Escolar Documentos
Profissional Documentos
Cultura Documentos
Warning
Warning
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F-code
PT
Section
C-code
Version no
T-code
000
SMX
BT Prime-Mover, Inc.
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2005-07-11
F-code
Section
C-code
PT
Ordering Spare Parts
Version no
T-code
000
SMX
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2005-07-11
F-code
Section
C-code
Standard Codes
Version no
T-code
001
SMX
Standard Codes
B-Code
= Business area
F-Code
= Product family
T-Code
= Product type
C-Code
= Component function
Worksheet standard
W-Code = Working code
R-Code
= Reason code
SO-Code = Assortment
F-Code List
PT
T-Code List
No.
Model
SMX45
C-Code List
No Function Group
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C-Code
Frame
0000
Motors
1000
2000
3000
Steering System
4000
Electrical System
5000
6000
7000
8000
Optionals / Attachments
9000
10
Tools
10000
2004-01-09
F-code
Section
C-code
Standard Codes
Version no
T-code
001
SMX
Return
2004-01-09
Table of Contents
Table of Contents
Ordering Spare Parts .................................................................................... 1
Standard Codes ............................................................................................. 3
Warning Symbols ......................................................................................... 13
Warning Levels .................................................................................................... 13
Safety ............................................................................................................ 15
General Safety ..................................................................................................... 15
33
33
34
34
35
36
39
40
41
47
48
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2004-05-17
Table of Contents
Jacking Truck Off The Floor ................................................................................. 58
Fork Section ................................................................................................................. 59
Tractor Section ............................................................................................................. 59
Lubricants ............................................................................................................ 59
Standard ....................................................................................................................... 59
Cold Storage ................................................................................................................ 59
64
64
64
64
65
65
65
65
65
65
65
66
66
66
67
67
67
67
67
67
68
68
68
68
68
68
69
Frame ............................................................................................................ 75
Theory of Operation ............................................................................................. 75
Maintenance ........................................................................................................ 75
Inspection ..................................................................................................................... 75
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2004-05-17
Table of Contents
Troubleshooting ................................................................................................... 76
Repair and Rebuild .............................................................................................. 76
83
83
83
83
Decals ............................................................................................................ 85
Decal with Protective Sheet ................................................................................. 85
Decal without Protective Sheet ............................................................................ 85
87
87
88
89
89
89
90
90
91
92
92
93
94
96
97
97
Transmission ................................................................................................ 99
Theory of Operation ............................................................................................. 99
Maintenance ........................................................................................................ 99
Fluid Changing ............................................................................................................. 99
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2004-05-17
Table of Contents
Drive Wheel Nut Inspection ......................................................................................... 115
121
121
121
122
135
135
135
136
141
141
141
142
146
147
148
150
152
153
154
155
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2004-05-17
Table of Contents
Shorts to Frame Test ............................................................................................. 157
161
164
168
168
169
170
171
172
174
176
179
179
180
180
181
188
188
188
188
189
194
195
199
200
200
201
202
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2004-05-17
Table of Contents
Switches ....................................................................................................... 219
Theory of Operation ............................................................................................
Maintenance .......................................................................................................
Troubleshooting ..................................................................................................
Repair and Rebuild .............................................................................................
219
220
222
223
224
224
225
226
226
227
230
231
232
233
239
240
241
241
242
243
10
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249
250
250
251
2004-05-17
Table of Contents
Hydraulic System ........................................................................................ 253
Theory of Operation ............................................................................................ 253
Lift ................................................................................................................................ 254
Lower ........................................................................................................................... 255
Relief Pressure ............................................................................................................ 256
266
267
268
269
270
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2004-05-17
11
Table of Contents
12
Return
2004-05-17
F-code
PT
Version no
Section
C-code
Warning Symbols
T-code
001
Warning Symbols
Always follow the warnings given in this Service Manual
and on the truck to avoid accidents from occurring.
1. Warning Levels
Warning levels
Warning text is given in four levels and provide information on
the risks, describe the consequences, and instruct how to
avoid accidents.
DANGER
Warns that an accident will occur if the instructions are not
followed.
The consequences are serious personal injury or possibly
death, and/or extremely large material damage.
WARNING
Warns that an accident can occur if the instructions are not
followed.
The consequences are serious personal injury or possibly
death, and/or large material damage.
CAUTION
Warns that an accident can occur if the instructions are not
followed.
The consequences are personal injury and/or material
damage.
NOTE!
Marks the risk of a accident or breakdown if the
instructions are not followed.
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2004-01-09
13
F-code
Section
C-code
PT
Prohibitory Symbols
Version no
T-code
001
Prohibitory Symbols
NO SMOKING
If smoking occurs in situations where a restriction against
smoking is stated, a serious accident can occur.
GENERAL PROHIBITION
If the prohibition is ignored, a serious accident can occur.
1. Ordinance Symbols
SAFETY SHOES
When the directive for safety shoes is given, safety shoes
shall always be worn to avoid personal injury.
PROTECTIVE GLASSES
When the directive for protective glasses is given,
protective glasses shall always be worn to avoid personal
injury.
14
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2004-01-09
F-code
Section
PT
Version no
C-code
Safety
T-code
001
Safety
1. General Safety
Do NOT operate or work on this truck unless trained,
qualified, and authorized to do so and have read the
Operators Manual.
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2004-01-09
15
F-code
Section
C-code
PT
Safety
Version no
T-code
001
Before working on this truck always press the red OFF (O)
key on the keypad and disconnect the truck battery connector
(unless this manual states otherwise.)
16
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2004-01-09
F-code
Section
PT
Version no
C-code
Safety
T-code
001
lubrication,
maintenance,
and
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2004-01-09
17
F-code
Section
C-code
PT
Safety
Version no
T-code
001
18
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2004-01-09
F-code
Section
PT
Version no
C-code
Safety
T-code
001
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2004-01-09
19
F-code
Section
C-code
PT
Battery Safety
Version no
T-code
001
Battery Safety
WARNING As a battery is being charged, an explosive
gas mixture forms within and around each
cell. If the area is not properly ventilated,
this explosive gas can remain in or around
the battery for several hours after charging.
Be sure there are no open flames or sparks
in the charging area. An open flame or
spark can ignite this gas, resulting in
serious damage or injury.
WARNING Battery electrolyte is a solution of sulfuric
acid and water. Battery acid causes burns.
Should any electrolyte come in contact with
clothing or skin, flush the area immediately
with cold water. Should the solution get on
your face or in the eyes, flush the area with
cold water and receive medical attention
immediately.
Read, understand and follow procedures, recommendations
and specifications available by the battery and battery
charger supplier.
20
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2004-01-09
F-code
Section
PT
Version no
C-code
Battery Safety
T-code
001
BT Prime-Mover, Inc.
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2004-01-09
21
F-code
Section
C-code
PT
Battery Safety
Version no
T-code
001
22
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2004-01-09
F-code
Section
PT
Version no
C-code
Battery Safety
T-code
001
Cable
Filler
Plugs
Keep filler plugs firmly in place at all times except when the
electrolyte level is checked, when water is added to the cells
or when the specific gravity is checked.
Make sure vent holes in filler plugs are open to allow gas to
escape from the cells.
Filler Plug
Vent Hole
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2004-01-09
23
F-code
Section
C-code
PT
Battery Safety
Version no
T-code
001
24
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2004-01-09
F-code
Section
C-code
PT
Static Discharge Precautions
Version no
T-code
001
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2004-01-09
25
F-code
Section
C-code
PT
Static Discharge Precautions
Version no
T-code
001
26
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2004-01-09
F-code
Section
PT
Version no
C-code
Welding Safety
T-code
001
Welding Safety
WARNING Flame cutting or welding on painted
surfaces may produce potentially harmful
fumes, smoke and vapors. Prior to
performing flame cutting or welding
operations, it is recommended that the
coating be removed in the vicinity where the
operation(s) will be performed.
WARNING Coating removal may be by mechanical
methods, chemical methods or a
combination of methods. Flame cutting and/
or welding operations should be carried out
in well ventilated areas using local exhaust
if necessary.
Before working on the truck, make sure of the following:
Fire protection equipment is nearby.
Know where the nearest eyewash station is located.
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2004-01-09
27
F-code
Section
C-code
PT
Welding Safety
Version no
T-code
001
28
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2004-01-09
F-code
Section
C-code
PT
M
Introduction, Service Manual
Version no
T-code
000
SMX
52761-8800
(563) 262-7700
The information contained in this service manual is intended
as a guide to help trained, qualified, and authorized
technicians safely service the truck.
The service manual is divided into four separate sections
which cover needed information for servicing the truck types.
The main subject for each of these sections is described
below.
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SECTION
SUBJECT
MACHINE INFORMATION
PLANNED MAINTENANCE
SERVICE INSTRUCTIONS
OPTIONS
2004-01-09
29
F-code
Section
C-code
PT
M
Introduction, Service Manual
Version no
T-code
000
SMX
30
Return
2004-01-09
F-code
Section
C-code
M
Contents, Section M
Version no
T-code
000
Contents, Section M
1. Machine Information
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M1.0
M2.0
2004-01-09
31
F-code
Section
C-code
M
Contents, Section M
Version no
T-code
000
32
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2004-01-09
F-code
Section
C-code
PT
M1.0
General Product Information
Version no
T-code
001
SMX
Forward
(Tractor-first)
Rearward
(Forks-first)
Right Side
BT Prime-Mover, Inc.
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2006-12-12
33
F-code
Section
C-code
PT
M1.0
General Product Information
Version no
T-code
001
SMX
To transport/lift passengers.
4500 (2241)
5.0 (127.0)
3.6 (5.8)
3.4 (5.5)
640 (290)
34
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SMX45
Above + battery
weight
2006-12-12
F-code
Section
C-code
PT
M1.0
General Product Information
Version no
T-code
001
SMX
1.5. Dimensions
The following diagram shows external dimensions for the
SMX45 truck in its standard design.
68.6 inch
(1742 mm)
23.0 inch
(585 mm)
26.6 inch
E (675 mm)
28.0 inch
(711 mm)
6
(15 0 inch
25
mm
)
6.8 inch
(172 mm)
6
Battery Compartment 7.8 inch
(198 mm)
47.9 inch
(1216 mm)
40
33
5.4 inch
(137 mm)
3.25 inch
(83 mm)
31.2 inch
(792 mm)
3.1 inch
(79 mm)
53.0 inch
(1346 mm)
Full Load Gradeability: 6%
2500 lbs (1133 kg) Load Gradeability: 10%
Dimensions shown in parentheses are metric, others are standard U.S. measure.
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2006-12-12
35
F-code
Section
C-code
PT
M1.0
General Product Information
Version no
T-code
001
SMX
Amp Hour
Length
Width
Height
Max Weight
152
26.5 inch
(675 mm)
7.5 inch
(192 mm)
26.45 inch
(672 mm)
GNB PalletPro
with 25 amp charger
195
26.5 inch
(675 mm)
7.5 inch
(192 mm)
26.25 inch
(665 mm)
4
7
8
10
Legend
36
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Truck voltage DC
Truck type
10
2006-12-12
F-code
Section
C-code
PT
M1.0
General Product Information
Version no
T-code
001
SMX
2. Main Components
1. Steering Control Handle:
The truck is to be controlled by the operator with 180 degree
steering angle. The truck has the ability to right-angle stack.
The brake is applied in the upper and lower position of the
steering control head.
2. Hydraulic unit:
Pump motor, pump, electric valve and oil tank integrated in a
compact unit.
4. Battery:
24 volt with different capacities and weights.
8. Operator Display:
Display includes hourmeter, error codes, parameters, hardware
and software part numbers.
9. Electrical panel:
24 volt electrical system. Truck speed is regulated by means of
a transistor controller.
12. Keypad:
Enter PIN-key code in the keypad and press green key (I) on
the keypad starts truck. Press red OFF (O) on the keypad to
shut off electrical power to the control system. Up to 10
operators can be assigned their own individual PIN-key code
for access to the truck.
BT Prime-Mover, Inc.
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2006-12-12
37
F-code
Section
C-code
PT
M1.0
General Product Information
Version no
T-code
001
SMX
16
1
12
1
4
7
O
2
5
8
0
3
6
9
I
14
15
13, 18
9, 10
8
2, 3
4
6
5
11
38
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2006-12-12
F-code
Section
C-code
PT
M1.1
Inch (SAE) and Metric Fasteners
Version no
T-code
001
SMX
10
10
1. Introduction
Threaded fasteners such as bolts, nuts, cap screws, and
studs are made to specifications that describe mechanical
strength and hardness of fastener. A fastener used in a
design application is selected in accordance with its
specifications. Parts used on this truck are purchased from
many countries. Many fasteners are similar but cannot be
used as direct replacements.
Service technicians must use replacement fasteners that
have the same specifications. Fasteners made to each
specification have identification marks for that specification.
This specification is commonly called grade for SAE
standards and property for metric standards. This section
describes identification of some common fasteners.
The metric system used is described as SI (International
System of Units, also called SI in all languages.) The SI
system of measurement is described in ISO Standard 1000,
1973.
BT Prime-Mover, Inc.
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2004-01-12
39
F-code
Section
C-code
PT
M1.1
Inch (SAE) and Metric Fasteners
Version no
T-code
001
SMX
2. Nomenclature, Threads
The thread design is specified by a series of numbers and
letters for inch and metric fasteners (see figure below.) The
diameter of shank of fastener is shown first in the series, e.g.
M12=12 mm, M20=20 mm (1/2=1/2 inch, 3/4=3/4 inch.)
The number of threads per inch is normally not shown for inch
nomenclature and only UNC (Unified National Coarse) or
UNF (Unified National Fine) is shown. This number of threads
per inch is not shown because a UNC or UNF fastener has a
standard number of threads per inch for a specific diameter.
The length of a shank is often indicated as part of the
description of a fastener. This length is shown in inches for
inch fasteners and in millimeters for metric fasteners.
A cap screw will have the following description:
Inch
Metric
M12 x 1.75 x 50
A
B
C
A =Shank diameter
B =Number of threads per unit of length
C =Type of thread
D =Shank length
40
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A =Thread size
B =Pitch
C =Length
2004-01-12
F-code
Section
C-code
PT
M1.1
Inch (SAE) and Metric Fasteners
Version no
T-code
001
SMX
3. Strength Identification
The most common property classes for metric fasteners are
8.8 and 10.9. The property class is marked with a number on
the head of the cap screw or on a nut. Property classes less
then 8.8 are often not marked. Grades for inch bolts go from 2
to 8. Grade 2 fasteners normally do not have marks. The
following tables show marks that identify grades and property
classes for different fasteners.
WARNING When fasteners must be replaced new
fasteners must be of same strength or
greater than original fasteners. The new
fasteners must also be the correct size.
NOTE!
BT Prime-Mover, Inc.
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2004-01-12
41
F-code
Section
C-code
PT
M1.1
Inch (SAE) and Metric Fasteners
Version no
T-code
001
SMX
Types of
Fasteners
Metric Fasteners
Inch Fasteners
5.2
4.6*
4.8*
5.8*
8.8
4.6
4.8
5.8
8.8
9.8
10.9
12.9
9.8
10.9
12.9
Markings
for size
M5 and
Larger
Same As Above
Hex Head
Flange Screws
5
12 Point
Flange Screws
Markings Not Required
8.8
12.9
8.8
12.9
4.8*
9.8
4.8
9.8
Sems
42
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2004-01-12
F-code
Section
C-code
PT
M1.1
Inch (SAE) and Metric Fasteners
Version no
T-code
001
SMX
Types of
Fasteners
Inch Fasteners
Metric Fasteners
5*
5.2*
8*
4.6*
4.8*
5.8*
8.8
4.6
4.8
5.8
8.8
9.8
10.9
12.9
9.8
10.9
12.9
Markings
for size
M5 and
Larger
8.1
or
Studs
or
or
10
Hex Nuts
12
10
12
10
12
10
10
10
10
12
12
12
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2004-01-12
12
43
F-code
Section
C-code
PT
M1.1
Inch (SAE) and Metric Fasteners
Version no
T-code
001
SMX
Types of
Fasteners
Inch Fasteners
B
B
C
C
Metric Fasteners
10
10
or
All Metal Prevailing
Torque Nuts
G
9
10
10
or
All Metal Prevailing
Torque Flange Nuts
or
44
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2004-01-12
F-code
Section
C-code
PT
M1.1
Inch (SAE) and Metric Fasteners
Version no
T-code
001
SMX
Types of
Fasteners
Inch Fasteners
Metric Fasteners
10
10
or
or
or
10
10
or
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2004-01-12
45
F-code
Section
C-code
PT
M1.1
Inch (SAE) and Metric Fasteners
Version no
T-code
001
SMX
Size and
Pitch
Property, Class
8.8*
Property, Class
10.9**
Property, Class
12.9***
Nm
in-lbs
Nm
in-lbs
Nm
in-lbs
5-6
8-10
20-25
44-53
71-88
177-221
7-8
12-14
30-35
62-71
106-124
265-309
8-10
14-16
------------
71-88
124-142
------------
Nm
ft-lbs
Nm
ft-lbs
Nm
ft-lbs
M8 x 1.25
M10 x 1.5
-----------40-45
-----------30-33
29-35
60-65
22-26
44-48
34-40
70-75
26-30
52-55
M12 x 1.75
M14 x 2
70-80
110-125
30-33
52-59
100-110
155-180
74-81
114-133
115-130
180-210
85-96
133-155
M16 x 2
M20 x 2.5
170-190
340-380
125-140
251-280
240-270
450-500
177-199
332-369
280-320
550-600
207-236
406-443
M24 x 3
580-650
428-479
800-900
590-664
900-1050
664-774
M30 x 3.5
1150-1300
848-959
1600-1800
1180-1328
1850-2100
1364-1549
M36 x 4
2000-2250
1479-1660
2800-3150
2065-2323
3250-3700
2397-2729
M5 x 0.8
M6 x 1
M8 x 1.25
Size and
Pitch
46
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2004-01-12
F-code
Section
C-code
PT
M1.1
Inch (SAE) and Metric Fasteners
Version no
T-code
001
SMX
BT Prime-Mover, Inc.
