most current information available. WARNING 1

MicroController Control Systems Index Index Specifications Component Measurements....................................... 5 Console ..................................................................... 7 Contactors ................................................................. 8 Control Panel (Layout) .............................................. 9 Current Measurements ............................................. 5 Direction Switch ........................................................ 7 Display Layout .......................................................... 7 Fuses ........................................................................ 8 Head Capacitor ......................................................... 8 Instrument Panel ....................................................... 7 Thermal Switch - Control Panel ................................ 8 Transistor Connections ............................................. 6 Transistor Measurements ......................................... 6 Systems Operation Accessory Circuits .................................................. 25 DC - DC Converter ............................................. 25 Horn Circuit ......................................................... 25 Hour Meter Circuit .............................................. 25 Actuation Circuit ...................................................... 26 Drive Circuit ............................................................ 34 Bypass Circuit ..................................................... 39 Control Circuit ..................................................... 34 Current Limit ....................................................... 38 Electrical Braking (Plugging) .............................. 40 Failure Protection Circuit .................................... 42 Flyback Circuit .................................................... 37 Power Circuit ...................................................... 35 Thermal Protection Circuits ................................ 42 General Information ................................................ 18 Glossary .................................................................. 11 Hydraulic Pump Motor Circuit ................................. 27 Flyback Circuit .................................................... 31 Lift Circuit ............................................................ 33 Lift Control Circuit ................................................32 Power Steering Circuit .........................................27 Power Steering Idle .............................................28 Location of Control Panel Components .................. 16 Logic Unit ................................................................ 18 Operational Circuit Elements .................................. 19 Accelerator Control ............................................. 24 Battery Discharge Indicator (BDI) ....................... 23 Central Vehicle Monitoring System..................... 19 Contactors .......................................................... 22 Current Sensor ................................................... 22 CVMS International Pictorial Symbols ................ 21 On Board “Run Time” Diagnostics (Fault Detection) ................................................. 19 Steer Angle Control ............................................ 24 Wait Mode........................................................... 22 Symbol Library ........................................................ 15 Testing And Adjusting Built-In Diagnostic Operation .................................. 47 Accessing Stored Error Codes ........................... 52 Erased Stored Error Codes ................................52 “Run Time” Diagnostics (Lift Truck in Operation) ...................................... 47 Quick Diagnostic Procedure ............................... 53 Saving Service Records ..................................... 52 “Self” Diagnostics (Lift Truck not in Operation) ................................ 49 Stored Error Codes............................................. 53 Component Tests .................................................. 105 Capacitor (Head) .............................................. 108 Conductor and Switch Continuity ..................... 108 Contactors ........................................................ 109 Contactor Components ..................................... 109 Current Sensor .................................................. 111 Diode Replacement .......................................... 112 Diodes ............................................................... 112 Driver Board (Off Vehicle) ................................. 116 Driver Board (On Vehicle) ................................. 113 Logic Unit Quick Reference Voltage Check ..... 105 Resistors (DR1, DR2, and PR1) ....................... 119 Thermal Switch ................................................. 120 Transistors DTR1, DTR2 and PTR1 ................. 118 Transistors Replacement DTR1, DTR2 and PTR1 .................................... 118 3

MicroController Control Systems Index Control and Power System Operational Checks .................................................................... 46 Electrical System Adjustments ...............................121 Accelerator Control Linkage ..............................121 BDI Adjustment ..................................................124 Bypass Dropout Adjustment ..............................128 Current Limit Test and Adjustment .....................127 Electrical Braking (Plugging) Current Test and Adjustment ..........................................128 Lift Sensor ..........................................................122 Parking Brake Switch.........................................121 Rapid Tune - Up Procedure ...............................124 Tilt and Auxiliary Switches .................................123 Valve Control Card Adjustment ..........................122 Preparation Tests and Checks .................................43 Programmable Features ........................................129 Activating Default Settings .................................129 Programmable or Settable Option Features .............................................................130 Quick Procedure for Programmable Features .............................................................132 Setting Procedure Option Features ...................129 System Tests and Adjustments ..............................102 Discharging Head Capacitor (HEAD CAP) ......................................................102 Logics Removal .................................................103 “Run Time” Tests................................................103 Test Equipment ..................................................102 Troubleshooting........................................................43 Troubshooting Problem List ....................................54 4

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DOOSAN Forklift Truck & Electric All Models Workshop Manual

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