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BT OE35 Service Manual

Electric counterbalanced order selector
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OE35
Electric Counterbalanced Order Selector
Effective Serial Number OE35027319000
Read and observe all warnings on this unit
WARNING
before operating it.
DO NOT operate this equipment unless all
WARNING
factory installed guards and shields are
properly secured in place.
Part no: 301460-003
Return
Service Manual
Date: January 29, 1998

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Summary of Contents for BT OE35

  • Page 1 Service Manual OE35 Electric Counterbalanced Order Selector Effective Serial Number OE35027319000 Read and observe all warnings on this unit WARNING before operating it. DO NOT operate this equipment unless all WARNING factory installed guards and shields are properly secured in place.
  • Page 2 Return...
  • Page 3 F-code Section C-code BT Standard Codes Version no T-code BT 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...
  • Page 4 F-code Section C-code BT Standard Codes Version no T-code Service Manual 1997-07-15 Return...

  • Page 5: Table Of Contents

    Introduction, Service Manual ..............11 Contents, Section M ..................13 Machine Information ................. 13 General Product Information ..............15 Presentation of the OE35 ................. 15 Main Components ..................20 Inch (SAE) and Metric Fasteners ..............23 Introduction ....................23 Nomenclature, Threads ................24 Strength Identification ................
  • Page 6 Disassembly .................... 105 Torque Generator ..................107 Disassembly .................... 109 Assembly ....................114 Steering System Pump ................121 General Information ................. 122 Removal ....................122 Installation ....................123 Disassembly .................... 125 Inspection ....................126 Assembly ....................126 © BT Products Return...
  • Page 7 Replacement of EV100 Components ............181 Instructions - EV100 Plugs ..............183 Direction Contactor ..................185 General Information ................. 186 Remove / replace contact tips ..............186 1A Speed Contactor ..................191 General Information ................. 192 © BT Products Return...
  • Page 8 Troubleshooting Chart ................243 Lift Pump Assembly ..................247 Removal ....................248 Disassembly .................... 249 Inspection ....................252 Assembly ....................254 Mast, 2 Stage ....................257 Shimming Mast on Truck................. 258 Two Stage Mast ..................262 © BT Products Return...
  • Page 9 Electrical Schematic Part 4 ..............298 Cautions and Warnings ................300 Operation Information ................302 Component Function and Relationship ............ 306 Truck Set Up On Site ................308 Troubleshooting Information ..............311 Troubleshooting Charts ................314 © BT Products Return...
  • Page 10 Table of Contents © BT Products Return...

  • Page 11: Warning Symbols

    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 crash/breakdown if the instructions are not followed. © BT Products Service Manual 1997-07-15 Return...

  • Page 12: Prohibitory Symbols

    F-code Section C-code Prohibitory Symbols Version no T-code Prohibitory Symbols NO SMOKING If smoking occurs in situations where a restriction agains smoking is stated, a serious accident can occur. OPEN FLAMES PROHIBITED If open flames are used in situations where open flames are prohibited, a serious accident can occur.
  • Page 13 Federal and State laws require that operators be completely trained in the safe operation of lift trucks. An Operator’s Manual is attached to every BT lift truck when it is manufactured. If the Operator’s Manual is missing from the truck, a new manual may be obtained by contacting: BT Prime-Mover, Inc.
  • Page 14 F-code Section C-code Introduction, Service Manual Version no T-code Service Manual 1997-07-15 Return...

  • Page 15: Introduction, Service Manual

    F-code Section C-code Contents, Section M Version no T-code Contents, Section M 1. Machine Information M1.0 GENERAL PRODUCT INFORMATION M2.0 TECHNICAL SERVICE DATA M3.0 ORDERING SPARE PARTS © BT Products Service Manual 1997-07-15 Return...
  • Page 16 F-code Section C-code Contents, Section M Version no T-code Service Manual 1997-07-15 Return...

  • Page 17: Presentation Of The Oe35

    General Product Information Version no T-code OE35 General Product Information 1. Presentation of the OE35 OE-35 is a battery powered counterbalanced order selector trucks. These trucks are intended solely to be operated handling pallets or similar load carriers indoors. In their standard design, the trucks are equipped with a steering wheel with all the controls for operating within easy access.
  • Page 18 C-code M1.0 General Product Information Version no T-code OE35 1.2. Forbidden Application of the Truck The trucks are designed for handling goods indoors. It is not permitted to use the trucks for other purposes including the following: Do not use in areas that contain gases which can...