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Torque Specification
71 - 88 in-lbs (8 - 10 Nm)
2004-01-12
47
F-code
Section
C-code
PT
M1.1
Inch (SAE) and Metric Fasteners
Version no
T-code
001
SMX
By
To Get
Multiply
By
To Get
inches
6.451
centimeters (cm)
centimeters
0.155
inches (in)
feet
0.093
meters (m)
meters
10.764
feet (ft)
Linear
Multiply
By
To Get
Multiply
By
To Get
inches
25.4
millimeters(mm)
millimeter
0.03937
inches (in)
feet
0.305
meters (m)
meter
3.280
feet (ft)
yards
0.914
meters (m)
meter
1.094
yards (yd)
miles
1.609
kilometers (km)
kilometer
0.621
miles (mi)
Mass
Multiply
By
To Get
Multiply
By
To Get
ounces (oz)
28.49
grams (g)
grams
0.035
ounces (oz)
pounds (lb)
0.454
kilograms (kg)
kilograms
2.205
pounds (lb)
907.18
kilograms (kg)
kilograms
0.001
0.907
metric ton
1.102
Power
Multiply
By
To Get
Multiply
By
To Get
horsepower
0.746
kilowatts (kW)
kilowatts
1.34
horsepower (hp)
Pressure
48
Multiply
By
To Get
Multiply
By
To Get
pounds/in
6.895
kilopascal (kPa)
kilopascals
0.145
pounds/in (psi)
pounds/in
0.007
megapascal (MPa)
megapascals
145.04
pounds/in (psi)
Return
2004-01-12
F-code
Section
C-code
PT
M1.1
Inch (SAE) and Metric Fasteners
Version no
T-code
001
SMX
Temperature
Multiply
By
To Get
Multiply
By
To Get
(Fahrenheit
-32)
0.56
Celsius (C)
(Celsius x 1.8)
+32
Fahrenheit (F)
Torque
Multiply
By
To Get
Multiply
By
To Get
inch pound
0.113
Newton meter
8.851
inch pounds
in-lbs
feet pound
1.356
Newton meter
0.738
foot pounds
ft-lbs
Velocity
Multiply
By
To Get
Multiply
By
To Get
miles/hour
1.609
kilometer/hour
(km/h)
kilometer/hour
0.621
miles/hour
(mph)
Volume
Multiply
By
To Get
Multiply
By
To Get
inches
16.387
centimeters (cm)
centimeters
0.061
inches (in)
inches
0.016
liters
liters
61.024
inches (in)
quarts, U.S.
0.946
liters
liters
1.057
quarts, U.S.
0.83
quarts, Imp.
1.205
gallons, U.S.
3.785
liters
liters
0.264
gallons, U.S.
(gal)
gallons, U.S.
0.83
gallons, Imp.
1.205
gallons, U.S.
(gal)
ounces
29.57
milliliters (ml)
milliliters
0.034
ounces (oz)
BT Prime-Mover, Inc.
Return
2004-01-12
49
F-code
Section
C-code
PT
M1.1
Inch (SAE) and Metric Fasteners
Version no
T-code
001
SMX
50
Return
2004-01-12
F-code
PT
Section
C-code
M2.0
Technical Service Data
Version no
T-code
002
SMX
Drive Unit
Type
Shunt wound
1.2 (0.90)
Duty factor
1 hour
0.59 (15)
1.85 (47)
44.8 (3.8)
Gear ratio
22:1
13.5 (0.4)
Drive Gear Ambient Temperatures
Wheels
Drive wheel - inch (mm)
710 (322)
1650 (748)
55 (74.6)
Return
3805 (1725)
2006-08-03
51
F-code
Section
C-code
PT
M2.0
Technical Service Data
Version no
T-code
002
SMX
Hydraulic Unit
Power - horsepower [hp] (kilowatts [kW])
1.9 (1.4)
Duty factor
0.35 (9)
1.13 (28.8)
17.98 (5)
3000 (20684)
Pump flow
1.0 cc
Tank volume
Approximately 1 quart
Hydraulic Ambient Temperatures
Sunoco TH
AFT
Fuses/circuit Breaker
Keypad and ETAC Fuse
10 Amp
10 Amp
110 Amp
Batteries
52
Return
2006-08-03
F-code
PT
Section
C-code
M2.0
Technical Service Data
Version no
T-code
002
SMX
Operating Speeds
Without load - mph (kph)
3.6 (5.8)
3.4 (5.5)
Lifting/lowering Time
2.3
3.0
2.8
Current Readings
Driving without load (amps taken at steady state)
14 Amp
42 Amp
38 Amp
95 Amp
BT Prime-Mover, Inc.
Return
2006-08-03
53
F-code
Section
C-code
PT
M2.0
Technical Service Data
Version no
T-code
002
SMX
54
Return
2006-08-03
F-code
PT
Version no
Section
C-code
P
Contents, Section P
T-code
001
Contents, Section P
1. Planned Maintenance
BT Prime-Mover, Inc.
Return
P1.0
INTRODUCTION, MAINTENANCE
P2.0
SERVICE SCHEDULE
P3.0
LUBRICATION CHART
P4.0
2004-01-14
55
F-code
Section
C-code
PT
P
Contents, Section P
Version no
T-code
001
56
Return
2004-01-14
F-code
PT
Section
C-code
P1.0
Introduction, Maintenance
Version no
T-code
000
SMX
Introduction, Maintenance
The schedule of maintenance and lubrication given in this
section of the service manual cover up to one years
operation of the truck. These schedules are based on hourly
usage and can be adapted to suit most schedules. The
following hourly usage figures have been used when
calculating the schedule:
Single shift, 30 hours per week usage
Double shift, 60 hours per week usage
Triple shift, 90 hours per week usage
The Planned Maintenance Schedule on page 61 is
based on the single shift schedule. The schedules are
intended only as a guide, not as a rigid structure. Owners of
the trucks may wish to adapt to local requirements; but it is
emphasized that the schedules represent minimum
manufacturer requirements, and all items should be included
in a service program to ensure minimum downtime and a high
status of the equipment.
BT Prime-Mover, Inc.
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2006-08-03
57
F-code
Section
C-code
PT
P1.0
Introduction, Maintenance
Version no
T-code
000
SMX
58
Return
2006-08-03
F-code
PT
Section
C-code
P1.0
Introduction, Maintenance
Version no
T-code
000
SMX
2. Lubricants
2.1. Standard
The standard conditioning truck is designed for operation in
temperatures down to 32 degrees F (0 degrees C).
BT Prime-Mover, Inc.
Return
2006-08-03
59
F-code
Section
C-code
PT
P1.0
Introduction, Maintenance
Version no
T-code
000
SMX
60
Return
2006-08-03
F-code
Section
PT
P2.0
Service Schedule
Version no
T-code
001
SMX
C-code
Service Schedule
1. Planned Maintenance Schedule
WORK REQUIRED
ITEM
1
2
3
4
5
0300
0300.1
0300.2
1700
1700.1
1700.2
1700.3
1700.4
2550
2550.1
2550.2
3300
3300.1
3300.2
3300.3
3500
3500.1
3500.2
4100
4100.1
5000
5000.1
5000.2
5000.3
5000.4
5000.5
5000.6
5000.7
250
1500
Interval in Days/Weeks/Months
1d
2m
12 m
General
Check for loose hardware. Tighten if necessary.
Note any unusual noise during operation
Check for leaks around drive unit and hydraulic system.
Visually inspect all cables for damage.
Check grease location points (see page 72.)
Frame
Check truck data plate and decals for legibility.
Check for crack formation and damage.
Motors
Check connections for proper contact.
Clean motor of dirt and dust.
Check condition of brushes, springs, and holders.
Check brush length. Replace brushes if necessary (see page 91.)
Drive Unit
Check oil in drive housing. Check for contamination in the oil (see
page 100.)
Change transmission oil (see page 99.)
Brake
Check brake operation.
Clean dust and debris.
Check brake disk for wear.
Wheels
Remove all string, wrapping, and debris.
Check all wheels for wear.
Steering Control Handle
Check return of control handle to upper rest position.
Electrical Control System
Check operation of horn button.
Check speed and thumb controls.
Check tiller arm/angle switches for adjustment.
Check steering operation.
Check lift/lower functions.
Check operation of main ON/OFF switch.
Check for electrical shorts in chassis.
BT Prime-Mover, Inc.
Return
Interval in Hours
2006-08-03
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
61
F-code
Section
C-code
PT
P2.0
Service Schedule
Version no
T-code
001
SMX
WORK REQUIRED
ITEM
5000.8
5110
5110.1
5110.2
5110.3
5110.4
5110.5
5111
5111.1
5400
5400.1
5400.2
5400.3
6000
6000.1
6000.2
6000.3
6000.4
6000.5
6420
6420.1
6420.2
6420.3
62
Return
Interval in Hours
250
1500
Interval in Days/Weeks/Months
1d
2m
12 m
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
2006-08-03
F-code
Section
PT
P2.0
Service Schedule
Version no
T-code
001
SMX
C-code
5110
5400
5111
0300
6420
5000
3550
4100
0300
6420
5700
1700
3300
3500
1700
6000
2550
BT Prime-Mover, Inc.
Return
2006-08-03
63
F-code
Section
C-code
PT
P2.0
Service Schedule
Version no
T-code
001
SMX
2.1. General
The following general inspections are to be made by the
operator. It is the operators responsibility to report any
problems with the truck to the appropriate personnel. The
truck should not be operated until it has been inspected and
repaired by a trained, qualified, and authorized technician.
The operator is ultimately responsible for the safe operation
of the truck.
2.1.1. Hardware
Inspect the truck for loose, damaged, or missing parts. All
shields and covers must be in place and functional. Inspect
truck for missing data plate or decals and make sure they are
legible. Report any problems to the appropriate personnel.
DO NOT operate the truck until it has been inspected and
repaired by a trained, qualified, and authorized technician.
Check all fasteners and connections, torque as required (see
page 47.) Check the drive wheel studs. Ensure that the lug
nuts and studs are tightened to the proper torque
specification (see page 47.) Check torque on motor end cap
bolts.
2.1.2. Noise
Check for any abnormal noise coming from the truck.
2.1.3. Leaks
Inspect the entire truck for leaks, especially around the
hydraulic pump assembly and the lift cylinder. Any sign of oil
on the floor under the truck is an indication that the truck may
be leaking hydraulic oil or transmission fluid. Report any
problems to the proper authorities. DO NOT operate the truck
until it has been inspected and repaired by a trained,
qualified, and authorized technician.
Check for proper fluid level in the drive unit. When the truck is
level, oil must be up to the bottom of the plug opening. If fluid
is low, check for leaks (see page 99.)
64
Return
2006-08-03
F-code
Section
PT
P2.0
Service Schedule
Version no
T-code
001
SMX
C-code
BT Prime-Mover, Inc.
Return
2006-08-03
65
F-code
Section
C-code
PT
P2.0
Service Schedule
Version no
T-code
001
SMX
2.2.5. Functions/Operations
Test truck for the proper operation of all functions including
the speed and thumb controls (arm angle switches), lift and
lower functions, brakes, steering, reverser button, horn button
and the main ON/OFF switch. Devices must be operational.
Report any problems to the proper authorities. DO NOT
operate the truck until it has been inspected and repaired by a
trained, qualified, and authorized technician.
2.2.6. Battery
Contact your battery supplier for specific instructions on
care and maintenance of the battery. Determine if the
battery needs to be washed down. This can only be done by
a trained, qualified, and authorized technician.
An average battery will have a specific gravity of 1.170 at the
80 percent discharged level. However, there are many
different batteries on the market. The battery supplier can
accurately determine the fully charged and 80 percent
charged levels. Contact an authorized battery supplier to
determine the overall condition of the battery.
The Battery Discharge Indicator (BDI) indicates the current
state of charge of the trucks battery. (See Parameter 21
on page 178.)
1
1/2
0
66
Return
2006-08-03
F-code
Section
PT
P2.0
Service Schedule
Version no
T-code
001
SMX
C-code
Return
2006-08-03
67
F-code
Section
C-code
PT
P2.0
Service Schedule
Version no
T-code
001
SMX
68
Return
2006-08-03
F-code
Section
PT
P2.0
Service Schedule
Version no
T-code
001
SMX
C-code
BT Prime-Mover, Inc.
Return
2006-08-03
69
F-code
Section
C-code
PT
P2.0
Service Schedule
Version no
T-code
001
SMX
70
Return
2006-08-03
F-code
Section
PT
P3.0
Lubrication Chart
Version no
T-code
000
SMX
C-code
Lubrication Chart
Pos. No
1
2
3
4
Interval/Running Hours
Service Point
360 h
Wheel bearings
Hydraulic system
Drive gear
Drive gear drain
720 h
L
C
C
L= Lubrication
1440 h
Lubricant
(See Lubricants
on page 72)
A
B
C
A
O
O
O
C = Check
O = Oil change
2
1
3
4
BT Prime-Mover, Inc.
Return
2004-01-14
71
F-code
Section
C-code
PT
P4.0
Oil and Grease Specifications
Version no
T-code
001
SMX
Location
Lubricant Specifications
Lubricant
A Grease
B Hydraulic oil
C Drive gear oil
D Sealant
Standard
Operation
Down To
32 F
(0 C)
Cold Storage
Continuous
Operation
Down To
5 F (-15 C)
Intermittent
Operation
Down To
-13 F (-25 C)
Mystik JT-6
Sunoco TH
ATF
Mobil-1 Synthetic Gear Lube 75W-90
or Texaco Synstar GL 75W-90
GE Weicon Silmate
Application area
72
Return
2006-08-03
F-code
PT
Version no
Section
C-code
S
Contents, Section S
T-code
000
Contents, Section S
1. Service Instructions
BT Prime-Mover, Inc.
Return
NO FUNCTION GROUP
C-CODE
FRAME
0000
MOTORS
1000
2000
3000
STEERING SYSTEM
4000
5000
6000
10
TOOLS
10000
2003-10-28
73
F-code
Section
C-code
PT
S
Contents, Section S
Version no
T-code
000
74
Return
2003-10-28
F-code
Section
PT
S0.1
Version no
T-code
001
SMX
C-code
0300
Frame
Frame
1. Theory of Operation
The carrier frame is the body section of the truck that contains
the drive motor, drive unit, drive wheel, controls, and steering
control handle (with electronic tiller arm card [ETAC.]) The lift
frame is the section of the truck that contains the battery, pull
rods, and load wheels, along with the hydraulic and electrical
systems.
2. Maintenance
See Planned Maintenance Schedule on page 61.
2.1. Inspection
WARNING When using compressed air, wear effective
chip-guarding and personal protective
equipment. Compressed air used for
cleaning MUST be reduced to less than 30
psi (207 kPa).
NOTE!
NOTE!
Return
2006-08-03
75
F-code
Section
C-code
PT
Frame
S0.1
0300
Version no
T-code
001
SMX
3. Troubleshooting
Inspect carrier frame and lift frame for crack formation and
damage.
NOTE!
76
Return
2006-08-03
F-code
Section
PT
S0.1
Version no
T-code
001
SMX
C-code
0300
Frame
3
4
8
6
32
31
29
30
20
28
19
18
17
28
27
11
16
10
15
13
15
26
12
14
25
21
24
23
22
Item
No.
Description
Item
No.
Description
Item
No.
1
2
3
4
5
6
7
12
13
14
15
16
17
18
Screw
Bracket, lift limit
Frame, carrier
Screw
Link assembly, upper
Bushing
Nut
23
24
25
26
27
28
29
Bushing
Pin
Pin
Screw
Pull rod assembly
Bushing
Screw
Frame, lift
19
Pin
30
Screw
9
10
11
Lift cylinder
Screw
Nut
20
21
22
Screw
Screw
Link
31
32
Pin
Pin
BT Prime-Mover, Inc.
Return
2006-08-03
Description
77
F-code
Section
C-code
PT
Frame
S0.1
0300
Version no
T-code
001
SMX
3
4
32
35
31
29
30
20
19
10
33 34
28
18
17
27
16
11
15
28
13 12
15
26
25
14
21
24
23
78
Return
22
2006-08-03
Item
No.
F-code
Section
PT
S0.1
Version no
T-code
001
SMX
C-code
0300
Frame
Description
Item
No.
Description
Item
No.
2
3
4
5
6
7
8
9
13
14
15
16
17
18
19
20
21
25
26
27
28
29
30
31
32
33
Pin
Screw
Pull rod assembly
Bushing
Screw
Screw
Pin
Pin
Spring, retainer
10
11
12
Screw
Nut
Screw
22
23
24
Link
Bushing
Pin
34
35
Nut
Washer
Description
Removal
NOTE!
BT Prime-Mover, Inc.
Return
2006-08-03
79
F-code
Section
C-code
PT
Frame
S0.1
0300
Version no
T-code
001
SMX
Wheel Fork
Set Screw
(Top View)
80
Return
2006-08-03
F-code
Section
PT
S0.1
Version no
T-code
001
SMX
C-code
0300
Frame
Installation
WARNING When using compressed air, wear effective
chip-guarding and personal protective
equipment Compressed air used for
cleaning MUST be reduced to less than 30
psi (207 kPa).
1. All parts should be cleaned and dried thoroughly.
Metal parts should be lightly oiled prior to
reassembly.
2. Press new bushing (23) into link (22). Push new
bushing (28) in pull rod (27).
3. Assemble pull rods (27) on links (22) to fit in frame
channel.
4. Install pins (19) and screws (20) in link (22).
5. Install pin (31) connecting pull rod (27) to wheel
fork assembly (1). Secure with set screws (30).
6. Install pins (32) in wheel fork assembly (1) and lift
frame (8). Secure with set screws (29).
7. If applicable, lubricate grease fitting (see page 72)
before turning truck back upright.
8. Return truck to the upright position.
9. Install battery on truck. If applicable, secure battery
bolts to the truck. Install truck cover(s) [see
page 84.]
10. Connect the battery connector to the truck.
WARNING DO NOT use your hands to check for
hydraulic leakage. Use a piece of
cardboard or paper to search for leaks.
