Doosan B20S-3 User manual

Specifications
Systems Operation
Testing & Adjusting
MicroController Control System
Models : B20S-3 B25S-3 B30S-3
for Electric Lift Trucks
SB4082E00
Dec. 2002

1
MicroController Control System 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. f 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 “WARN NG” 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 NOT CE 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. f a tool, procedure, workmethod or operating technique
not specifically recommended by DAEWOO is used, you must satisfy yourself that it is safe for you and others.
ou 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.
ARNING

3
MicroController Control System Index
Index
Specifications
Component Measurements........................................5
Console......................................................................7
Contactor ...................................................................8
Control Panel (Layout) ...............................................9
Current Measurements..............................................5
Direction S itch.........................................................7
Display Layout............................................................7
Fuses.........................................................................8
H2/HP Technical Specifications .................................5
Instrument Panel........................................................7
MOSFET Connections...............................................6
MOSFET Measurements...........................................6
Thermal Senders-Control Panel ................................8
System Operation
Accessory Circuits ...................................................22
DC-DC Converter Circuit .....................................22
Horn Circuit..........................................................22
Hour Meter Circuit................................................22
Actuation Circuit.......................................................25
Description of Connectors........................................23
Drive Circuit .............................................................31
Bypass Circuit......................................................36
Control Circuit......................................................31
Current Limit........................................................35
Electrical Braking (Regenerative and Plugging) ..37
Flyback Cicrcuit....................................................34
Po er Circuit........................................................32
General Information .................................................16
Glossary...................................................................10
Hydraulic Pump Circuit ............................................26
Flyback Cicrcuit....................................................29
Lift Circuit.............................................................27
Lift Control Circuit................................................30
Po er Circuit........................................................28
Po er Steering Circuit .........................................26
Location of Control Panel Components ...................15
Operational Circuit Elements....................................17
Battery Discharge Indicator (BDI)........................21
Central Vehicle Monitoring System.......................17
Chat (Wait) Mode .................................................20
Contactor..............................................................20
CVMS International Pictorial Symbols..................19
“On Board” “Run Time”
Diagnostics(Fault Detection) ................................17
Shunts..................................................................20
Symbol Library.........................................................14
Thermal Protection Circuits......................................40
Control Panel .......................................................40
Drive Motor...........................................................40
Hydraulic Pump Motor..........................................40
Testing And Adjusting
Alarm Displayed on
the Console & Instrument Panel...............................46
Analysis of ALARMS Displayed on the Console......47
Component Tests ...................................................100
Conductor and S itch Continuity.......................100
Contactor ...........................................................101
Control and Po er System Operation Checks.........45
Digital Console.......................................................105
ADJUSTMENTS : Adjust Battery.......................112
ADJUSTMENTS : SET BATTERY TYPE ...........111
Description of ALARMS Functions.....................116
Description of PARAMETER CHANGE Menu.....119
Description of PROGRAM VACC Function........113
Description of RESTORE PARAM. Function......118
Description of SAVE PARAM. Function..............117
Description of SET OPTIONS Functions...........109
Description of Standard Console Menu.............107
Description of TESTER Functions .....................114
Ho to use the PARAMETER CHANGE Menu......122
Ho to use the TESTER Functions....................115
PARAMETER Settings.......................................121
Using Digital Console.........................................106

4
MicroController Control System Index
Electrical System Adjustments...............................102
Accelerator Control Linkage ..............................102
Lift Sensor..........................................................103
Parking Brake S itch.........................................102
Tilt and Auxiliary S itches Adjustment..............104
Valve Control Card Adjustment..........................103
LED Diagnosis for Drive controller...........................47
Preparation Tests and Checks .................................41
System Tests and Adjustments................................96
Discharge Head Capacitors.................................96
Logics Removal....................................................97
“Run Time” Tests ..................................................99
Test Equipment ....................................................96
Quick Diagnostic Mode............................................44
Troubleshooting........................................................41
Troubleshooting Problem List.............................52~95