  • Page 19: General Product Information

    Section C-code M1.0 General Product Information Version no T-code OE35 1.4. OE35 Dimensions The following diagram shows external dimensions for the OE35 truck in its standard design. 24.0” Minimum 42.0” 4.0” 30.0” Maximum 70” Turning Radius 76.0” 60.0” Picking 80.0”...
  • Page 20 F-code Section C-code M1.0 General Product Information Version no T-code OE35 1.5. Data Plate The following diagram shows the data plate used on the truck. Legend 1. Truck model number 2. Truck serial number 3. Truck capacity 4. Mast serial number 5.
  • Page 21 Know the U.L. construction type of this truck and make certain that trucks of this type may be operated in restricted areas before you enter. Never take an unauthorized truck in restricted or hazardous areas. © BT Products Service Manual 1997-09-24 Return...
  • Page 22 Section C-code M1.0 General Product Information Version no T-code OE35 2. Main Components 1. Steering wheel The truck is to be controlled by the operator with 180 degree steering angle. 2. Parking brake pedal The brake is applied in the up position.
  • Page 23 20. Circuit circuit fuses 15A, BT Control fuse part number 201324 400A, 24 volt BT Pump fuse part number 25094-03 300A, 36 volt BT Pump fuse part number 25094-04 300A, BT Drive fuse part number 25094-04 21. Travel speed / direction selection To select direction rotate in the direction you wish to move.

  • Page 24: Main Components

    F-code Section C-code M1.0 General Product Information Version no T-code OE35 Main Components Chart Service Manual 1997-09-24 Return...

  • Page 25: Introduction

    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 Products Service Manual 1997-09-24 Return...

  • Page 26: Nomenclature, Threads

    F-code Section C-code M1.1 Inch (SAE) and Metric Fasteners Version no T-code 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 the shank of the fastener is shown first in the series, e.g.

  • Page 27: Inch (Sae) And Metric Fasteners

    The new fasteners must also be the correct size. NOTE! Identification marks are according to bolt strength. The higher the number, or the increase in the number of marks, indicates increased bolt strength. © BT Products Service Manual 1997-09-24 Return...
  • Page 28 F-code Section C-code M1.1 Inch (SAE) and Metric Fasteners Version no T-code Table 1. Bolt and Screw Designations Metric Fasteners Inch Fasteners Types of Strength Levels: Property Classes Strength Levels: SAE Grades Fasteners Markings Not Required 4.6* 4.8* 5.8* 10.9 12.9 Markings for size...
  • Page 29 10.9 12.9 Markings for size M5 and 12.9 10.9 Larger Studs Optional Geometric Symbols for Size M5 through M11 ONLY. Hex Nuts Markings Not Required Hex Slotted Nuts Markings Not Required Hex Flange Nuts © BT Products Service Manual 1997-09-24 Return...
  • Page 30 F-code Section C-code M1.1 Inch (SAE) and Metric Fasteners Version no T-code Table 3. Torque Nut Designations Inch Fasteners Types of Metric Fasteners Strength Levels: SAE Grades Strength Levels: Property Classes Fasteners All Metal Pre- vailing Torque Nuts All Metal Pre- vailing Torque Flange Nuts Service Manual...
  • Page 31 Types of Metric Fasteners Inch Fasteners Strength Levels: Property Classes Fasteners Strength Levels: SAE Grades Markings Not Require Nylon Insert Pre- vailing Torque Nuts Markings Not Required Nylon Insert Pre- vailing Torque Flange Nuts © BT Products Service Manual 1997-09-24 Return...
  • Page 32 F-code Section C-code M1.1 Inch (SAE) and Metric Fasteners Version no T-code Table 5. Fastener Torque Values Property, Class Property, Class Property, Class Size and Pitch 8.8* 10.9** 12.9*** • in.-lb • in.-lb • in.-lb M5 x 0.8 44-53 62-71 8-10 71-88 M6 x 1...
  • Page 33 To Get horsepower 0.746 kilowatts (kW) kilowatts 1.34 horse- power(hp) PRESSURE Multiply To Get Multiply To Get pounds/in² 6.895 kilopascal (kPa) kilopascals 0.145 pounds/in² (psi) pounds/in² 0.007 megapascal (MPa) megapascals 145.04 pounds/in² (psi) © BT Products Service Manual 1997-09-24 Return...
  • Page 34 F-code Section C-code M1.1 Inch (SAE) and Metric Fasteners Version no T-code TEMPERATURE Multiply To Get Multiply To Get (Fahrenheit 0.56 Celsius (C) (Celsius x 1.8) Fahrenheit (F) -32) TORQUE Multiply To Get Multiply To Get inch pound 0.113 Newton meter (N•m) Newton meter 8.851 inch pounds in.-lb...