Escaping fluid under pressure can
penetrate the skin causing injury. Relieve
pressure before disconnecting hydraulic or
other lines. Tighten all connections before
applying pressure. Keep hands and body
away from pinholes and nozzles which
eject fluids under high pressure.
BT Prime-Mover, Inc.
Return
2006-08-03
81
F-code
Section
C-code
PT
Frame
S0.1
0300
Version no
T-code
001
SMX
Cylinder Retention
Trucks with serial numbers 34271001 - Up are equipped with
the retainer spring (33), nut (34), and washer (35, see
page 78.) To install these parts on trucks prior to these serial
numbers, see drawing below.
Retainer
0.25 inch
(6.5 mm)
5.118 inch
(130 mm)
82
Return
2006-08-03
F-code
PT
Section
C-code
S0.2
0340
Inspection Covers
Version no
T-code
000
SMX
Inspection Covers
1. Theory of Operation
The truck covers are easily removed for access to the
components. During operation of the truck, the covers must
be secured to the truck.
2. Maintenance
See Planned Maintenance Schedule on page 61.
3. Troubleshooting
Inspect covers for damage. Damaged covers should be
replaced.
BT Prime-Mover, Inc.
Return
2004-01-30
83
F-code
Section
C-code
PT
S0.2
Inspection Covers
Version no
T-code
000
SMX
0340
Item
No.
84
Return
Description
Clip
Cover, upper
Screw
Cover, lower
Bumper
Lockwasher
Screw
2004-01-30
F-code
Section
PT
S0.3
Version no
T-code
000
SMX
C-code
0851
Decals
Decals
Remove and replace any decals that are damaged or
missing. Remove a damaged decal by using a sharp edge to
peel the decal from the surface. Use caution not to scratch or
damage the paint on the truck when removing the decal. New
warning decals are free from BT Prime-Mover. Refer to truck
parts book for location and quantities of the decal.
Using a cleaning solution, thoroughly clean the surface of the
truck before applying a new decal. Allow the surface to dry
completely, be sure that there is no residue. Touch up the
paint in area of the decal, as required.
BT Prime-Mover, Inc.
Return
2004-01-30
85
F-code
Section
C-code
PT
Decals
S0.3
0851
Version no
T-code
000
SMX
86
Return
2004-01-30
F-code
Section
PT
S1.0
1700
Electric Motors
Version no
T-code
001
SMX
C-code
Electric Motors
Electric motors provide power to the transmission and
hydraulic systems. Motor speed and direction are controlled
by the transistor controller or contactor with inputs from the
operator controls.
1. Theory of Operation
The lift pump motor assembly consists of the pump motor,
pump assembly and lift valve assembly. The pump motor and
pump are an integrated unit. The drive unit assembly consists
of the electromagnetic brake assembly, drive motor,
transmission assembly and drive wheel. The drive motor is
part of the drive unit. The steering bearing is mounted on top
of the drive unit assembly.
2. Maintenance
A routine maintenance schedule with recorded findings is the
best way to reduce costly shut-downs and repair of
equipment during operating hours. The goal of any
maintenance program, long-life and trouble-free operation, is
related to time spent making inspections and correcting minor
problems as they occur.
Inspect the motor more frequently when working in an
abnormally severe or corrosive environment or if in a rigorous
duty cycle. Set up and maintain a strict inspection schedule to
obtain the maximum efficiency from the electrical equipment.
Operating environments of truck motors varies widely.
The following recommendations should be applied as actual
conditions dictate:
Normal Service:
Severe Service:
Extreme Service:
Chemical processing
Cold storage operation
Processing plants (poultry, meat)
BT Prime-Mover, Inc.
Return
2006-08-04
87
F-code
Section
C-code
PT
S1.0
Electric Motors
1700
Version no
T-code
001
SMX
3. Troubleshooting
When a motor has trouble in operation, a reasonable decision
has to be made as to the proper corrective course of action.
88
Return
2006-08-04
F-code
Section
PT
S1.0
1700
Electric Motors
Version no
T-code
001
SMX
C-code
Brush
Shield
Figure 1-1: Drive Motor Brush Shield
BT Prime-Mover, Inc.
Return
2006-08-04
89
F-code
Section
C-code
PT
S1.0
Electric Motors
1700
Version no
T-code
001
SMX
Brushes
Brushes
Figure 1-2: Pump Motor
Spring
90
Return
2006-08-04
F-code
Section
PT
S1.0
1700
Electric Motors
Version no
T-code
001
SMX
C-code
Return
2006-08-04
91
F-code
Section
C-code
PT
S1.0
Electric Motors
1700
Version no
T-code
001
SMX
Contactor
Pump Motor
Reservoir
3
1
2
Item
No.
Description
1
2
3
4.2.1. Removal
1. Park truck on a level surface and make sure
parking brake is applied and load wheels are
blocked to prevent accidental movement.
2. Release pressure in hydraulic system by pressing
the lowering button on steering control handle until
lift cylinder is completely collapsed.
Hydraulic
Line
Pump
Assembly
92
Return
2006-08-04
F-code
Section
PT
S1.0
1700
Electric Motors
Version no
T-code
001
SMX
C-code
Power
Cables
BT Prime-Mover, Inc.
Return
2006-08-04
93
F-code
Section
C-code
PT
S1.0
Electric Motors
1700
Version no
T-code
001
SMX
1 2
31
10
30
6
11
9
8
15
14
12
13
5
4
18
20
22
19
23
24
17 16
21
25
28
26
27
35
34
35
EE
94
Return
2006-08-04
Item No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
BT Prime-Mover, Inc.
Return
Description
Ring, retainer
Gear
Key
Case
Terminal
Screw
Nut
Section
PT
S1.0
1700
Electric Motors
Version no
T-code
001
SMX
Item No.
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
Washer
Field
Isolator
Bearing
Shim
Seal
Armature
Key
Ring, retainer
Hub
Band, cover E
F-code
2006-08-04
C-code
Description
Screw
Cover
Plate, brush
Spring
Brush
Nut
Ring, retainer
Bearing
Lockwasher
Screw
Shoe, pole
Washer
Screw
Lockwasher
Nut
Band Cover EE
Screw EE
95
F-code
Section
C-code
PT
S1.0
Electric Motors
1700
Version no
T-code
001
SMX
Steering Bearing
Carrier
Frame
Steering
Control Head
Drive Wheel
Drive Motor
bly
sem
s
A
e
Brak
Transmission
Assembly
96
Return
2006-08-04
F-code
Section
PT
S1.0
1700
Electric Motors
Version no
T-code
001
SMX
C-code
4.4.1. Removal
WARNING There is no brake on the truck when the
drive motor is removed from the
transmission assembly. Block all wheels to
reduce the risk of truck movement.
1. Park the truck on a level surface and make sure
parking brake is applied and load wheels are
blocked to prevent accidental movement.
2. Press red OFF button O on the keypad. Depress
main ON/OFF switch to the OFF position.
3. Disconnect the battery connector from the truck.
4. Jack truck and block the frame (see page 58.)
5. Remove truck cover(s) [see page 84.]
6. Disconnect cable/wires from the terminal block on
the transmission.
7. Remove brake assembly from drive motor.
Terminal Block
Connections
8. Disassemble
assembly.
drive
motor
from
transmission
4.4.2. Installation
WARNING When using compressed air, wear effective
chip-guarding and personal protective
equipment. Compressed air used for
cleaning MUST be reduced to less than 30
psi (207 kPa).
1. Thoroughly clean all parts with non-corrosive
cleaning fluid and air dry all parts.
2. Reassemble
assembly.
drive
motor
on
transmission
BT Prime-Mover, Inc.
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2006-08-04
97
F-code
Section
C-code
PT
S1.0
Electric Motors
1700
Version no
T-code
001
SMX
98
Return
2006-08-04
F-code
Section
PT
S2.0
2550
Transmission
Version no
T-code
001
SMX
C-code
Transmission
1. Theory of Operation
This transmission is of the double reduction gear type. The
gears are a combination of helical and straight cut gears for
strength and low noise. The final drive gear is mounted on
opposing tapered roller bearings. The intermediate gear is
mounted on ball bearings. Gears and bearings are enclosed
in an oil filled case. The drive motor is mounted externally
with the drive motor pinion gear mounted on the armature
shaft. The brake is mounted on the drive motor.
2. Maintenance
See Planned Maintenance Schedule on page 61.
Fill/Level Plug
Drain Plug
NOTE!
BT Prime-Mover, Inc.
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2006-08-04
99
F-code
Section
C-code
PT
S2.0
Transmission
2550
Version no
T-code
001
SMX
3. Troubleshooting
Because of the uncomplicated nature of the transmission,
troubleshooting is limited to identifying problems if they are
mechanical or electrical in nature. Fluid leaks are obviously
mechanical in nature and can be found by visual inspection.
Unusual noise and/or slow running could be mechanical or
electrical in nature. Generally, if the problem is caused
internally in the transmission, then metal contamination will
be evident in the oil. If there is a mechanical problem outside
of the transmission, then it will become evident by inspecting
the drive motor and brakes. See page 111 for instructions to
release the brake, if necessary.
100
Return
2006-08-04
3
1
F-code
Section
PT
S2.0
2550
Transmission
Version no
T-code
001
SMX
9
6
11 10
24
13
10
12
Item No.
11 14
15
16
17
18
19
20
23
21
BT Prime-Mover, Inc.
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Transmission
TransmissionMounting
Mounting
22
C-code
2006-08-04
Description
1
2
3
4
5
6
7
8
9
10
Screw
Cushion, upstop
Screw
Mount, stem
Screw
Clip
Stem, handle
Screw, set
Steering control head
Washer
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Bushing
Spring
Sleeve
Washer
Screw
Lockwasher
Carrier frame
Drive unit
Drive motor
Brake assembly
Transmission assembly
Steering bearing
Drive wheel
Pin
101
F-code
Section
C-code
PT
S2.0
Transmission
2550
Version no
T-code
001
SMX
22
19
20
21
14 15
17
16
18
13
4
10
12
11
Item No.
1
2
3
4
5
6
7
8
102
Return
6
Transmission
Assembly
9
Description
Stud
Axle
Seal
Bearing
Spacer
O ring
Plug
Gear
Item No.
9
10
11
12
13
14
15
Description
Ring, retainer
Gear
Cover
Plug
Vent
Screw
Lockwasher
Item No.
16
17
18
19
20
21
22
Description
Bearing
Gear
Bearing
Retainer ring
Gear
Key
Case
2006-08-04
F-code
Section
PT
S2.0
2550
Transmission
Version no
T-code
001
SMX
C-code
Removal
WARNING There is no brake on the truck when the
drive motor is removed from the
transmission assembly. Block all wheels to
reduce the risk of truck movement.
NOTE!
1. Lower forks.
2. Press red OFF button O on the keypad. Depress
main ON/OFF switch to the OFF position.
3. Disconnect the battery connector from the truck.
4. Remove truck cover(s) [see page 84.]
5. If applicable, remove bolts securing the battery to
the truck. Remove the battery from the truck.
6. Jack truck and block the frame (see page 58.)
7. Disconnect handle harness.
Bolts
Stem
Mount
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2006-08-04
103
F-code
Section
C-code
PT
S2.0
Transmission
2550
Version no
T-code
001
SMX
Wiring Harness
Connector
104
Return
2006-08-04
F-code
Section
PT
S2.0
2550
Transmission
Version no
T-code
001
SMX
C-code
Disassembly
NOTE!
Thoroughly clean the outside of the gear case with a noncorrosive cleaning fluid. Dry all parts and proceed as follows.
1. Remove screws (14) and lockwashers (15)
securing gear case cover (11). Remove gear case
cover (11).
2. Remove retaining ring (19) securing the top pinion
gear (20). Remove top pinion gear (20) and key
(21) attached to drive motor armature shaft.
NOTE!
Reassembly
NOTE!
Return
2006-08-04
105
F-code
Section
C-code
PT
S2.0
Transmission
2550
Version no
T-code
001
SMX
Installation
CAUTION Make sure the main ON/OFF switch is OFF
and the battery connector is removed from
truck before proceeding.
NOTE!
1. If removed earlier,
assembly (22).
install
steering
bearing
with
screws
(15)
and
106
Return
2006-08-04
F-code
Section
PT
S2.0
2550
Transmission
Version no
T-code
001
SMX
C-code
BT Prime-Mover, Inc.
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2006-08-04
107
F-code
Section
C-code
PT
S2.0
Transmission
2550
Version no
T-code
001
SMX
108
Return
2006-08-04
F-code
PT
Section
C-code
S3.0
3300
Parking Brake System
Version no
T-code
001
SMX
BT Prime-Mover, Inc.
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2006-08-04
109
F-code
Section
C-code
PT
S3.0
3300
Parking Brake System
Version no
T-code
001
SMX
40
33
8
110
Return
2006-08-04
F-code
PT
Section
C-code
S3.0
3300
Parking Brake System
Version no
T-code
001
SMX
2. Maintenance
See Planned Maintenance Schedule on page 61.
BT Prime-Mover, Inc.
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2006-08-04
111
F-code
Section
C-code
PT
S3.0
3300
Parking Brake System
Version no
T-code
001
SMX
Air Gap
0.008 - 0.014 inch
(0.2 - 0.36 mm)
Mounting Bolt
Coil Housing
Friction disk
Pressure Plate
3. Troubleshooting
Check brake disk for wear. Replace friction disk if worn
unevenly or when its total thickness is reduced to 0.20 inch
(5.5 mm).
112
Return
2006-08-04
F-code
Section
PT
C-code
S3.0
3300
Parking Brake System
Version no
T-code
001
SMX
1
8
Item
No.
Description
Item
No.
Transmission assembly
Disk
Brake assembly
Coil
Flange, friction
Screw
Hub
Retaining ring
Description
Removal
1. Park truck on a level surface and make sure
parking brake is applied and load wheels are
blocked to prevent accidental movement.
2. Press red OFF button O on the keypad. Depress
main ON/OFF switch to the OFF position.
3. Disconnect the battery connector from the truck.
BT Prime-Mover, Inc.
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2006-08-04
113
F-code
Section
C-code
PT
S3.0
3300
Parking Brake System
Version no
T-code
001
SMX
6
5
Installation
1. Inspect friction flange (3) for wear, replace if the
surface is worn unevenly. Install friction disk (5) on
hub (4). Place friction flange (3) on motor.
2. Install brake coil assembly on the motor end.
Adjust gap (see page 111.) Torque mounting bolts
to 50 in-lbs (5.6 Nm).
3. Connect the battery connector to the truck.
4. Remove blocks. Turn main ON/OFF switch to the
On position and turn key switch ON.
5. Test truck for proper operation before returning to
service.
6. Install truck cover(s).
114
Return
2006-08-04
F-code
Section
PT
S3.1
Version no
T-code
001
SMX
C-code
3530
Drive Wheel
Drive Wheel
1. Theory of Operation
The drive wheel is mounted on the transmission drive axle.
The drive wheel is part of the drive unit assembly.
Drive Wheel Specifications
10 inch X 5 inch (255 X 125 mm)
2. Maintenance
See Planned Maintenance Schedule on page 61.
BT Prime-Mover, Inc.
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Service Manual
2006-08-04
115
F-code
Section
C-code
PT
S3.1
Drive Wheel
3530
Version no
T-code
001
SMX
NOTE!
116
Return
Service Manual
2006-08-04
F-code
Section
PT
S3.1
Version no
T-code
001
SMX
C-code
3530
Drive Wheel
3. Troubleshooting
Inspect wheel and tire for wear and damage. Trash that is
wrapped around the wheel and axle will cause premature tire
wear and bearing damage. The floors should be kept clean of
trash to reduce risk of damage to wheel and tire.
Item No.
1
2
3
4
Description
Wheel assembly
Tire
Hub
Nut
Removal
The drive wheel can be removed without removing the
transmission by the following steps:
1. Park truck on a level surface and make sure
parking brake is applied and load wheels are
blocked to prevent accidental movement.
BT Prime-Mover, Inc.
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Service Manual
2006-08-04
117
F-code
Section
C-code
PT
S3.1
Drive Wheel
3530
Version no
T-code
001
SMX
Installation
1. Install new tire and hub (3) on transmission drive
axle and secure with nuts (4). In a crossing pattern,
torque nuts to 55 ft-lbs (74.6 Nm).
2. Attach bumper with bolts, apply Loctite 243 to
bolts, and tighten.
3. Remove blocking. Connect the battery connector
to the truck.
4. Turn the main ON/OFF switch to the ON position.
Enter key code and press the green ON button I
on the keypad.
5. Check operation of drive wheel.
118
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Service Manual
2006-08-04
F-code
Section
PT
S3.1
Version no
T-code
001
SMX
C-code
3530
Drive Wheel
Circular
Ram
New
Tire
Worn
Tire
Press
Table
BT Prime-Mover, Inc.
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Service Manual
2006-08-04
119
F-code
Section
C-code
PT
S3.1
Drive Wheel
3530
Version no
T-code
001
SMX
7. Begin pressing new tire onto hub and old tire off
wheel. Run press slowly for the first few inches of
travel, because this is the critical stage of the
operation. If tire begins to cock to one side, stop
press and realign tire. A sharp jar with a softheaded mallet will usually realign tire on hub.
8. Release press. Remove wheel, tire assembly, and
old tire from press table. Inspect wheel and tire
assembly.
9. Install wheel assembly following the procedure for
the specific type of wheel.
120
Return
Service Manual
2006-08-04
F-code
Section
PT
S3.2
Version no
T-code
001
SMX
C-code
3550
Load Wheels
Load Wheels
1. Theory of Operation
The load wheels are mounted on the pallet forks to support
the rated load at the forks fully raised height. Load wheels
contain sealed bearings on both sides.
Load Wheel Specifications
3.25 inch X 4.50 inch (82 X 115 mm)
2. Maintenance
Inspect the wheels for wear and debris wrapped around the
wheels. Check load wheel bearings for binding or excessive
play. See Planned Maintenance Schedule on page 61.
3. Troubleshooting
Inspect load wheel bearings for chunking, bond failure, and
excessive or uneven wear. Make sure wheels are functioning
smoothly and sufficient grease is applied to load wheel
bearings and linkage.