5
MicroController Control System Specifications
Specifications
Component Measurements
H2 / HP Technical Specifications
Motor Types : ...................................................................................................DC Series Traction + DC Series Pump
Power ratings : Traction.....................................................................................................................................13.5k
Pump ........................................................................................................................................11.0k
Supply Voltage : ....................................................................................................................................................48V
Traction Motor Switching frequency : .................................................................................................................18kHz
Pump Motor Switching frequency : ....................................................................................................................18kHz
Temperature range : ............................................................................................................................-30˚C to + 40˚C
Maximum Controller temperature : .......................................................................................................................85˚C
Current Measurements
Component Meter
Scale Meter Positive (+) Test Lead Meter Ne ative (-) Test Lead Desired Indication
CONTACTOR COILS (resistance Indication)
Line, Bypass 200 X Y 90 to 110 ohms
Directional, Regen 200 X Y 60 to 80 ohms
48V SYSTEM CURRENT VALUES (AMPS)
Maximum Traction Motor Current Maximum Pump Motor Current
650 ± 5 % 600 ± 5 %

6
MicroController Control System Specifications
MOSFET Connections
1. Gate 2. Drain 3. Source
22
123
3
1
MOSFET Measurements
SPECIFICATIONS
Multimeter Setting (+) Test Lead (-) Test Lead Results
Resistance Gate Source Over 20 Mohms
Resistance Gate Drain Over 20 Mohms
Resistance Drain Source Over 20 Mohms
Resistance Drain Gate Over 20 Mohms
Resistance Source Gate Over 20 Mohms
Resistance Source Drain Over 20 Mohms
Diode Drain Source 0.4 ~ 0.7V

7
MicroController Control System Specifications
Display Layout
Instrument Panel
(1) Tighten screws that fasten the instrument panel to
a torque of
................................... 0.5 to 0.7
N • m (4 to 6 lb • in)
1
Console
(1) Tighten bolts that fasten the cover to a torque of
...............................1.5 to 2.5
N • m (13 to 22 lb • in)
Direction Switch
(1) Torque bolts that hold bracket to steering
column to................2.8 to 3.4
N • m (25 to 31 lb • in)
(2) Torque bolts that hold bracket to switch to
...............................3.4 to 3.9
N • m (31 to 35 lb • in)
1
12

8
MicroController Control System Specifications
Thermal Senders - Control Panel
Thermal protection at..............................80 °C (176 °F )
Contactor
Torque for nuts that hold contactor bridge
assembly.........................................2.2
N • m (20 lb • in)
Fuses
Traction ................................................................675A
Pump....................................................................400A
Key.........................................................................10A
Horn.......................................................................10A
DC / DC Converter.................................................10A
Light.......................................................................10A
Option light.............................................................10A

9
MicroController Control System Specifications
(1) Use a backup wrench to hold bolts and tighten
nuts the fasten bus bars and cables to a torque of
.....................................4 to 6
N • m (36 to 54 lb • in)
(2) Tighten screw that fasten the controllers to heatskin
to a torque of
.....................................2 to 4
N • m (18 to 36 lb • in)
(3) Use a backup wrench to hold bolts and tighten
the nuts that fasten the cables or bus bars to a
contactors to a torque of
.....................................4 to 6
N • m (36 to 54 lb • in)
(4) Tighten screw that fasten the contactors to
backplate to a torque of
.....................................2 to 4
N • m (18 to 36 lb • in)
(5) Apply sealant (Loctite cataloge No. & name No. 242,
Adhesive/Sealane) on the bolts used to tighten the
heatskin to the control panel to a torque of
................................10 to 14
N • m (90 to 125 lb • in)
(6) Control panel plate. Apply a small amount of
D557047 Thermal Joint Compound on control
panel plate and mating surface prior to assembly.
Control Panel (Layout)