  • Page 35: Conversion Of Metric And English Units

    4 in. x 6 in. Load wheel weight with rated load, lb HYDRAULIC LIFT PUMP Revolutions/min at work pressure Duty factor Minimum brush length 0.625 in. 0.625 in. Minimum commutator diameter 2.80 in. 2.80 in. © BT Products Service Manual 1997-10-21 Return...
  • Page 36 F-code Section C-code M2.0 Technical Service Data Version no T-code OE35 MODEL 24 Volt 36 Volt Minimum brush spring tension 40-65 oz 40-65 oz Part number 300282-000 300281-000 HYDRAULIC STEERING PUMP Revolutions/min at work pressure Duty factor Minimum brush length 0.625 in.

  • Page 37: Technical Service Data

    (fast speed) 57 fpm 57 fpm Lower with load (2-Stage) (slow speed) (fast speed) 30 fpm 30 fpm Lower with load (3-Stage) (slow speed) 30 fpm 30 fpm (fast speed) 53 fpm 53 fpm © BT Products Service Manual 1997-10-21 Return...
  • Page 38 F-code Section C-code M2.0 Technical Service Data Version no T-code OE35 MODEL 24 Volt 36 Volt CURRENT CONSUMPTION Driving without load 120 Amp 120 Amp Driving with rated load 140 Amp 140 Amp Lifting without load (2-Stage) (slow speed) 168 Amp...
  • Page 39 5. Note the part number. 6. Call the local BT dealer and state the part number. If you cannot find the machine model, serial number, or the article number, call the local BT dealer and he will help you.
  • Page 40 F-code Section C-code M3.0 Ordering Spare Parts Version no T-code Service Manual 1997-07-15 Return...

  • Page 41: Ordering Spare Parts

    - Use only spare parts approved by BT. - Always clean the equipment and carry out a full safety check after service.
  • Page 42 F-code Section C-code P1.0 Introduction, Maintenance Version no T-code Service Manual 1997-07-15 Return...

  • Page 43: Service Schedule

    Check torque of motor bolts 1700.5 Check for abnormal noise in motor bearings 2550 Drive Gear 2550.1 Check for oil leakage 2550.2 Clean motor of dirt and dust 2550.3 Check torque of motor bolts © BT Products Service Manual 1997-10-21 Return...
  • Page 44 F-code Section C-code P2.0 Service Schedule Version no T-code OE35 ITEM WORK REQUIRED Interval in Hours 1200 3600 Interval in Days/Weeks/Months 12 m 36 m 3100 Brake 3100.1 Clean dust and debris 3100.2 Check brake operation 3500 Wheels 3500.1 Remove all string, wrapping and debris 3500.2...
  • Page 45 Lube all grease fittings 7400 Lifting device 7400.1 Check the clearance of the forks 7400.2 Check the forks for damage and cracks 7400.3 Check the forks for wear and cracks 7400.5 Lube all grease fittings © BT Products Service Manual 1997-10-21 Return...
  • Page 46 F-code Section C-code P2.0 Service Schedule Version no T-code OE35 3100 7310 5200 4100 1700 2550 6000 5300 0640 5400 5710 7400 5110 0000 3500 Service Manual 1997-10-21 Return...

  • Page 47: Planned Maintenance Procedures

    1.2. Dash Display The dash display is a four segment light emitting diode (LED) display that displays the status codes, hourmeter readings, and battery discharge indication from the controller. © BT Products Service Manual 1997-10-21 Return...
  • Page 48 P2.0 Planned Maintenance Procedures Version no T-code OE35 1.3. Hydraulic System 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.

  • Page 49: Services To Be Performed Monthly Or Every 250 Operating Hours

    80% discharged level. However, there are many different batteries on the market. Only the battery manufacturer can accurately determine the fully charged and 80% charged levels. Contact the battery manufacturer for this information. © BT Products Service Manual 1997-10-21 Return...
  • Page 50 P2.0 Planned Maintenance Procedures Version no T-code OE35 2.5. Electrical Connections All electrical connections should be checked that they are clean and tight. Plug-in connectors should be unplugged and plugged back in to clean the terminals. If the truck is equipped...
  • Page 51 There are some pivot points and other items that need to be lubricated but do not have grease fittings. Lubricate these non-greasable wear points with a drip oil can using 10 wt. machine oil. © BT Products Service Manual 1997-10-21 Return...