BT Prime-Mover, Inc.
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2006-08-04
121
F-code
Section
C-code
PT
S3.2
Load Wheels
3550
Version no
T-code
001
SMX
Item
No.
1
2
Description
Bearing
Wheel, load
Removal
1. Park the truck on a level surface.
2. Lift forks to maximum height and block (see
page 58.)
3. Press red OFF button O on the keypad. Depress
main ON/OFF switch to the OFF position.
4. Disconnect the battery connector from the truck.
5. Remove axle set screw.
122
Return
2006-08-04
F-code
Section
PT
S3.2
Version no
T-code
001
SMX
C-code
3550
Load Wheels
Installation
1. Install bearings in the new load wheel with seal
side out.
2. Place the new load wheel upright on a level
surface. Position the bearing over the load wheel.
Put a flat metal plate over the bearing and tap the
bearing in place with a plastic mallet. Make sure
the bearing is fully seated in the load wheel.
3. Align the wheel with the holes in the load arm
casting.
4. Install the axle through the load arm hole and
wheel. Align the dimple in the axle with the set
screw hole.
5. Install and tighten the set screw.
6. Lower truck and remove blocks.
7. Connect the battery connector to the truck.
8. Turn main ON/OFF switch to the ON position.
Enter key code and press the green ON button I
on the keypad.
9. Test truck for proper operation before returning to
service.
BT Prime-Mover, Inc.
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2006-08-04
123
F-code
Section
C-code
PT
S3.2
Load Wheels
3550
Version no
T-code
001
SMX
124
Return
2006-08-04
F-code
PT
Section
C-code
S3.3
3560
Caster Wheel (Optional)
Version no
T-code
001
SMX
2. Maintenance
Normal maintenance includes lubricating the grease fittings
on the caster assembly periodically. (See Planned
Maintenance Schedule on page 61.)
2.1. Inspection
Caster
Assembly
BT Prime-Mover, Inc.
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2005-07-11
125
F-code
Section
C-code
PT
S3.3
3560
Caster Wheel (Optional)
Version no
T-code
001
SMX
3. Troubleshooting
Lubricate caster swivel as necessary.
20
7
8
7
19
9
10
11
18
10
12
17
15
14
13
14
13
16
126
Return
2005-07-11
F-code
Section
PT
Item
No.
1
2
3
4
5
6
7
Description
Caster Assembly
Fitting, grease
Pin
Cap
Bearing cup
Plate
Washer, thrust
Item
No.
8
9
10
11
12
13
14
Description
Bearing, thrust
Arm
Washer assembly
Nut
Nut
Washer, flat
Bearing
C-code
S3.3
3560
Caster Wheel (Optional)
Version no
T-code
001
SMX
Item
No.
15
16
17
18
19
20
Description
Wheel
Screw
Screw
Block, torsion
Housing
O Ring
Removal
1. Park truck on a level surface and make sure
parking brake is applied and load wheels are
blocked to prevent accidental movement.
2. Press red OFF button O on the keypad. Depress
main ON/OFF switch to the OFF position.
3. Disconnect the battery connector from the truck.
4. Hoist truck so caster wheel is approximately 2
inches (50 mm) off the floor and securely block.
5. Before disassembly thoroughly clean exterior of
the caster assembly in a cleaning solution to
remove all contamination.
6. Remove caster assembly screws from bumper.
Remove caster assembly and take to a suitable
work area.
7. Remove nuts (11) and (12) and washers (10) from
screws (16) and (17). Remove screws (16) and
(17) from assembly. Remove arms (9).
8. Remove flat washers (13) and bearings (14) from
wheel (15). Inspect bearings (14).
9. Disassemble housing (19) by removing pin (3), cap
(4), and plate (6). Remove bearing (5) from plate
(6). Remove O ring (20), thrust washers (7), and
thrust bearing (8) from housing (19). Inspect
bearings (5) and (8).
BT Prime-Mover, Inc.
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2005-07-11
127
F-code
Section
C-code
PT
S3.3
3560
Caster Wheel (Optional)
Version no
T-code
001
SMX
Installation
WARNING When using compressed air, wear effective
chip-guarding and personal protective
equipment. Compressed air used for
cleaning MUST be reduced to less than 30
psi (207 kPa).
1. All parts should be cleaned and dried thoroughly.
Metal parts should be lightly oiled prior to
reassembly.
2. Pack all bearings with grease (see page 72.)
3. Install O ring (20), thrust bearing (8), and thrust
washers (7) in housing (19).
4. Install bearing (5) and cap (4) in plate (6). Install
plate (6) on housing (19) and secure with pin (3).
5. Install bearings (14) and flat washers (13) in new
wheel (15).
6. Install arms (9) on housing (19) and secure with
screws (16) and (17), washer (10), and nuts (11)
and (12).
7. Install caster assembly to bumper and secure with
screws.
8. Connect the battery connector to the truck.
9. Remove blocks. Turn main ON/OFF switch to the
ON position. Enter key code and press the green
ON button I on the keypad.
10. Test truck for proper operation before returning to
service.
128
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2005-07-11
F-code
PT
Section
C-code
S4.0
4100
Steering Control Handle
Version no
T-code
001
SMX
2. Maintenance
See Planned Maintenance Schedule on page 61.
2.1. Inspection
WARNING When using compressed air, wear effective
chip-guarding and personal protective
equipment. Compressed air used for
cleaning MUST be reduced to less than 30
psi (207 kPa).
NOTE!
3. Troubleshooting
Check fasteners and the ease of steering.
BT Prime-Mover, Inc.
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2006-08-07
129
F-code
Section
C-code
PT
S4.0
4100
Steering Control Handle
Version no
T-code
001
SMX
9
6
4
8
11 10
24
13
10
12
11 14
15
16
17
18
19
22
20
23
21
130
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2006-08-07
F-code
PT
Item
No.
Description
Section
Version no
T-code
001
SMX
Item
No.
C-code
S4.0
4100
Steering Control Handle
Description
1
2
3
4
5
6
7
8
9
Screw
Cushion, upstop
Screw
Mount, stem
Screw
Clip
Stem, handle
Screw, set
Steering control head
13
14
15
16
17
18
19
20
21
Sleeve
Washer, plastic
Screw
Lockwasher
Carrier frame
Drive unit
Drive motor
Brake assembly
Transmission assembly
10
11
12
Washer
Bushing
Spring
22
23
24
Steering bearing
Drive wheel
Pin
Removal
1. Park truck on a level surface and make sure
parking brake is applied and load wheels are
blocked to prevent accidental movement.
2. Release pressure in hydraulic system by pressing
the lowering button on steering control handle.
3. Press red OFF button O on the keypad. Depress
main ON/OFF switch to the OFF position.
4. Disconnect the battery connector from the truck.
5. Remove screws (1) securing lower steering control
handle cover (4).
BT Prime-Mover, Inc.
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2006-08-07
131
F-code
Section
C-code
PT
S4.0
4100
Steering Control Handle
Version no
T-code
001
SMX
Cover
Screw
Wiring Harness
Connector
NOTE!
Return
2006-08-07
F-code
PT
Section
C-code
S4.0
4100
Steering Control Handle
Version no
T-code
001
SMX
Installation
NOTE!
Plastic Washer
Harness
Sleeve
Spring
6. Remove blocks.
7. Connect the battery connector to the truck.
BT Prime-Mover, Inc.
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2006-08-07
133
F-code
Section
C-code
PT
S4.0
4100
Steering Control Handle
Version no
T-code
001
SMX
134
Return
2006-08-07
F-code
PT
Section
C-code
S4.1
4100
Steering Control Head
Version no
T-code
001
SMX
2. Maintenance
See Planned Maintenance Schedule on page 61.
3. Troubleshooting
Check fasteners and ease of steering.
BT Prime-Mover, Inc.
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2006-08-07
135
F-code
Section
C-code
PT
S4.1
4100
Steering Control Head
Version no
T-code
001
SMX
13
46
14
15
45
16
44
17
43
42
20
19
18
21
41
22
25
17
29 28
26
27
24
23
30
32 31
35
38
34
38
34 33
37 36
39
31 32 40
1
3
5
6
11
8
10
136
Return
2006-08-07
F-code
PT
BT Prime-Mover, Inc.
Return
T-code
001
SMX
Description
Item
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
Screw
Plate
Handle
Screw
Cover (option)
Pad, key
Screw
Screw
Relief, strain
Plate
Handle assembly, control
Insert, blank
Button, no function
Button, reverser
Button, horn (right)
Housing
Switch, horn
Display
Electronic Tiller Arm Card (ETAC)
Spring
Housing
Screw
Gasket
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
2006-08-07
C-code
S4.1
4100
Steering Control Head
Version no
Item
No.
Section
Description
Spring
Screw
Screw
Tie, cable
Screw
Tie, cable
Thumb control assembly
Screw
Washer
Switch, right
Bearing
Stop lug
Arm
Axle
Support
Spring
Switch, left
Button, horn (left)
Seal
Cap, transparent plastic
Button, lift / lower
Insert, lower
Insert, lift
137
F-code
Section
C-code
PT
S4.1
4100
Steering Control Head
Version no
T-code
001
SMX
Removal
1. Park truck on a level surface and make sure
parking brake is applied and load wheels are
blocked to prevent accidental movement.
2. Release pressure in hydraulic system by pressing
the lowering button on steering control head.
3. Press red OFF button O on the keypad. Depress
main ON/OFF switch to the OFF position.
4. Disconnect the battery connector from the truck.
5. Remove screw (7) from key pad. Unplug and
remove key pad (6) from handle (3).
6. Holding the top cover (16) firmly, remove screws
(4) and (8).
7. Disconnect the cable connected to ETAC (19).
8. Remove screws (22) from housing (21) to gain
access to ETAC (19).
NOTE!
138
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2006-08-07
F-code
PT
Section
C-code
S4.1
4100
Steering Control Head
Version no
T-code
001
SMX
Installation
NOTE!
BT Prime-Mover, Inc.
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2006-08-07
139
F-code
Section
C-code
PT
S4.1
4100
Steering Control Head
Version no
T-code
001
SMX
140
Return
2006-08-07
F-code
Section
PT
S4.2
4180
Steering Bearing
Version no
T-code
000
SMX
C-code
Steering Bearing
1. Theory of Operation
The steering bearing is part of the drive unit assembly. The
vertical and horizontal loads are carried by the steering
bearing.
2. Maintenance
Inspect for wear or damage.
3. Troubleshooting
Probable Cause
Worn or damaged
steering bearing
BT Prime-Mover, Inc.
Return
2004-02-13
Required Action
Replace bearings
141
F-code
Section
C-code
PT
S4.2
Steering Bearing
4180
Version no
T-code
000
SMX
4
5
Item No.
142
Return
Description
Screw
Lockwasher
Bearing
Stop, steering
Transmission assembly
2004-02-13
F-code
Section
PT
S4.2
4180
Steering Bearing
Version no
T-code
000
SMX
C-code
Removal
1. Park truck on a level surface and make sure
parking brake is applied and load wheels are
blocked to prevent accidental movement.
2. Release pressure in hydraulic system by pressing
the lowering button on steering control head.
3. Press red OFF button O on the keypad. Depress
main ON/OFF switch to the OFF position.
Disconnect the battery connector from the truck.
4. Jack truck and block the frame (see page 58.)
5. Remove truck cover(s) [see page 84.]
6. Disconnect all electrical connections on drive
motor and brake assembly.
7. Remove transmission (see page 103.)
8. Remove screws (1) and lockwashers (2) from
bearing (3). Remove bearing (3) from transmission
assembly (5).
BT Prime-Mover, Inc.
Return
2004-02-13
143
F-code
Section
C-code
PT
S4.2
Steering Bearing
4180
Version no
T-code
000
SMX
Installation
1. Install new bearing (3) and secure with
lockwashers (2) and screws (1) on transmission.
2. Install transmission (see page 106.)
3. Connect all electrical connections.
4. Refill transmission with fluid as needed (see
page 72.)
5. Install truck cover(s) [see page 84.]
6. Remove blocks.
7. Connect the battery connector to the truck.
8. Turn main ON/OFF switch to the ON position.
Enter key code and press the green ON button I
on the keypad. Operate the trucks hydraulic
system and check operation of system as a whole.
Look for leaks and tight places on the lifting
linkage.
144
Return
2004-02-13
F-code
PT
Section
C-code
S5.0
5000
Electrical Functions
Version no
T-code
002
SMX
Electrical Functions
1. Theory of Operation
The travel control system on the truck is electrically controlled
and monitored. The lift/lower systems are electrically
controlled and hydraulically operated. All circuits are
protected against overload with automatic resetting circuit
breakers. Refer to the following detailed electrical circuit
schematics as they apply. The complete electrical circuit
schematics can be found starting on page 194. When starting
the truck, the transistor controller checks the closing
sequence of the micro switches in the circuit. For information
on the transistor controller see page 239.
Normal Operation
1. When the truck is first powered on, it displays an
hourmeter (see parameter 20 on page 178) for the
first five seconds. Then, it normally displays the
battery state-of-charge throughout operation.
2. While a Caution error code is tripped, it is
displayed 3.4 seconds out of every 5.1 seconds.
The other 1.7 seconds shows normal display.
3. When battery state-of-charge is zero percent, lift is
not allowed. When the battery state-of-charge is 10
percent or lower, the battery light blinks.
BT Prime-Mover, Inc.
Return
2006-12-12
145
F-code
Section
PT
S5.0
Electrical Functions
Version no
T-code
002
SMX
C-code
5000
Pressure Oil
Return Oil
B+ Circuit
B- Circuit
Signal
Pre-Charge Voltage
146
Return
Symbol
Designation
Symbol
M1
Designation
A1
A2
M3
Pump Motor
F50
S18-1
Horn Switch
F51
S18-2
H1
Horn
S21
Drive Motor
Horn Switch
Main ON/OFF Switch
J11
S24
J41
S25
K4
S36
K10
Main Contactor
Y1
Brake Coil
K30
Y10
2006-12-12
F-code
Section
PT
C-code
S5.0
5000
Electrical Functions
Version no
T-code
002
SMX
Pressure Oil
BT Prime-Mover, Inc.
Designation
Symbol
M1
Designation
Return Oil
A1
A2
M3
Pump Motor
B+ Circuit
F50
S18-1
Horn Switch
F51
S18-2
H1
Horn
B- Circuit
Return
Symbol
S21
Drive Motor
Horn Switch
Main ON/OFF Switch
J11
S24
Signal
J41
S25
K4
S36
Pre-Charge Voltage
K10
Main Contactor
Y1
Brake Coil
K30
Y10
2006-12-12
147
F-code
Section
PT
S5.0
Electrical Functions
Version no
T-code
002
SMX
C-code
5000
Pressure Oil
Return Oil
B+ Circuit
B- Circuit
Signal
Pre-Charge Voltage
148
Return
Symbol
Designation
Symbol
M1
Designation
A1
A2
M3
Pump Motor
F50
S18-1
Horn Switch
F51
S18-2
H1
Horn
S21
Drive Motor
Horn Switch
Main ON/OFF Switch
J11
S24
J41
S25
K4
S36
K10
Main Contactor
Y1
Brake Coil
K30
Y10
2006-12-12
F-code
PT
Section
C-code
S5.0
5000
Electrical Functions
Version no
T-code
002
SMX
BT Prime-Mover, Inc.
Return
2006-12-12
149
F-code
Section
PT
S5.0
Electrical Functions
Version no
T-code
002
SMX
C-code
5000
150
Return
2006-12-12
F-code
Section
PT
C-code
S5.0
5000
Electrical Functions
Version no
T-code
002
SMX
Pressure Oil
BT Prime-Mover, Inc.
Return
Symbol
Designation
Symbol
M1
Designation
Return Oil
A1
A2
M3
Pump Motor
B+ Circuit
F50
S18-1
Horn Switch
F51
S18-2
B- Circuit
H1
Horn
S21
Drive Motor
Horn Switch
Main ON/OFF Switch
J11
S24
Signal
J41
S25
K4
S36
Pre-Charge Voltage
K10
Main Contactor
Y1
Brake Coil
K30
Y10
2006-12-12
151
F-code
Section
PT
S5.0
Electrical Functions
Version no
T-code
002
SMX
C-code
5000
Pressure Oil
Symbol
Return Oil
A2
M3
Pump Motor
B+ Circuit
F50
S18-1
Horn Switch
F51
S18-2
Horn Switch
H1
Horn
S21
J11
S24
J41
S25
K4
S36
K10
Main Contactor
Y1
Brake Coil
K30
Y10
Pre-Charge Voltage
M1
Designation
Signal
152
Designation
A1
B- Circuit
Return
Symbol
Drive Motor
2006-12-12
F-code
PT
Section
C-code
S5.0
5000
Electrical Functions
Version no
T-code
002
SMX
1.6. Reverser
Pressure Oil
Return Oil
B+ Circuit
B- Circuit
Signal
Pre-Charge Voltage
Symbol
Designation
Symbol
M1
Designation
A1
A2
M3
Pump Motor
F50
S18-1
Horn Switch
F51
S18-2
H1
Horn
S21
Drive Motor
Horn Switch
Main ON/OFF Switch
J11
S24
J41
S25
K4
S36
K10
Main Contactor
Y1
Brake Coil
K30
Y10
BT Prime-Mover, Inc.
Return
2006-12-12
153
F-code
Section
PT
S5.0
Electrical Functions
Version no
T-code
002
SMX
C-code
5000
1.7. Lift
When the lift button is pressed, the transistor controller
provides a negative pin J5-4 to the main contactor coil (K10),
closing the main contactor (K10) to the main contactor relay
(K4). The main contactor relay (K4) provides battery voltage
to the positive side of pump contactor coil (K30). The
transistor controller provides a negative in J5-6 to the pump
contactor coil (K30) closing the pump contactor.