  • Page 52: Services To Be Performed Annually Or Every 1200 Operating Hours

    C-code P2.0 Planned Maintenance Procedures Version no T-code OE35 3. Services to be performed annually or every 1200 operating hours The annual planned maintenance service will take a longer period of time to complete than does the monthly service. This would be a good time to arrange other repairs that have been noted on the monthly service.
  • Page 53 Turn the set screws back in transmission cover only until spring resistance is felt. Then turn each set screw an additional 1/4 in. turn and secure in place with locknuts. Test braking action. © BT Products Service Manual 1997-10-21 Return...
  • Page 54 F-code Section C-code P2.0 Planned Maintenance Procedures Version no T-code OE35 Service Manual 1997-10-21 Return...

  • Page 55: Lubrication Chart

    600 h 1200 h Section 6 for Code) Wheel bearings Mast bearings Lifting linkage Hydraulic syste Steering bearings Drive gear Drive gear drain L= Lubrication C = Check O = Oil change 6, 7 © BT Products Service Manual 1997-10-21 Return...
  • Page 56 F-code Section C-code P3.0 Lubrication Chart Version no T-code OE35 Service Manual 1997-10-21 Return...

  • Page 57: Oil And Grease Specifications

    Texaco 15 Hydraulic system Transmission oil SAE 80w/90 SAE 75w Gears Motor oil SAE 40 SAE5w-20 SAE5w-20 Chains Grease Molykote Molykote Molykote Mast rails 200025 200025 200025 Grease 49670-00 49670-00 49670-00 Mast rails © BT Products Service Manual 1997-10-21 Return...
  • Page 58 F-code Section C-code P4.0 Oil and Grease Specifications Version no T-code OE35 Service Manual 1997-10-21 Return...

  • Page 59: Contents, Section S

    DRIVE GEAR / TRANSMISSION 2000 BRAKE / WHEEL SYSTEM 3000 STEERING SYSTEM 4000 ELECTRICAL / PNEUMATIC SYSTEM 5000 HYDRAULIC SYSTEM 6000 LIFTING MAST / CYLINDERS 7000 PERIPHERAL / INSTALLATION 8000 EQUIPMENT OPTIONS / ATTACHMENTS 9000 © BT Products Service Manual 1997-04-15 Return...
  • Page 60 F-code Section C-code Contents, Section S Version no T-code Service Manual 1997-04-15 Return...

  • Page 61: Inspection Covers

    Rivet, pop Panel Guard, right spring Channel, Harness Cable, manual Guard, left spring Shield, back cover Rivet, pop Shield, front top Screw, socket head Shield Nut, clip Washer, flat Mat, floor Pocket, manual © BT Products Service Manual 1997-10-23 Return...

  • Page 62: Removal Of Plastic Dash Panel

    S0.1 0340 Inspection Covers Version no T-code OE35 1. Removal Of Plastic Dash Panel Before starting disassembly of any parts, thoroughly clean out side of assembly with safety solvent or other non- corrosive cleaning fluid. Air dry all parts. Be extremely careful when working with WARNING solvent.
  • Page 63 16. Open wire harness plug. Push wires out of plug. Use AMP tool #305183. 17. Remove other handle bracket. 18. Slide handle to right and remove. 19. Remove three screws in bottom of dash panel. Tip dash from bottom and remove. © BT Products Service Manual 1997-10-23 Return...
  • Page 64 F-code Section C-code S0.1 0340 Inspection Covers Version no T-code OE35 Service Manual 1997-10-23 Return...

  • Page 65: Drive Motor

    We have reviewed many troubleshooting guides and have reduced them to a few which seem to be the most effective Symptom/Cause relationships. © BT Products Service Manual 1997-07-15 Return...
  • Page 66 F-code Section C-code S1.0 1700 Drive Motor Version no T-code TABLE #1 Drive Motor Troubleshooting Indications, Causes. and Correction of Unsatisfactory Brush Performance Indications Immediate Causes Primary Faults Sparking Commutator surface condition 1-2-3-43-44-45-46-49-59-60 Overcommutation 7-12-31-33 Undercommutation 7-12-30-32 Too rapid reversal of current 7-12-30-32 Faulty machine adjustment 8-9-11...
  • Page 67 Wrong brush grade Raw copper surface Embedded copper See “Copper in brush face” Bad service condition 43-45-47-49 Wrong brush grade 59-61 Rapid commutator Burning 2-3-11-14 wear with blackened Severe sparking See “Sparking” surface © BT Products Service Manual 1997-07-15 Return...
  • Page 68 F-code Section C-code S1.0 1700 Drive Motor Version no T-code Rapid commutator Foreign material in brush face 43-45-47-49 wear with bright surface Wrong brush grade copper dragging Brush vibration 39-52-58-59 Indications Appearing as Heating Indications Immediate Causes Primary Faults Heating in windings Severe load condition 38-41-42-53 Unbalanced magnetic field...
  • Page 69 25. Open or high resistance connection at commutator 26. Poor connection at shunt terminal 27. Short circuit in field or armature winding 28. Ground in field or armature winding 29. Reversed polarity on main pole or interpole © BT Products Service Manual 1997-07-15 Return...
  • Page 70 F-code Section C-code S1.0 1700 Drive Motor Version no T-code Machine Design 30. Commutating zone too narrow 31. Commutating zone too wide 32. Brushes too thin 33. Brushes too thick 34. Magnetic saturation of interpoles 35. High bar-to-bar voltage 36. High ratio of brush contact to commutator surface area 37.

  • Page 71: Drive Motor 24 Volt

    Screw, retainer Holder, brush Bearing Shield, com. end Brush Retainer Terminal Spring Armature Washer Screw, brush Shield, drive Bushing Screw, holder Seal, shaft Gasket Bushing Screw, clamp Washer Washer Kit, “EE” Washer Screw, pole © BT Products Service Manual 1997-10-21 Return...

  • Page 72: Component Repair

    C-code S1.1 1700 Drive Motor 24 Volt Version no T-code OE35 1. Component Repair Disassembly 1. Scribe or center punch locating marks in the commutator end head and the frame. Although locating marks are not always necessary because of locating pins in some motors, they can save a lot of time when the motor does not have locating pins.

  • Page 73: Inspection And Troubleshooting

    Although the bearing may appear or feel good, the bearing races have been brinelled and will fail within a relatively short period of service. © BT Products Service Manual 1997-10-21 Return...
  • Page 74 C-code S1.1 1700 Drive Motor 24 Volt Version no T-code OE35 2.4. Brush and Commutator The brushes and commutator should be inspected for even wear and good commutation. Good Commutation:A dark uniform coloring pattern at the brush wearing surface. Poor...
  • Page 75 Most commercial growlers incorporate a test light as shown in opposite illustration. Grounded Circuit Touch one test lead to a clean bare metal spot on the frame and check all terminals with the other lead. If a © BT Products Service Manual 1997-10-21 Return...
  • Page 76 C-code S1.1 1700 Drive Motor 24 Volt Version no T-code OE35 grounded condition exists, the test light will light. Open Circuit Check between all connecting terminals with test leads. If the bulb fails to light, an open circuit is indicated.
  • Page 77 1. Whenever ball bearings are pressed into an end head or onto a shaft, always press against the race that is absorbing the pressure. Press on the outer race when installing into end heads. © BT Products Service Manual 1997-10-21 Return...

  • Page 78: When Changing Brushes

    S1.1 1700 Drive Motor 24 Volt Version no T-code OE35 Press against the inner race when installing onto a shaft. 2. End heads having slip-fit bearings are normally retained by a snap ring. Always install new snap ring(s). 2.7.3. After Assembly The motor should be connected as specified in Troubleshooting, and tested to the specifications.

  • Page 79: Drive Motor 36 Volt

    OE35 Drive Motor 36 Volt POS. NO DESCRIPTION POS. NO DESCRIPTION coil, field Head, commutstor end Lead Band, head Brush Armature assembly Spring, brush Plate, brush Head, drive end Ring, retainer Seal Bearing © BT Products Service Manual 1997-10-21 Return...

  • Page 80: Component Repair

    C-code S1.2 1700 Drive Motor 36 Volt Version no T-code OE35 1. Component Repair 1.1. Disassembly 1. Scribe or center punch locating marks in commutator end head and the frame. Although locating marks are not always necessary because of locating pins in some motors, they can save a lot of time when the motor does not have locating pins.