Pressure Oil
Return Oil
B+ Circuit
B- Circuit
Signal
Pre-Charge Voltage
154
Return
Symbol
Designation
A1
Symbol
M1
Designation
Drive Motor
A2
M3
Pump Motor
F50
S18-1
Horn Switch
F51
S18-2
Horn Switch
H1
Horn
S21
J11
S24
J41
S25
K4
S36
K10
Main Contactor
Y1
Brake Coil
K30
Y10
2006-12-12
F-code
Section
PT
C-code
S5.0
5000
Electrical Functions
Version no
T-code
002
SMX
1.8. Lower
When the lower button is pressed, the transistor controller
provides a negative pin J5-4 to the main contactor coil (K10),
closing the main contactor (K10) to the main contactor relay
(K4). The main contactor relay (K4) provides battery voltage
to the positive side of lowering valve coil (Y10). The transistor
controller provides a negative pin J5-2 to the lowering valve
coil (Y10), opening the hydraulic lowering valve.
Pressure Oil
BT Prime-Mover, Inc.
Return
Symbol
Designation
Symbol
Return Oil
A2
M3
Pump Motor
B+ Circuit
F50
S18-1
Horn Switch
F51
S18-2
Horn Switch
B- Circuit
H1
Horn
S21
J11
S24
Signal
J41
S25
K4
S36
Pre-Charge Voltage
K10
Main Contactor
Y1
Brake Coil
K30
Y10
M1
Designation
A1
2006-12-12
Drive Motor
155
F-code
Section
PT
S5.0
Electrical Functions
Version no
T-code
002
SMX
C-code
5000
2. Maintenance
Connections must be kept clean and tight. The electrical
components should be protected from moisture. If the truck is
equipped with cold storage, or corrosive environment
application package, then the di-electric compound (part
number 302249-000) in the plug-in connectors should be
renewed periodically. This compound is available through the
parts department of your authorized Prime-Mover Dealer.
2.1. Wiring
Many electrical problems are caused by a bad or dirty battery.
Make sure battery is clean. Check the electrolyte level and
battery level.
CAUTION Unless otherwise directed, disconnect
battery connector when checking electrical
circuits or components with an ohmmeter.
Electrical current can damage the
ohmmeter.
Visually inspect all wiring and electrical components for the
following:
2.1.1. Definitions
Continuity. A continuous and uninterrupted path between
two or more locations in an electrical circuit, typically having a
resistance of less than 1 ohm.
Open Circuit. A lack of a continuous path between two or
more electrical connections. Generally, when such a circuit is
tested, it will have a resistance greater than one megohms.
Pulse Width Modulation. Pulse Width Modulation (PWM),
also called chopping, controls the speed of the motor by
156
Return
2006-12-12
F-code
PT
Section
C-code
S5.0
5000
Electrical Functions
Version no
T-code
002
SMX
BT Prime-Mover, Inc.
Return
Accumulation of dirt
2006-12-12
157
F-code
Section
PT
S5.0
Electrical Functions
Version no
T-code
002
SMX
C-code
5000
Insulation breakdown
Bare wires
Batteries
Motors
Heat sinks
Bus bars
Solenoids
Contactors
Terminal strips
Switches
158
Return
2006-12-12
F-code
PT
Section
C-code
S5.0
5000
Electrical Functions
Version no
T-code
002
SMX
Return
2006-12-12
159
F-code
Section
PT
S5.0
Electrical Functions
Version no
T-code
002
SMX
C-code
5000
160
Return
2006-12-12
F-code
PT
Section
C-code
S5.0
5000
Electrical Functions
Version no
T-code
002
SMX
3. Troubleshooting
3.1. Troubleshooting Flowchart
Troubleshooting
Truck Fault
Code
Yes
Find Code
(see page 181)
No
Transistor
Controller
Error
Code
Yes
Find Code
(see page 246)
No
Yes, Traction/Overall
Check
Troubleshooting
Chart
No
Go to charts
(see page 189)
Yes, Hydraulic
Go to charts
(see page 261)
General Troubleshooting
(see Service Display page 169)
BT Prime-Mover, Inc.
Return
2006-12-12
161
F-code
Section
PT
S5.0
Electrical Functions
Version no
T-code
002
SMX
C-code
5000
Return
2006-12-12
F-code
PT
Section
C-code
S5.0
5000
Electrical Functions
Version no
T-code
002
SMX
40
33
8
BT Prime-Mover, Inc.
Return
2006-12-12
163
F-code
Section
PT
S5.0
Electrical Functions
Version no
T-code
002
SMX
C-code
5000
26
3
6
57
Power Cables
on Left Side
Figure 5-2: Terminal Block
NOTE!
164
Return
2006-12-12
F-code
Section
PT
C-code
S5.0
5000
Electrical Functions
Version no
T-code
002
SMX
Stem
Mount
Stem Handle
Transmission
Assembly
BT Prime-Mover, Inc.
Return
2006-12-12
165
F-code
Section
PT
S5.0
Electrical Functions
Version no
T-code
002
SMX
C-code
5000
Wire 24
Wire 51 - S25
Wire 50 - S24
Figure 5-5: Stem Mount Switch Wiring
166
Return
2006-12-12
F-code
PT
Section
C-code
S5.0
5000
Electrical Functions
Version no
T-code
002
SMX
BT Prime-Mover, Inc.
Return
2006-12-12
167
F-code
Section
PT
S5.0
Electrical Functions
Version no
T-code
002
SMX
C-code
5000
A - Numerical Field
B - Hour Meter Indicator
C - Parameter Control
D - Battery Indicator
E - Error Indicator
Operator Display
3.3.1. Special Modes
To enter a special truck mode proceed as follows:
1. Hold down horn switch.
2. Enter PIN code on keypad and push green ON
button (l) or turn key switch ON.
3. Release horn switch at desired display mode.
Options for the display mode are follows:
168
Return
2006-12-12
F-code
PT
Section
C-code
S5.0
5000
Electrical Functions
Version no
T-code
002
SMX
Flashing Symbol
Displayed Data
NOTE!
BT Prime-Mover, Inc.
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2006-12-12
169
F-code
Section
C-code
PT
S5.0
Electrical Functions
Version no
T-code
002
SMX
5000
II
III IV
C
1A
6F
G
7
5
E
4
D
170
Return
2
B
3
C
DP
DP
Digit
Segment
I
I
I
I
1
2
3
4
DP
II
II
II
II
II
II
II
II
1
2
3
4
5
6
7
DP
III
III
III
III
III
III
III
III
2
3
4
5
6
7
DP
Function
Input (J5-14): Arm angle B see below
Input (J5-15): Lift limit
Input (J5-12): Arm angle A see below
Input (J5-2): Lower valve (lit if valve present &
not powered)
Input (J5-5): Brake (lit if brake is present & not
released)
2006-12-12
F-code
PT
Section
C-code
S5.0
5000
Electrical Functions
Version no
T-code
002
SMX
16
Comment
Motor drive, plug or active neutral braking
Field reversal (transitional)
Disable (major fault, such as severe overvoltage)
Regen
Regen taper (transitional)
No activity: main contactor open because no output
requested for 30 seconds or an error occurred
Passive restraint
17
24
65
74
129
144
13
BT Prime-Mover, Inc.
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2006-12-12
171
F-code
Section
PT
S5.0
Electrical Functions
Version no
T-code
002
SMX
C-code
5000
NOTE!
NOTE!
172
Return
2006-12-12
F-code
PT
Section
C-code
S5.0
5000
Electrical Functions
Version no
T-code
002
SMX
NOTE!
Truck Parameters
Parameters 1-7 are Driver Parameters (7 parameters for each Drive PIN code entered
Parameter
Name
Unit
Range
Step
Default
Description
10 to 40
20
70 to 98
94
Acceleration
30 to 90
80
Deceleration
40 to 90
65
min
0 to 20
BT Prime-Mover, Inc.
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2006-12-12
173
F-code
Section
C-code
PT
S5.0
Electrical Functions
Version no
T-code
002
SMX
5000
NOTE!
01 6
Service Key
39
174
Return
2006-12-12
F-code
PT
Section
C-code
S5.0
5000
Electrical Functions
Version no
T-code
002
SMX
Parameter
Name
10
Range
Step
Default
Description
Pin code
(keypad only)
0 to 9999
14
Creep speed
-10 to 10
-5
20
Hourmeter
selection
1 to 5
21
Battery size
(The lower the
number, the
deeper the
discharge to
the battery.)
1 to 20
25
Service
interval
0 to 2000
50
39
Access code
1 to 4
BT Prime-Mover, Inc.
Return
Unit
hours
2006-12-12
175
F-code
Section
PT
S5.0
Electrical Functions
Version no
T-code
002
SMX
C-code
5000
Return
2006-12-12
F-code
PT
Section
C-code
S5.0
5000
Electrical Functions
Version no
T-code
002
SMX
BT Prime-Mover, Inc.
Return
2006-12-12
177
F-code
Section
PT
S5.0
Electrical Functions
Version no
T-code
002
SMX
C-code
5000
Parameter 14
Defines speed at low throttle positions. A negative number
enhances low speed maneuverability. A positive number
makes the truck more responsive.
Parameter 20
Choose the hourmeter 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
Data must be provided on the battery installed on the truck.
To adjust the disconnection point of the battery discharge
indicator, measure the following:
WARNING The battery can be destroyed if the
parameter settings are not correct.
NOTE!
concentration
should
be
178
Return
2006-12-12
F-code
PT
Section
C-code
S5.0
5000
Electrical Functions
Version no
T-code
002
SMX
Parameter 39
Determines whether the truck has a key switch or keypad and
what access level service personnel will have to the driver
parameters. This parameter is adjustable as follows:
1 = Key switch connected, driver parameters open
2 = Key switch connected, driver parameters must be
opened with service key
3 = Keypad connected, driver parameters open
4 = Keypad connected, driver parameters must be
opened with a service key.
3.5.2. Operating Parameter Programming
The following operating parameters may be programmed by
the operator:
Parameter 1 - Slow speed range 10 - 40
Parameter 2 - Fast speed range 70 - 98
Parameter 3 - Acceleration range 30 - 90
Parameter 4 - Deceleration range 40 - 90
Parameter 5 - Automatic time off interval (with keypad
only) - from 0 minute to 20 minutes (a setting of 0
disables automatic time off.)
Additional truck parameters may be viewed but cannot be
changed by the operator.
3.5.3. Display Part Numbers (Pn)
1. Enter special truck mode (see page 168.)
2. Press and hold horn button until Pn is displayed.
3. Use the thumb control to scroll and display the
following information:
BT Prime-Mover, Inc.
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2006-12-12
179
F-code
Section
PT
S5.0
Electrical Functions
Version no
T-code
002
SMX
C-code
5000
180
Return
2006-12-12
F-code
PT
Section
C-code
S5.0
5000
Electrical Functions
Version no
T-code
002
SMX
Steering control handle was not in up position at power ON or after the truck has not been used for a time.
Performance Limits
Code is cleared as soon as steering control handle is put in the Top Brake position.
Possible Causes
with corrective
actions/checks
1.
2.
Performance Limits
Truck functions are not allowed until after this code has been cleared.
Possible Causes
with corrective
actions/checks
1.
Thumb control was not in neutral position at power ON, or a throttle position sensor failure was detected. Also
see code 160 on page 187.
Performance Limits
Possible Causes
with corrective
actions/checks
1.
2.
3.
BT Prime-Mover, Inc.
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2006-12-12
181
F-code
Section
C-code
PT
S5.0
Electrical Functions
Version no
T-code
002
SMX
5000
Transistor controller could not be reset via the CAN-bus at power ON or transistor controller reports main ON/
OFF switch is open.
Performance Limits
Truck functions are not allowed after code has been set.
This code can only be cleared after the problem is resolved and truck is turned OFF and back ON.
Possible Causes
with corrective
actions/checks
1.
2.
4.
5.
6.
PTC R1 missing, bad, or tripped (very high resistance, due to excessive current while main contactor is
open; should automatically recover.)
a. Carefully check to see if R1 is hot (tripped); if so unplug battery and allow it to cool. Locate low
impedance path that tripped R1 and correct.
Wire #24 at OV.
a. Check that J5 is connected, fuse and wiring.
b. Check for 24V at J5-16.
Short or open circuit in CAN wiring or electrical noise in CAN wiring due to bad connection or outside
interference, both at power ON.
a. Check CAN wiring.
b. Try operating truck in different environment.
Bad transistor controller.
Performance Limits
None.
Possible Causes
with corrective
actions/checks
1.
2.
Voltage at transistor controller B+ connection less than 17V (when main contactor is closed.) Low voltage can
also cause problems such as electrical components not powering up / staying activated and CAN errors.
Performance Limits
Truck functions are allowed unless the voltage was below 13V, in which case the truck must be restarted (Code
C28) may be displayed.)
Possible Causes
with corrective
actions/checks
1.
2.
3.
4.
5.
182
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2006-12-12
F-code
PT
Section
C-code
S5.0
5000
Electrical Functions
Version no
T-code
002
SMX
Performance Limits
Truck functions are allowed unless the voltage was above 34V, in which case the truck must be restarted (error
142, see page 186, may be displayed.)
Possible Causes
with corrective
actions/checks
1.
2.
3.
High or low temperature (such as above 185 degrees F [85 degrees C] or below -13 degrees [25 degrees C] at
transistor controller heat sink.
Performance Limits
Code is cleared when transistor controller heat sink temperature recovers (see item 7 on page 191.)
Possible Causes
with corrective
actions/checks
1.
2.
3.
4.
Performance Limits
Truck functions are allowed, but maximum speed value sent to transistor controller is reduced.
Possible Causes
with corrective
actions/checks
1.
2.
3.
4.
5.
Performance Limits
Corrective Action
Possible Causes
with corrective
actions/checks
BT Prime-Mover, Inc.
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2006-12-12
183
F-code
Section
C-code
PT
S5.0
Electrical Functions
Version no
T-code
002
SMX
5000
NOTE!
Code E101 - Transistor Controller Does Not Correspond with the Type of Truck
Reason
Possible Causes
with corrective
actions/checks
1.
Possible Causes
with corrective
actions/checks
1.
2.
3.
4.
5.
Transistor controller attempted to deliver more current than allowed to main contactor coil; traction motor field
winding, or digital output.
Possible Causes
with corrective
actions/checks
1.
Contactor probably present but transistor controller could not close it successfully.
Possible Causes
with corrective
actions/checks
1.
2.
3.
184
Return
2006-12-12
F-code
PT
Section
C-code
S5.0
5000
Electrical Functions
Version no
T-code
002
SMX
Possible Causes
with corrective
actions/checks
1.
2.
3.
4.
5.
Possible Causes
with corrective
actions/checks
1.
2.
Possible Causes
with corrective
actions/checks
1.
2.
3.
Possible Causes
with corrective
actions/checks
1.
2.
3.
Electronic Tiller Arm Card (ETAC) software detected that checksum was invalid.
Possible Causes
with corrective
actions/checks
1.
2.
Bad software.
a. If applicable, try downloading new software.
Bad ETAC.
Possible Causes
with corrective
actions/checks
1.
BT Prime-Mover, Inc.
Return
2.
Bad software.
a. If applicable, try downloading new software.
Bad ETAC.
2006-12-12
185
F-code
Section
C-code
PT
S5.0
Electrical Functions
Version no
T-code
002
SMX
5000
Possible Causes
with corrective
actions/checks
1.
2.
3.
4.
Possible Causes
with corrective
actions/checks
1.
2.
3.
4.
Possible Causes
with corrective
actions/checks
1.
2.
3.
Possible Causes
with corrective
actions/checks
1.
2.
3.
4.
Possible Causes
with corrective
actions/checks
1.
2.
3.
4.
186
Return
2006-12-12
F-code
PT
Section
C-code
S5.0
5000
Electrical Functions
Version no
T-code
002
SMX
ETAC detected problem with the throttle position sensors, including the sensor used to initiate reversing. Also
see code 20 on page 181.
Possible Causes
with corrective
actions/checks
1.
Bad ETAC.
Possible Causes
with corrective
actions/checks
1.
2.
3.
4.
5.
Possible Causes
with corrective
actions/checks
1.
Possible Causes
with corrective
actions/checks
1.
2.
Possible Causes
with corrective
actions/checks
1.
2.
3.
Transistor controller did not receive CAN data from ETAC or transistor controller self-test failed.
Possible Causes
with corrective
actions/checks
1.
2.
3.
4.
NOTE!
BT Prime-Mover, Inc.
Return
2006-12-12
187
F-code
Section
PT
S5.0
Electrical Functions
Version no
T-code
002
SMX
C-code
5000
188
Return
2006-12-12
F-code
PT
Section
C-code
S5.0
5000
Electrical Functions
Version no
T-code
002
SMX
Remedy
With main ON/OFF switch OFF and battery disconnected, check wiring between transistor
controller and main contactor (K10.)
With main ON/OFF switch OFF and battery connector disconnected, measure resistance between
J5-16 and J5-4. If resistance is approximately 50 ohms, check wires for shorts to frame, B+, B-, or
other conductors. If none found replace transistor controller.
Disconnect and measure resistance of main contactor (K10) coil. If resistance is not approximately
50 ohms, replace coil.
Remedy
With main ON/OFF switch OFF and battery disconnected, disconnect wires F1 and F2 from the
transistor controller. Check wiring between motor and transistor controller.
With main ON/OFF switch OFF and battery connector disconnected, disconnect drive motor cable
at transistor controller terminal M-. Connect battery connector, turn key switch ON. If Code 1,3
(see page 246) is still displayed, replace transistor controller. If Code 1,3 is not displayed,
disconnect battery, remove wires F1 and F2 at transistor controller and measure resistance in
wiring harness between wires F1 and F2. If less than 1.0 ohm, replace transistor controller.
Bad motor
With main ON/OFF switch OFF and battery disconnected, remove wires F1 and F2 at motor. If
greater than 2.0 ohm, replace motor.
BT Prime-Mover, Inc.
Return
Remedy
Replace transistor controller.
2006-12-12
189
F-code
Section
C-code
PT
S5.0
Electrical Functions
Version no
T-code
002
SMX
5000
Remedy
Battery problems
Transistor
controller
programming changed
Binding
motor
drive
wheel
or
ETAC
assembly/drive
Remedy
Battery problem
Remedy
Battery problems
Bad
battery
terminals
disconnect plug
quick
Verify battery voltage at key switch input. Turn main ON/OFF switch OFF and disconnect battery
connector. Check for continuity and wiring shorts between B- battery to transistor controller B- and
key switch circuit wiring and fuses. Repair or replace. Measure voltage at transistor controller B+. If
24V, replace transistor controller.
Jack and block truck. With main ON/OFF switch OFF and battery connected, while attempting
travel, measure voltage between A2, transistor controller B+, B-, and F1, F2, M1, and M3. If not
24V, repair or replace wiring.
190
Return
2006-12-12
F-code
PT
Section
C-code
S5.0
5000
Electrical Functions
Version no
T-code
002
SMX
Remedy
Battery problems
Make sure load wheels rotate freely, If not repair or replace (see page 122.)
Jack and block truck (see page 58.) Turn main ON/OFF switch ON. Pull steering control handle
down to release brake. Check drive wheel to see if it spins freely. If not, repair or replace (see
page 117.)
Jack and block truck (see page 58.) Turn main ON/OFF switch ON. Pull steering control handle
down to release brake. Check brake disk to see if it spins freely. If not, adjust, repair or replace
(see page 111 or page 112.)
Jack and block truck (see page 58.) Turn main ON/OFF switch ON. Pull steering control handle
down to release brake. Check the brake disk to see if it spins freely. Turn main ON/OFF switch
OFF. Remove brake disk and check armature shaft. Remove motor and repair or replace drive unit
or drive motor (see page 97.)
Worn brushes
Bad drive motor (may test ok with no
load, but fail under load)
Truck overloaded
extreme conditions
or
operating
in
Check mounting of transistor controller. Check to make sure transistor controller is secure and in
contact with truck frame (acts as a heatsink.) If transistor controller is mounted correctly, replace
transistor controller.
Jack and block truck (see page 58.) With main ON/OFF switch ON and battery connected, while
attempting travel, measure voltage between B- and transistor controller B+, B- and J5-16. If not
24V, repair or replace wiring.
Remedy
Battery problems
Transistor
controller
programming not correct
ETAC
Verify programming.
With main ON/OFF switch OFF and battery connector disconnect, check drive motor brushes (see
page 90) and motor (see page 97.)
Wiring System
1. Truck functions partially, some functions do work when
commanded.
Possible Cause
Remedy
With main ON/OFF switch OFF and battery connector disconnect, visually inspect wiring in the
handle where the wiring leaves the handle and over the brake. Repair or replace.
With main ON/OFF switch OFF and battery connector disconnect, visually inspect wiring. Repair or
replace.
BT Prime-Mover, Inc.
Return
2006-12-12
191
F-code
Section
PT
S5.0
Electrical Functions
Version no
T-code
002
SMX
C-code
5000
Remedy
Check control wires, especially wires 1, 20, and 22 (red in steering control arm cable) and 40
(black in steering control arm cable.)
Bad connectors
Repair and replace bad connectors (check connector J11 at steering control arm base, connector
into ETAC and connector J5 to transistor controller.)
F50 Open
Remedy
Check for proper operation of arm angle switch A and correct if necessary. Check wiring,
transistor controller and switch adjustment.
3. No travel.
Possible Cause
Arm angle switch failure
Remedy
Check arm angle switch adjustment (see page 220), wiring and transistor controller.
Remedy
Bad horn
Replace horn.
5. No lift.
Possible Cause
Remedy
Adjust lift limit switch (see page 221) or replace lift limit switch (see page 225.)
Failed ETAC.
192
Return
2006-12-12
F-code
Section
PT
C-code
S5.0
5000
Electrical Functions
Version no
T-code
002
SMX
Main
Harness
3
2
1
4
7
5
8
Contactor
Panel
Assembly
9
I
Contactor
Power
Cable
Circuit
Breaker
Lift Limit
Switch
Steering Control
Handle Harness
Hydraulic
System
Relay
10 Amp
Fuse
Transmission
Assembly
Power
Cables
Power
Cables
BT Prime-Mover, Inc.
Return
2006-12-12
193
F-code
Section
PT
S5.0
Electrical Functions
Version no
T-code
002
SMX
C-code
5000
194
Return
Ledger
2006-12-12
Return
BT Prime-Mover, Inc.
2006-12-12
HORN SWITCH
S18-2
HORN SWITCH
S18-1
DISPLAY
A6
Ledger
E.T.A.C.
A2
TRUCKS
WITH
KEYPAD
KEYPAD
A17
F-code
PT
Section
S5.0
5000
Electrical Functions
Version no
T-code
002
SMX
C-code
195
F-code
Section
PT
S5.0
Electrical Functions
Version no
T-code
002
SMX
C-code
5000
Electrical Legend
Symbol
A1
A2
A2-S1 to A2-S9
A2-S10 to A2-S18
A2-S17
A2-S19
A2-S20
A6
A17
B+
BCB1
F50
F51
H1
J11
J41
K4
K10
K30
M1
M3
S17
S18-1
S18-2
S21
S24
S25
S36
Y1
Y10
196
Return
Description
Transistor controller
Transistor controller
Speed Ref Value
Speed Ref Value
Reverser
Lift
Lower
Transistor controller
Transistor controller
Battery
Battery
Circuit breaker
Fuse
Fuse
Horn
Wire Connection
Wire Connection
Contactor Relay
Contactor
Solenoid
Motor
Motor
Switch
Switch
Switch
Switch
Switch
Switch
Switch
Coil
Coil
Function
Drive motor
Electronic Tiller Arm Card
Electronic Tiller Arm Card
Electronic Tiller Arm Card
Electronic Tiller Arm Card
Electronic Tiller Arm Card
Electronic Tiller Arm Card
Operator Display
Keypad
Positive
Negative
Drive / Pump motor circuit
Keypad and tiller arm circuit
Main control
Remark
E.T.A.C.
24 volt
24 volt
110 amp
10 amp
10 amp
2006-12-12
F-code
PT
Section
C-code
S5.0
5000
Electrical Functions
Version no
T-code
002
SMX
Electrical Graphics
Graphic
BT Prime-Mover, Inc.
Return
Graphic
Description
Battery
Brake (coil)
Contactor
Diode
Main On/Off
Switch
Fuse
A1
Description
A2
Horn
Inductive sensor
(normally closed)
Inductive sensor
(normally open)
Key switch
Magnet switch
(normally closed)
Magnet switch
(normally open)
Motor
Potentiometer
2006-12-12
197
F-code
Section
PT
S5.0
Electrical Functions
Version no
T-code
002
SMX
C-code
5000
Electrical Graphics
Graphic
Description
Graphic
Description
Push button switch
(normally open)
Resistor
Switch
Switch
(normally closed)
Switch
(normally open)
Valve
198
Return
2006-12-12
F-code
Section
PT
S5.1
Version no
T-code
001
SMX
C-code
5110
Battery
Battery
1. Theory of Operation
Check the trucks data plate for the weight of the battery
required for the truck. Contact your local battery supplier for
the purchase of a proper voltage battery. A 24 volt battery
may not be supplied with the truck.
2. Maintenance
Information in this section does not supercede or replace
information available by the battery and battery charger
supplier. Read, understand, and follow the procedures
available by the battery and battery charger supplier. Notify
your supervisor if there are any concerns or questions
regarding the battery or procedures.
BT Prime-Mover, Inc.
Return
2006-08-08
199
F-code
Section
C-code
PT
Battery
S5.1
5110
Version no
T-code
001
SMX
2.3. Charging
OSHA regulations require that battery charging installations
be located in areas designated for that specific purpose. Such
areas must provide for flushing and neutralizing spilled
electrolyte, fire protection, protecting charging equipment
from damage by trucks and adequate ventilation of fumes
from gassing batteries.
To charge a battery, direct current is passed through the
battery cells in the direction opposite that of discharge.
Charging time is 5 to 20 percent longer than discharge time.
200
Return
2006-08-08
F-code
Section
PT
S5.1
Version no
T-code
001
SMX
C-code
5110
Battery
2.4. Storage
Before storing the battery, make sure the electrolyte is at the
proper level in all the cells, the filler plugs are tight, and the
battery is fully charged. Store battery in a clean, cool, dry
location away from radiators and other sources of heat.
Check electrolyte level and specific gravity every 30 days
during storage. Whenever specific gravity is less than 1.230,
charge the battery.
BT Prime-Mover, Inc.
Return
2006-08-08
201
F-code
Section
C-code
PT
Battery
S5.1
5110
Version no
T-code
001
SMX
3. Troubleshooting
Many electrical problems are caused by a bad or dirty battery.
Make sure the battery is clean. Check the electrolyte level
and battery level. Look for simple causes of problems. A
trained, qualified, and authorized technician should perform
testing and troubleshooting on batteries.
202
Return
2006-08-08
F-code
Section
PT
S5.1
Version no
T-code
001
SMX
C-code
5110
Battery
BT Prime-Mover, Inc.
Return
2006-08-08
203
F-code
Section
C-code
PT
Battery
S5.1
5110
Version no
T-code
001
SMX
204
Return
2006-08-08
F-code
PT
Section
C-code
S5.2
5110
Swing Out Battery Pack
Version no
T-code
002
SMX
2. Maintenance
WARNING Battery electrolyte is a solution of sulfuric
acid and water. Battery acid causes burns.
Should any electrolyte come in contact with
clothing or skin, flush the area immediately
with cold water. Should the solution get on
your face or in the eyes, flush the area with
cold water and receive medical attention
immediately.
CAUTION Before working on the battery, review
Battery Safety beginning on page 20.
Batteries may weigh more than 200 pounds
(91 kg). Use extreme care during
replacement. Use a suitable replacement
device or hoist for lifting.
Return
2006-08-08
205
F-code
Section
C-code
PT
S5.2
5110
Swing Out Battery Pack
Version no
T-code
002
SMX
Start
24 volt system
15 amps
Start
Finish
24 volt system
25.6 volts
30.0 volts
2. Visually inspect
disconnected.
charger
with
all
power
coils
for
obvious
206
Return
2006-08-08
F-code
PT
NOTE!
Section
C-code
S5.2
5110
Swing Out Battery Pack
Version no
T-code
002
SMX
BT Prime-Mover, Inc.
Return
2006-08-08
207
F-code
Section
C-code
PT
S5.2
5110
Swing Out Battery Pack
Version no
T-code
002
SMX
208
Return
2006-08-08
F-code
PT
Section
C-code
S5.2
5110
Swing Out Battery Pack
Version no
T-code
002
SMX
Return
2006-08-08
209
F-code
Section
C-code
PT
S5.2
5110
Swing Out Battery Pack
Version no
T-code
002
SMX
causing
3. Troubleshooting
The charger incorporates a very simple and reliable design
which makes troubleshooting relatively easy. The repair
procedure involves testing the output of the charger and then
testing individual components. The test procedures follow a
logical sequence of electrical flow through the circuit. Only
standard hand tools and an AC/DC volt/ohm meter are
required. A battery hydrometer is recommended.
WARNING Before checking charger, disconnect AC
power supply, unplug batteries, and
discharge capacitor with an insulated
screwdriver. All tests should be made with
extreme caution when a test calls for power
to be on at the charger.
210
Return
2006-08-08
F-code
PT
Section
C-code
S5.2
5110
Swing Out Battery Pack
Version no
T-code
002
SMX
19
4
3
7
8
18
15
12
11
16
20
17
10
13
14
Battery Specifications
Exide type GC-3 6 volt
75-91 AMPS
Trojan type T-90 or T-1900
6 volts 75-91 AMPS
BT Prime-Mover, Inc.
Return
2006-08-08
211
F-code
Section
C-code
PT
S5.2
5110
Swing Out Battery Pack
Version no
T-code
002
SMX
Item No.
1
2
3
4
5
6
7
8
9
10
212
Return
Description
Battery pack complete
Decal
Charger, battery
Decal, warning
Screw
Cable assembly
Cover
Screw
Decal, warning
Tray, left
Item No.
11
12
13
14
15
16
17
18
19
20
Description
Screw
Grommet
Screw
Support, battery
Nut, clip
Screw
Nut, clip
Tray, right
Decal
Tray, cord
2006-08-08
F-code
Section
PT
C-code
S5.2
5110
Swing Out Battery Pack
Version no
T-code
002
SMX
3
11
11
1
6
2
11 10
11
1
11
11
1
2
11
1
2
11
Battery Specifications
Exide type GC-3 6 volt
75-91 AMPS
Item
No.
1
2
3
4
5
6
7
8
9
10
11
Description
Boot
Nut
Tie, cable
Cable
Cable
Battery connector
Cable
Cable
Battery
Cable
Washer, flat
BT Prime-Mover, Inc.
Return
2006-08-08
213
F-code
Section
C-code
PT
S5.2
5110
Swing Out Battery Pack
Version no
T-code
002
SMX
15
14
11
4
16
13
10
12
7
3
2
214
Return
Item No.
Description
Item No.
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Washer, flat
Decal, serial number
Bracket
Tray
Cable, SB175 plug
Battery connector
Cable, AC power
Screw, securing
2006-08-08
F-code
PT
Section
C-code
S5.3
5190
Battery Connector
Version no
T-code
000
SMX
Battery Connector
1. Theory of Operation
Battery Connector
2. Maintenance
Visually inspect cables and connectors. Negative and positive
cables should be visually inspected for breaks and wear.
Check connectors for damage and to ensure proper
connections of cables.
2.1. Inspection
1. Press red OFF button O on the keypad. Depress
main ON/OFF switch to the OFF position.
2. Disconnect the battery connector from the truck.
3. Check the battery connectors for damaged cables.
4. Check to see if cables are pulling out of the
connectors.
5. Check cables at battery terminals. Connections
should be tight, with no corrosion.
6. Check inside connectors at internal contacts for
damage, dirt, or corrosion. DO NOT use a metal
object to clean connectors.
7. Connector housings must not be cracked or
broken.
3. Troubleshooting
Make sure cable wires are in good condition and connector
has proper connections to cables.
BT Prime-Mover, Inc.
Return
2004-03-08
215
F-code
Section
PT
S5.3
Battery Connector
Version no
T-code
000
SMX
C-code
5190
Item
No.
9
5
1
2
3
4
5
6
7
8
9
Description
Puller
Cable, negative
Cable, positive
Nut
Connector, SB-175
Cable, positive
Cable, negative
Screw, cap
Screw, cap
8
5
7
6
216
Return
2004-03-08
F-code
PT
Section
C-code
S5.3
5190
Battery Connector
Version no
T-code
000
SMX
BT Prime-Mover, Inc.
Return
2004-03-08
217
F-code
Section
PT
S5.3
Battery Connector
Version no
T-code
000
SMX
C-code
5190
218
Return
2004-03-08
F-code
Section
PT
S5.4
Version no
T-code
001
SMX
C-code
5310
Switches
Switches
1. Theory of Operation
The main ON/OFF switch (S21) is provided on the truck. In
the OFF position, battery power to all control functions is
interrupted. In the ON position, battery potential is provided to
all control functions via the transistor controller.
The arm angle switches are located at the base of the
steering control handle stem. The arm angles switches (S24)
and (S25) determine brake activation and truck travel speed.
Each switch is activated by the steering control handle
position. The steering control handle must be positioned
beyond 6 degrees of the upper rest position and above 8
degrees from the bottom in order for switches to close,
permitting travel. When steering control handle is within 6
degrees of the upper rest position, parking brake is activated.
When steering control handle is between 6 to 41 degrees of
the upper rest position, arm angle B switch (S25) closes and
enables slow speed operation. When steering control handle
is placed beyond 41 degrees from the upper rest position,
arm angle A switch (S24) also closes enabling fast speed
operation. When the steering control handle is placed in the
bottom 8 degrees of the operating range, arm angle switch B
(S25) opens, activating the parking brake.
Position
A Switch
(S24)
B Switch
(S25)
Function
Top 6
Open
Open
Top Brake
6 to 41
Open
Closed
Slow
41 plus
Closed
Closed
Fast
Bottom 8
Closed
Open
Bottom Brake
When forks are fully raised, lift-limit switch (S36) turns the
hydraulic pump motor off. This keeps the pump from trying to
extend the lift cylinder beyond its maximum travel. A twoposition (ON/OFF) optional key switch (S17) is located on the
main console, which energizes all truck control functions
when in the ON position, provided the main ON/OFF switch is
in the ON position.
BT Prime-Mover, Inc.
Return
2006-08-08
219
F-code
Section
C-code
PT
Switches
S5.4
5310
Version no
T-code
001
SMX
2. Maintenance
General
Examine switch for signs of arcing, overheating,
discoloration, cracking, or other physical damage. Replace
switch if such damage is noticed.
Use an ohmmeter set to a low resistance scale to measure
resistance across the switch. In a closed position, the switch
should be less than 1 ohm. In an open position, the switch
should show a resistance greater than 10 megohms.
With the battery connected, use a voltmeter to check for
voltage on both the positive and negative side of the switch
while in the closed position. The voltage must be the same on
both sides of the switch. If not, the switch is worn or bad.
220
Return
2006-08-08
NOTE!
F-code
Section
PT
S5.4
Version no
T-code
001
SMX
C-code
5310
Switches
Lift Limit
Switches
BT Prime-Mover, Inc.
Return
2006-08-08
221
F-code
Section
C-code
PT
Switches
S5.4
5310
Version no
T-code
001
SMX
3. Troubleshooting
To troubleshoot the main ON/OFF switch see page 148, arm
angle switches see page 150 and/or page 152 and for the lift
limit switch see page 259.
222
Return
2006-08-08
F-code
Section
PT
S5.4
Version no
T-code
001
SMX
C-code
5310
Switches
3
4
15
14
9
5 10
10
7
7
11
12
13
Item No.
Description
Item No.
Nut
11
Screw
12
Screw
Bracket
13
Nut
Bracket
Screw
14
Switch, horn
Screw
10
Lockwasher
15
Button, horn
BT Prime-Mover, Inc.
Return
Description
2006-08-08
Item No.
Description
223
F-code
Section
C-code
PT
Switches
S5.4
5310
Version no
T-code
001
SMX
Installation
1. Install new main ON/OFF switch and connect the
wires to the switch terminal.
2. Connect the battery connector to the truck.
3. Turn the main ON/OFF switch to the ON position.
Enter key code and press the green ON button I
on the keypad.
4. Test truck for proper operation before returning to
service.
5. Install truck cover(s).
224
Return
2006-08-08
F-code
Section
PT
S5.4
Version no
T-code
001
SMX
C-code
5310
Switches
Installation
1. Mount the switch to the mounting bracket.
2. Connect the wires to the switch.
3. Connect the battery connector to the truck.
4. Turn main ON/OFF switch to the ON position.
Enter key code and press the green ON button I
on the keypad. Test drive the truck.
5. Adjust switch if necessary (see page 220.)
6. Press red OFF button O on the keypad. Depress
main ON/OFF switch to the OFF position.
7. Install truck cover(s).
Installation
1. Connect the wires to the terminal.
2. Install new lift limit switch.
3. Connect the battery connector to the truck.
4. Turn main ON/OFF switch to the ON position.
Enter key code and press the green ON button I
on the keypad.
5. Test truck for proper operation before returning to
service.
6. Install truck cover(s).
BT Prime-Mover, Inc.
Return
2006-08-08
225
F-code
Section
C-code
PT
Switches
S5.4
5310
Version no
T-code
001
SMX
Installation
1. Install new key switch.
2. Connect the wires to the terminal.
3. Connect the battery connector to the truck.
4. Turn main ON/OFF switch to the ON position. Turn
key switch ON.
5. Test truck for proper operation before returning to
service.
6. Install truck cover(s).
Installation
1. Connect the wires to the terminal.
2. Install new horn switch.
3. Connect the battery connector to the truck.
226
Return
2006-08-08
F-code
Section
PT
S5.4
Version no
T-code
001
SMX
C-code
5310
Switches
Installation
1. Install new main ON/OFF switch and key switch
mounting bracket.
Keypad
Cover
Keypad
BT Prime-Mover, Inc.
Return
2006-08-08
227
F-code
Section
C-code
PT
Switches
S5.4
5310
Version no
T-code
001
SMX
228
Return
2006-08-08
F-code
Section
PT
C-code
S5.5
5390
Fuses/Circuit Breakers
Version no
T-code
001
SMX
Fuses/Circuit Breakers
Fuse F50
Fuse F51
1. Theory of Operation
The keypad and electronic tiller arm card (ETAC) circuit FU50
fuse is 10 Amps. The main ON/OFF switch circuit fuse FU51
is 10 Amps. The fuses are located on the contactor panel.
10A, Fuse Keypad and ETAC, part number 2527512 (supplied with main harness)
2. Maintenance
Examine the fuse for signs of overheating, discoloration,
cracking, or other physical damage. Check for blown fuse
through the fuse window. If fuse is damaged replace it. To
test a fuse, remove or isolate it from the electrical circuit. Do
this by removing the fuse from the truck or by removing all the
connections from one side of the fuse. Use an ohmmeter set
to Rx1 scale and measure the resistance across the fuse.
The resistance should be less than 1 ohm.
BT Prime-Mover
Return
2006-08-08
229
F-code
Section
C-code
PT
S5.5
5390
Fuses/Circuit Breakers
Version no
T-code
001
SMX
230
Return
2006-08-08
F-code
PT
Section
C-code
S5.5
5390
Fuses/Circuit Breakers
Version no
T-code
001
SMX
BT Prime-Mover
Return
Evidence of overheating
Nicks in insulation
2006-08-08
231
F-code
Section
C-code
PT
S5.5
5390
Fuses/Circuit Breakers
Version no
T-code
001
SMX
232
Return
2006-08-08
F-code
PT
Section
C-code
S5.5
5390
Fuses/Circuit Breakers
Version no
T-code
001
SMX
Wire #24
Wire #26
BT Prime-Mover
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2006-08-08
233
F-code
Section
C-code
PT
S5.5
5390
Fuses/Circuit Breakers
Version no
T-code
001
SMX
3. Troubleshooting
During troubleshooting and repairs, it is sometimes
necessary to unmate a connector, move a harness, cut a
cable tie, or remove wire from a bracket. Note carefully the
location of wire and all protective or securing attachments
before moving harness. When replacing fuses, make sure
fuses are installed in the proper position.
234
Return
2006-08-08
F-code
Section
PT
S5.6
5436
Contactor Panel
Version no
T-code
000
SMX
C-code
Contactor Panel
1. Theory of Operation
The main contactor (K10) controls the transmission of battery
power to the drive motor.
2. Maintenance
Visually inspect the contactors for any signs of burning or
physical damage.
3. Troubleshooting
3.1. Resistance Testing
1. Press red OFF button O on the keypad. Depress
main ON/OFF switch to the OFF position.
2. Remove truck cover(s) [see page 84.]
3. Disconnect the wires from the coil contactor.
4. Connect one coil lead of ohmmeter to the coil lead
from contactor. Connect the other lead to the lead
from the contactor.
5. The reading should be between 20 and 40 ohms. If
resistance is outside that range, replace contactor.
BT Prime-Mover, Inc.
Return
2004-03-10
235
F-code
Section
C-code
PT
S5.6
Contactor Panel
5436
Version no
T-code
000
SMX
4
1
3
2
17
16
18
15
14
10
9
11
12
13
236
Return
2004-03-10
Item No.
Description
F-code
Section
PT
S5.6
5436
Contactor Panel
Version no
T-code
000
SMX
Item No.
C-code
Description
Drive controller
10
Screw
Screw
11
Contactor
12
Horn
Panel
13
Screw
Battery connector
14
Relay
Nut
15
Screw
Decal, breaker
16
Breaker, circuit
Decal, fuse
17
Bar, bus
Lockwasher
18
Screw
Removal
1. Press red OFF button O on the keypad. Depress
main ON/OFF switch to the OFF position.
Disconnect the battery connector from the truck.
2. Remove truck cover(s) [see page 84.]
X and Y
Terminals
Bus Bar
BT Prime-Mover, Inc.
Return
2004-03-10
237
F-code
Section
C-code
PT
S5.6
Contactor Panel
5436
Version no
T-code
000
SMX
Installation
1. Secure contactor (3) to the electrical panel (4) with
screws (2).
2. Secure bus bar (17) and cable to the contactor (3)
with screws (15).
3. Connect the wires to the X and Y terminals.
4. Connect the battery connector to the truck.
5. Turn main ON/OFF switch to the ON position.
Enter key code and press the green ON button I
on the keypad.
6. Test truck for proper operation before returning to
service.
7. Install truck cover(s).
238
Return
2004-03-10
F-code
PT
Section
C-code
S5.7
5460
Transistor Controller
Version no
T-code
001
SMX
Transistor Controller
1. Theory of Operation
WARNING Interchanging the transistor controller
with another truck model could cause
internal failure to the transistor
controller. The warranty will be void if
the transistor controller is interchanged
from one truck to another!
The transistor controller is programmed specifically for this
truck. It is microprocessor based and programmable
designed for separately excited motors. The transistor
controller provides smooth control of the traction (drive) motor
utilizing four distinct operating modes. An LED is built into the
transistor controller that communicates controller status.
Return
2006-12-12
239
F-code
Section
PT
S5.7
Transistor Controller
Version no
T-code
001
SMX
C-code
5460
1.2. Interface
The direction control section controls the drive motor direction
by manipulating the drive motor field polarity according to the
directional signal inputs from the Electronic Tiller Arm Card
(ETAC).
The thumb control section controls the drive motor speed and
torque by monitoring the position change of the arm angle A
and arm angle B switches. Variable motor speed is
accomplished by separate control of field and armature
currents.
The reverser circuitry in the ETAC provides the directional
travel control commands to the transistor controller.
The control circuit section controls all truck inputs and outputs
(excluding steering control handle head inputs.)
The ETAC controls. The transistor controller is the slave.
240
Return
2006-12-12
F-code
Section
PT
C-code
S5.7
5460
Transistor Controller
Version no
T-code
001
SMX
Control
wire plug
16-pins
M-
B-
B+
F1
F2
BT Prime-Mover, Inc.
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2006-12-12
241
F-code
Section
PT
S5.7
Transistor Controller
Version no
T-code
001
SMX
C-code
5460
MF1
F2
Connecting
Negative connection to battery
Overcurrent protected and K10 switched
positive connection to the battery and motor
armature
Motor armature
Motor field
Motor field
242
Return
2006-12-12
F-code
PT
Section
C-code
S5.7
5460
Transistor Controller
Version no
T-code
001
SMX
Connecting
CAN High
IN/OUT Lower Valve
Not Used
Out Main Contactor
IN/OUT Brake
OUT Pump Contactor
OUT Horn
CAN Low
Not Used
Not Used
Not Used
IN Arm Angle A
Not Used
IN Arm Angle B
IN Lift Limit
IN +24 VDC
1.6. Definitions
Overtemperature. Overtemperature of the transistor
controller is from 185 degrees F (85 degrees C) and above.
Overheating is unusual, but can occur if the transistor
controller is installed incorrectly or overloaded. At
overtemperature the drive current limit is linearly decreased
from full set current down to zero. Plug current is not reduced
by any thermal conditions to allow full plugging strength at all
times.
Undertemperature. When the transistor controller is
operating at less than 13 degrees F (25 degrees C), the
current limit is cut back resulting in reduced travel speed and
acceleration.
Pulse Width Modulation. Pulse Width Modulation (PWM),
also called chopping, controls the speed of the motor by
switching the battery voltage to the motor on and off very
quickly.
BT Prime-Mover, Inc.
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2006-12-12
243
F-code
Section
PT
S5.7
Transistor Controller
Version no
T-code
001
SMX
C-code
5460
2. Maintenance
There are no serviceable parts inside the transistor controller.
No attempt should be made to open the transistor controller.
OPENING THE TRANSISTOR CONTROLLER WILL VOID
THE WARRANTY!
2.1. Safety
WARNING Because there is a risk of short circuits,
remove all watches and jewelry; always use
insulated tools.
The transistor controller is essentially a high-power device.
When working around any battery powered vehicle, proper
safety precautions should be taken. These include, but are
not limited to the following: proper training, wearing eye
protection, avoiding loose clothing, removing watches and
jewelry, and using insulated tools.
2.2. Cleaning
It is recommended that the transistor controller exterior be
cleaned periodically with an approved and regulated air
supply (blower.) Although the transistor controller virtually
requires no maintenance if properly installed, the following is
recommended on a regular basis of 250 hours for cold
storage and 1500 hours for standard environment.
1. Remove power by disconnecting the battery at the
battery connector.
2. Discharge capacitors in the transistor controller by
connecting a load (such as a contactor coil or horn)
across the transistor controllers B+ and B-
244
Return
2006-12-12
F-code
PT
Section
C-code
S5.7
5460
Transistor Controller
Version no
T-code
001
SMX
3. Troubleshooting
3.1. Diagnostics and Troubleshooting
The transistor controller provides diagnostic information to
assist technicians in troubleshooting drive system problems.
The information can also be obtained by looking at the status
LED built in the transistor controller that is visible through the
window label.
Transistor
Controller
J5 Connector
Return
2006-12-12
245
F-code
Section
PT
S5.7
Transistor Controller
Version no
T-code
001
SMX
C-code
5460
Program
LCD Display
OFF
N/A
ON
N/A
0,1
No known faults
1, 1
Current shunt
1, 2
Hardware
failsafe
1, 3
M- shorted
1, 4
2, 1
SRO
Throttle Fault 1
EMR REV
Wiring
HPD
Throttle Fault 2
2, 2
2, 3
2, 4
3, 1
246
Return
CONT COIL/
FLD Short
Probable Cause
Explanation
2006-12-12
F-code
PT
Error
Code
Program
LCD Display
3, 2
Main CONT
Welded
3, 3
3, 4
4, 1
4, 2
4, 3
4,4
Section
Version no
T-code
001
SMX
Probable Cause
C-code
S5.7
5460
Transistor Controller
Explanation
BT Prime-Mover, Inc.
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2006-12-12
247
F-code
Section
PT
S5.7
Transistor Controller
Version no
T-code
001
SMX
C-code
5460
248
Return
2006-12-12
F-code
Section
C-code
PT
S5.8
5700
Electronic Tiller Arm Card (ETAC)
Version no
T-code
000
SMX
BT Prime-Mover, Inc.
Return
2004-03-10
249
F-code
Section
C-code
PT
S5.8
5700
Electronic Tiller Arm Card (ETAC)
Version no
T-code
000
SMX
2. Maintenance
See Planned Maintenance Schedule on page 61.
3. Troubleshooting
See Error Codes (E) on page 180.
250
Return
2004-03-10
F-code
Section
C-code
PT
S5.8
5700
Electronic Tiller Arm Card (ETAC)
Version no
T-code
000
SMX
Reverser
Button
Push
Button
Electronic
Horn
Button Tiller Arm
Right Card (ETAC)
Lift/Lower
Button
Display
Horn
Button
Left
Housing
Horn Button/
Switch
Speed
Control
Steering
Control Handle
BT Prime-Mover, Inc.
Return
Keypad
2004-03-10
251
F-code
Section
C-code
PT
S5.8
5700
Electronic Tiller Arm Card (ETAC)
Version no
T-code
000
SMX
Removal
1. Press red OFF button O on the keypad. Depress
main ON/OFF switch to the OFF position.
2. Disconnect the battery connector from the truck.
3. Remove screw from keypad. Unplug and remove
keypad.
4. While holding the top cover firmly, remove screws
securing the top cover assembly to the handle.
5. Disconnect the ETAC cable.
CAUTION To avoid risk of static discharge that can
damage the electronics, make sure to take
the necessary precautions before working
with electronics (see page 25.)
NOTE!
Installation
CAUTION Do not use excessive force when prying on
the button or damage could result to the
locking tabs.
1. Install new ETAC board with screws.
2. Connect the cable to ETAC.
3. Install keypad and secure with screw. Connect the
keypad plug.
4. Connect the battery connector to the truck.
5. Turn the main ON/OFF switch to the ON position.
Enter key code and press the green ON button I
on the keypad.
6. Test truck for proper operation before returning to
service.
252
Return
2004-03-10
F-code
Section
PT
S6.0
6000
Hydraulic System
Version no
T-code
001
SMX
C-code
Hydraulic System
1. Theory of Operation
The hydraulic system consists of a compact hydraulic unit,
including a electric solenoid valve, pressure relief valve and a
cylinder for lifting the forks. The hydraulic solenoid activates
the hydraulic lowering valve that releases pressure on the lift
cylinder to lowing the forks. The hydraulic system is protected
by a relief valve installed in the adapter body.
Lift
Cylinder
Component Enclosure
Hydraulic Lines Joining
Motor (Electric)
Hydraulic Pump
Solenoid
Valve
Filter
Check
Valve
Reservoir (Vented)
1.3 GPM
3000
PSI
Check Valve
Hydraulic Lines Crossing
Orifice
M3
1.25
CC
Filter
Reservoir
BT Prime-Mover, Inc.
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2006-08-08
253
F-code
Section
PT
S6.0
Hydraulic System
Version no
T-code
001
SMX
C-code
6000
1.1. Lift
When the lift button is pushed, the lift pump solenoid is
energized starting the pump and motor. Fluid is drawn from
the reservoir, through a pick up screen to the inlet of the gear
pump. As the gear pump rotates, oil is forced out the pressure
port and is blocked from returning to the reservoir by a closed
relief valve and lowering valve. Oil continues to flow to the top
of the lift cylinder and pushes against the end of cylinder rod
to extend the rod from the cylinder tube. When the lift pump
motor is shut off and the gear pump is not turning, the
cylinder is held extended by a closed check valve and
normally closed lowering valve.
Pressure Oil
Return Oil
B+ Circuit
B- Circuit
Signal
Pre-Charge Voltage
1.3 GPM
3000
PSI
M3
254
Return
1.25
CC
2006-08-08
F-code
Section
PT
S6.0
6000
Hydraulic System
Version no
T-code
001
SMX
C-code
1.2. Lower
Hydraulic fluid is retained in the hydraulic cylinder by a check
valve and electrical hydraulic lowering valve. When the
solenoid is energized, oil passage from the cylinder to
reservoir is opened. Due to the load on the lift cylinder, fluid is
forced out of the lift cylinder and back to the reservoir while
the lift cylinder is retracting. Lowering speed is regulated by a
flow regulator. This process allows the truck to lower.
Pressure Oil
Return Oil
B+ Circuit
B- Circuit
1.3 GPM
Signal
Pre-Charge Voltage
3000
PSI
M3
BT Prime-Mover, Inc.
Return
1.25
CC
2006-08-08
255
F-code
Section
PT
S6.0
Hydraulic System
Version no
T-code
001
SMX
C-code
6000
Pressure Oil
Return Oil
B+ Circuit
B- Circuit
Signal
Pre-Charge Voltage
1.3 GPM
3000
PSI
M3
256
Return
1.25
CC
2006-08-08
F-code
Section
PT
S6.0
6000
Hydraulic System
Version no
T-code
001
SMX
C-code
2. Maintenance
To prolong the life of the truck, keep all fittings and
connections tight to prevent leaks. To avoid damage or
distortion, do not over-tighten brass fittings. Before removing
any component from the hydraulic system, wash the
component and surrounding area with cleaning solution to
prevent foreign matter from entering the system. Cap and
plug all openings immediately. Whenever removing fitting
with a pipe thread, use a sealing compound on the
outside of threads before reinstalling. (Do not use
Teflon tape.) Make sure all parts are clean. When installing
a hose assembly, make sure that it is not twisted when fittings
are tightened. Always use two wrenches on a swivel-type
fitting, one to hold the fitting and the other to tighten the hose.
Return
2006-08-08
257
F-code
Section
PT
S6.0
Hydraulic System
Version no
T-code
001
SMX
C-code
6000
1. Lower forks.
2. Press red OFF button O on the keypad. Depress
main ON/OFF switch to the OFF position.
3. Disconnect the battery connector from the truck.
4. Remove truck cover(s) [see page 84.]
Lift Cylinder Hose
258
Return
2006-08-08
F-code
Section
PT
S6.0
6000
Hydraulic System
Version no
T-code
001
SMX
C-code
3. Troubleshooting
NOTE!
BT Prime-Mover, Inc.
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2006-08-08
259
F-code
Section
PT
S6.0
Hydraulic System
Version no
T-code
001
SMX
C-code
6000
260
Return
2006-08-08
F-code
Section
PT
S6.0
6000
Hydraulic System
Version no
T-code
001
SMX
C-code
Remedy
With main ON/OFF switch in the ON position, the pin key code entered
in the keypad, the green ON button I pressed on the keypad, and the
lift switch depressed, does main contactor (K10) and pump contactor
(K30) energize (click)? If not, check Service Display on page 169. If
no signal is detected, check mechanical problems in the steering
control head. Replace electronic tiller arm card ETAC (A2) as a last
alternative in resolving problem.
With main ON/OFF switch in the ON position, the pin key code entered
in the keypad, the green ON button I pressed on the keypad, and the
lift switch depressed, does main contactor (K10) and pump contactor
(K30) energize (click)? If not, measure voltage between pump contactor
coil terminals. If B+ voltage is present, replace the pump contactor.
With main ON/OFF switch in the ON position, the pin key code entered
in the keypad, the green ON button I pressed on the keypad, and the
lift switch depressed, does pump contactor (K30) energize (click)? If
yes, measure voltage between B- and lift pump motor terminal. If okay,
check lift motor brushes (see page 91.)
Bad pump
If motor is okay, remove motor from the pump and rotate pump shaft by
hand. Replace pump if not okay.
Remedy
Battery problems
BT Prime-Mover, Inc.
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2006-08-08
261
F-code
Section
C-code
PT
S6.0
Hydraulic System
Version no
T-code
001
SMX
6000
Possible Cause
Remedy
Bad lift
brushes
Check lift motor brushes (see page 91.) If brushes are okay, replace lift
pump.
pump
motor
or
Bad pump
If motor is okay, remove motor from the pump and rotate pump shaft by
hand. Replace pump if necessary.
Remedy
With main ON/OFF switch in the ON position, cycle the lower switch.
Does the lower solenoid valve energize (click)? If yes, disconnect the
battery connector, then slowly loosen, but DO NOT REMOVE the
hydraulic line at the hydraulic pump assembly. Have drain pan and rags
ready and allow the forks to slowly lower.
With main ON/OFF switch in the ON position, the pin key code entered
in the keypad, the green ON button I pressed on the keypad, and the
lower button depressed, check Service Display on page 169. If no
signal is detected, check mechanical problems in the steering control
handle head. Replace ETAC (A2) as a last alternative in resolving
problem.
Remedy
Battery problems
262
Return
2006-08-08
Possible Cause
F-code
Section
PT
S6.0
6000
Hydraulic System
Version no
T-code
001
SMX
C-code
Remedy
Contaminated or bad
pressure relief valve
5. Slow Lower.
Possible Cause
Remedy
Plugged or malfunctioning
flow hydraulic lowering valve
Contamination
solenoid valve
in
Mechanical binding
mechanism
lowering
in
lift
NOTE: If pump hits relief and lower is attempted, lowering will be slow. Release lower button
momentarily, then continue to lower. Normal lower speed should resume.
6. Load Drifting/Settling.
Possible Cause
Remedy
Leaking or contaminated
hydraulic lowering valve
BT Prime-Mover, Inc.
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2006-08-08
263
F-code
Section
PT
S6.0
Hydraulic System
Version no
T-code
001
SMX
C-code
6000
39
38
37
40
7
5
6
36
35 34 33
32
8
9
10
12
31
30
14
15
16
17
13
11
18
19
41
20
21
29
22
23
24
25
28
27
264
Return
26
2006-08-08
Item No.
BT Prime-Mover, Inc.
Return
Description
F-code
Section
PT
S6.0
6000
Hydraulic System
Version no
T-code
001
SMX
Item No.
Description
22
Tube
Pump motor
23
Magnet
Solenoid
24
Strainer
Washer, flat
25
Clamp, hose
Lockwasher
26
Reservoir
Screw
27
Elbow, 90 degrees
28
Breather
Plug
29
Tube
Plug
30
O Ring
10
31
O Ring
11
32
Adapter
12
Valve, relief
33
Seat, relief
13
Coil, 24 Volt
34
Plunger
14
Spring
35
Spring
15
Coupler
36
O Ring
16
O Ring
37
Cap
17
Pump assembly
38
Gasket
18
Washer
39
Cable
19
Screw
40
Nut, adjustment
20
Seal, washer
41
Insert, tube
21
Fitting
2006-08-08
C-code
265
F-code
Section
PT
S6.0
Hydraulic System
Version no
T-code
001
SMX
C-code
6000
Pump Motor
Lift Motor
Solenoid
Lowering
Valve
Adapter Body
(Pump)
Fill/Vent
Plug
Hydraulic
Reservoir
266
Return
2006-08-08
F-code
Section
PT
S6.0
6000
Hydraulic System
Version no
T-code
001
SMX
C-code
Installation
1. Install hydraulic unit on the truck and bolt bracket.
2. Install hydraulic line on hydraulic unit.
3. Fill reservoir with specified fluid (see page 72.) Use
a funnel with a flexible neck. Fill reservoir to within
1 inch (25.4 mm) below filler plug elbow. Use up to
0.8 quart (0.75 liter).
4. Install vent plug.
5. Connect the wires and cables to the pump motor.
6. Connect the battery connector to the truck. Turn the
main ON/OFF switch to the ON position. Enter key
code and press the green ON button I on the
keypad.
7. Raise and lower forks. Check hoses and fittings for
leaks.
8. Check hydraulic fluid level in the reservoir (see
page 257.)
9. Install truck cover(s).
BT Prime-Mover, Inc.
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2006-08-08
267
F-code
Section
PT
S6.0
Hydraulic System
Version no
T-code
001
SMX
C-code
6000
Inspection
1. Inspect seat where hydraulic lowering valve stem
seals against the adapter body. The sealing
surface must be completely clean and free from
any nicks or damage.
Installation
1. Thread adapter body into the adapter (32) and
torque to 204 - 240 in-lbs (23 - 27 Nm).
2. Install solenoid coil (13) and torque nut to 48 to 60
in-lbs (5 to 7 Nm).
3. Connect the wires to the terminals.
4. Install truck cover(s).
5. Connect the battery connector to the truck.
6. Turn the main ON/OFF switch to the ON position.
Enter key code and press the green ON button I
on the keypad.
4.3. Reservoir
Removal
1. Remove hydraulic unit from truck (see page 266.)
2. Remove hose clamp securing hydraulic reservoir to
the adapter (32) housing.
3. Tap reservoir (26) lightly to loosen. Wiggle reservoir
sideways while pulling up on the pump and motor at
the same time to remove.
4. Remove reservoir (26) and properly dispose of old
hydraulic fluid.
5. After fluid has drained, flush the inside of the
reservoir with a suitable cleaning solution.
6. Dry the inside of the reservoir with clean, dry
compressed air.
Inspection
1. Inspect the reservoir O ring and inside leading
edge for defects. Replace if necessary.
268
Return
2006-08-08
F-code
Section
PT
S6.0
6000
Hydraulic System
Version no
T-code
001
SMX
C-code
Installation
1. Lubricate O ring with hydraulic fluid. Install O ring.
2. Carefully install reservoir on adapter (32) housing
and attach with hose clamp. Torque clamp to 48 60 in-lbs (5.5 - 7 Nm).
3. Install hydraulic unit on truck (see page 267.)
Filter Screen
Inspection
1. Inspect filter screen and inlet tube for defects.
Replace if necessary.
Installation
1. Install inlet tube sealing washer and fitting in the
pump housing. Torque to 245 - 275 in-lbs (27 - 31
Nm).
2. Install hydraulic reservoir to gain access to the
pump.
3. Install hydraulic unit on truck (see page 267.)
BT Prime-Mover, Inc.
Return
2006-08-08
269
F-code
Section
PT
S6.0
Hydraulic System
Version no
T-code
001
SMX
C-code
6000
270
Return
2006-08-08
F-code
Section
PT
S6.1
Version no
T-code
000
SMX
C-code
6420
Lift Cylinder
Lift Cylinder
1. Theory of Operation
The lift cylinders are the positive displacement type, meaning
there are NO seals on the inner end of the cylinder rod.
2. Maintenance
Inspect cylinder for leakage. Inspect cylinder rod for gouges
or pits. Fluid leakage indicates that the seal is worn. Replace
seal, wiper and lock ring when fluid leakage becomes
excessive.
2.1. Inspection
WARNING When using compressed air, wear effective
chip-guarding and personal protective
equipment. Compressed air used for
cleaning MUST be reduced to less than 30
psi (207 kPa).
NOTE!
NOTE!
3. Troubleshooting
Check cylinder for leakage.
BT Prime-Mover, Inc.
Return
2006-12-12
271
F-code
Section
C-code
PT
S6.1
Lift Cylinder
6420
Version no
T-code
000
SMX
3
2
Item No.
Description
Item No.
1
2
3
Cylinder assembly
Rod, cylinder
Ring, retaining
4
5
6
Description
Wiper, rod
Seal, rod
Tube
272
Return
2006-12-12
NOTE!
F-code
Section
PT
S6.1
Version no
T-code
000
SMX
C-code
6420
Lift Cylinder
Removal
1. Raise and block lift frame. Release pressure in
cylinder by activating lowering valve.
Lift
Frame
Inspection
1. Clean and dry all parts thoroughly. Remove all
nicks and burrs with an emery cloth.
2. Inspect inside surface of cylinder tube (6) for
excessive wear or scoring.
3. Inspect outside surface of cylinder rod (2) for nicks,
scratches or scoring.
BT Prime-Mover, Inc.
Return
2006-12-12
273
F-code
Section
C-code
PT
S6.1
Lift Cylinder
6420
Version no
T-code
000
SMX
Assembly
1. Using seal tool, install new seal (5) on the inside
diameter of cylinder tube (6). Install new wiper (4)
with lips facing inward to bottom on cylinder tube
(6).
Seal Tool
NOTE!
Installation
1. In order to prevent air from filling the cylinder
assembly, it is recommended that the cylinder rod
(2) is fully retracted.
2. Install upper mount first and hold in place with
shoulder bolt.
3. Connect the hydraulic hose and use the pump to
extend the cylinder.
4. Place bottom of cylinder in line with lower pocket.
5. Raise and unblock lifting frame of unit.
6. Install truck cover(s) [see page 84.]
7. Connect the battery connector to the truck.
274
Return
2006-12-12
NOTE!
F-code
Section
PT
S6.1
Version no
T-code
000
SMX
C-code
6420
Lift Cylinder
BT Prime-Mover, Inc.
Return
2006-12-12
275
F-code
Section
C-code
PT
S6.1
Lift Cylinder
6420
Version no
T-code
000
SMX
276
Return
2006-12-12
Index
Index
A
Application
Intended Truck Application
Prohibited Truck . . . . . . .
. . . . . . . . . . . .33
. . . . . . . . . . . .34
B
Battery . . . . . . . . . . . . . . . . . . . . . . . . . .199
Interface . . . . . . .
Legend . . . . . . . .
Normal Operation .
Service Display . .
Service Parameters
Special Modes . . .
Truck Fault Codes
Wiring . . . . . . . .
. . . . . . . . . . . . . . . . 240
. . . . . . . . . . . . . . . . 196
. . . . . . . . . . . . . . . . 145
. . . . . . . . . . . . . . . . 169
. . . . . . . . . . . . . . . 175
. . . . . . . . . . . . . . . . 168
. . . . . . . . . . . . . . . . 181
. . . . . . . . . . . . . . . . 156
Electrical Functions
. . . . . . . . . . . . . . . . . . . . .111
. . . . . . . . . . . . . . . . . . . . .111
Brake Disk . . . . . . . . . . . . . . . . . . . . . . .112
. . . . . 147
. . . . . 146
. . . . . 154
. . . . . 155
. . . . . 148
. . . . . 153
. . . . . 150
Electrical Schematic . . . . . . . . . . . . . . . . 194
Error Codes . . . . . . . . . . . . . . . . . . . . . . 180
ETAC . . . . . . . . . . . . . . . . . . . . . . . . . . 249
. . . . . . . . . . . . . . . . . . . . . . . . . .20
Battery Connector . . . . . . . . . . . . . . . . . .215
Safety
Battery Pack
Swing Out
. . . . . . . . . . . . . . . . . . . . . .205
Fasteners
Caster
. . . . . . . . . . . . . . . . . . . . . . . . .125
Contactor Panel . . . . . . . . . . . . . . . . . . .236
Conversion Formulas . . . . . . . . . . . . . . . .48
Wheel
Cylinder
Lift . . . . . . .
Retention Kit
. . . . . . . . . . . . . . . . . . . .271
. . . . . . . . . . . . . . . . . . . . .82
D
Decals . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Definitions
Electrical . . . . . . . .
Transistor Controller
. . . . . . . . . . . . . . .156
. . . . . . . . . . . . . . .243
Drive Motor Brush Replacement . . . . . . . . .89
Drive Wheel
Specifications
. . . . . . . . . . . . . . . . . . . .115
E
Electric Motors . . . . . . . . . . . . . . . . . . . . .87
Electrical
Di-electric Compound
Error Code History .
Error Codes . . . . . .
Functions . . . . . . .
Graphics . . . . . . . .
BT Prime-Mover, Inc.
Return
. . . . . . . . . . . . . .156
. . . . . . . . . . . . . . .180
. . . . . . . . . . . . . . .180
. . . . . . . . . . . . . . .145
. . . . . . . . . . . . . . .197
Designations . . . . . .
Strength Identification
Torque Values . . . . .
. . . . . . . . . . . . . . . 42
. . . . . . . . . . . . . . . 41
. . . . . . . . . . . . . . . 46
Fault Codes
. . . . . . . . . . . . . . . 245
. . . . . . . . . . . . . . . 181
Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Fuses/Circuit Breakers . . . . . . . . . . . . . . 229
Transistor Controller
Truck . . . . . . . . . .
G
Grease Location Points . . . . . . . . . . . . . . . 72
H
Hydraulic
. . . . . . . . . . 269
. . . . . . . . . . 254
. . . . . . . . . . 255
. . . . . . . . . . 256
. . . . . . . . . . 268
Hydraulic Schematic . . . . . . . . . . . . . . . . 253
Filter Screen and Inlet Tube
Lift Schematic . . . . . . . . .
Lower Schematic . . . . . . .
Relief Pressure Schematic .
Reservoir . . . . . . . . . . . .
Hydraulic System
Changing Fluid . . . . . . . . .
Pump Pressure Relief Valve
Troubleshooting Charts . . .
2004-03-19
. . . . . . . . . . 257
. . . . . . . . . . 259
. . . . . . . . . . 261
277
Index
I
Interface
ETAC and Transistor Controller
. . . . . . . . . . 25
. . . . . . . . . . 27
Service Key . . . . . . . . . . . . . . . . . . . . . . 174
Spare Parts, Ordering . . . . . . . . . . . . . . . . . 1
Steering Bearing . . . . . . . . . . . . . . . . . . 141
Steering Control Handle . . . . . . . . . . . . . 129
Static Discharge Precautions
Welding . . . . . . . . . . . . . .
. . . . . . . .240
Switch
L
Lift Pump . . . . . . . . . . . . . . . . . . . . . . . .270
Load Wheel
. . . . . . . . . . . . . . . . . . . .121
Lubricants . . . . . . . . . . . . . . . . . . . . .59, 72
Cold Storage . . . . . . . . . . . . . . . . . . . . .59
Standard . . . . . . . . . . . . . . . . . . . . . . . .59
Lubrication Chart . . . . . . . . . . . . . . . . . . .71
Specifications
Arm Angle . . . . . . . . . . . . . . . .
Converting Keypad to Key Switch
Horn . . . . . . . . . . . . . . . . . . .
Key . . . . . . . . . . . . . . . . . . . .
Lift Limit . . . . . . . . . . . . . . . . .
Master Control ON/OFF . . . . . . .
Symbols
Caution . .
Danger . . .
Ordinance .
Prohibitory
Warning . .
. . . . . . . . . . . . . . . . . . . . . . 13
. . . . . . . . . . . . . . . . . . . . . . 13
. . . . . . . . . . . . . . . . . . . . . . 14
. . . . . . . . . . . . . . . . . . . . . . 14
. . . . . . . . . . . . . . . . . . . . . . 13
M
Motor
. . . . . . . . . . . . . . . . . . . . . . . . . .96
. . . . . . . . . . . . . . . . . . . . . . . . . .92
Motor Brush Inspection and Replacement . .89
Drive
Pump
Transmission
Fluid Changing
. . . . . . . . . . . . . . . . . . . 242
. . . . . . . . . . . . . . . . . . . 240
. . . . . . . . . . . . . . . . . . . 241
. . . . . . . . . . . . . . . . . . . . 99
Troubleshooting
. . . . . . . . . . . . . . . . . 161
. . . . . . . . . . . . . . . . . 261
Truck Torque Specifications . . . . . . . . . . . 47
Electrical System
Hydraulic System
Parameters
. . . . . . . . . . . . . . . . .174
. . . . . . . . . . . . . . . . .172
Planned Maintenance Schedule . . . . . . . . .61
Pump Motor Brush Replacement . . . . . . . .90
Changing Service
Changing Truck .
S
Safety
Battery
278
Return
. . . . . . 224
. . . . . . 227
. . . . . . 226
. . . . . . 226
. . . . . . 225
. . . . . . 224
. . . . . . . . . . . . . . . . . . . . . . . . .20
Wheels
Caster (Optional)
Drive . . . . . . . .
Load . . . . . . . .
Wiring
. . . . . . . . . . . . . . . . . 125
. . . . . . . . . . . . . . . . . 115
. . . . . . . . . . . . . . . . . 121
Circuit Breaker . . . .
Harness . . . . . . . .
Master Control Relay
Power Cables . . . .
. . . . . . . . . . . . . . . 232
. . . . . . . . . . . . . . . 230
. . . . . . . . . . . . . . . 233
. . . . . . . . . . . . . . . 231
2004-03-19
Return
Back Cover
Return