  • Page 81: Inspection And Troubleshooting

    Although the bearing may appear or feel good, the bearing races have been brinelled and will fail within a relatively short period of service. © BT Products Service Manual 1997-10-21 Return...
  • Page 82 C-code S1.2 1700 Drive Motor 36 Volt Version no T-code OE35 2.4. Brush and Commutator The brushes and commutator should be inspected for even wear and good commutation. Good Commutation: A dark uniform coloring pattern at the brush wearing surface.
  • Page 83 Grounded Circuit Touch one test lead to a clean bare metal spot on the frame and check all terminals with the other lead. If a grounded condition exists, the test light will light. © BT Products Service Manual 1997-10-21 Return...
  • Page 84 C-code S1.2 1700 Drive Motor 36 Volt Version no T-code OE35 Open Circuit Check between all connecting terminals with test leads. If the bulb fails to light, an open circuit is indicated. Shorted Circuit Check condition of coil insulation and look for signs of overheating.
  • Page 85 2.7.2. Bearing Installation 1. Whenever ball bearings are pressed into an end head or onto a shaft, always press against the race that is absorbing the pressure. © BT Products Service Manual 1997-10-21 Return...

  • Page 86: When Changing Brushes

    S1.2 1700 Drive Motor 36 Volt Version no T-code OE35 Press on the outer race when installing into end heads. Press against the inner race when installing onto a shaft. 2. End heads having slip-fit bearings are normally retained by a snap ring. Always install new snap ring(s).

  • Page 87: Transmission

    If there is a mechanical problem outside of the transmission, then it will become evident by inspecting the drive motor and brakes. © BT Products Service Manual 1997-10-21 Return...

  • Page 88: Removal

    F-code Section C-code S2.0 2550 Transmission Version noT-code OE35 3. Removal POS. POS. POS. DESCRIPTION DESCRIPTION DESCRIPTION Screw, cap Lockwasher Washer Lockwasher Screw, cap Bearing Clamp Bearing, roller Nut, twin Spacer Eccentric, adjuster Switch Ring, retainer Screw, cap Screw, machine...
  • Page 89 15. Remove the three cap screw that bolt the transmission pivot mount to the truck frame. 16. The transmission can now be lifted up and away from the truck. © BT Products Service Manual 1997-10-21 Return...
  • Page 90 F-code Section C-code S2.0 2550 Transmission Version noT-code OE35 17. Remove retaining ring from pivot tube and remove pivot mounting bracket. The pivot bearing outer race is pressed into the bracket. Service Manual 1997-10-21 Return...

  • Page 91: Transmission Disassembly / Assembly

    Pin, dowel Shim, 0.010 in. Gear Plate, brake Screw, cap Seal, oil Disc, brake Screw, cap Hub, axle Rod, brake Lockwasher Locknut Lever, brake Gear, drive Kit, drive axle Pin, roll Bearing Spring Bearing © BT Products Service Manual 1997-10-21 Return...

  • Page 92: Disassembly

    C-code S2.0 2550 Transmission Disassembly / Assembly Version noT-code OE35 4. Disassembly Before starting disassembly of any parts, thoroughly clean out side of assembly with safety solvent or other non- corrosive cleaning fluid. Air dry all parts. Be extremely careful when working with WARNING solvent.
  • Page 93 9. Remove brake discs, plates and retaining shafts. Drive Motor Motor Brake Adapter O ring Separator Pads Bushing Brake Adjusting Motor Brake Disc Pinion 10. Remove axle locknut and nub from axle. Remove axle from case. © BT Products Service Manual 1997-10-21 Return...
  • Page 94 F-code Section C-code S2.0 2550 Transmission Disassembly / Assembly Version noT-code OE35 11. Remove bearing races from case. Locknut Case Seal Drive Gear Wheel Bearing Bearing 12. Remove motor pinion bearing and cover and intermediate gear bearing and cover from side cover.
  • Page 95 “snapped” together by striking with a lead hammer. 29. Install a new gasket on the drive motor. Use a small amount of Loctite 515 as sealant. Drive Motor Gasket Motor Adapter Motor Pinion © BT Products Service Manual 1997-10-21 Return...
  • Page 96 S2.0 2550 Transmission Disassembly / Assembly Version noT-code OE35 30. Install the bushings and O ring for the brake actuating rod into the gear case. 31. Install the drive motor in the gear case. 32. Install the brake actuating rod through the drive motor into the gear case.
  • Page 97 44. Install the baffle in the bottom of the gear case. (if used) 45. Use a solid bead of Loctite 515 “gasket eliminator” around the gear case cover flange. Circle all bolt holes and dowel pin holes. © BT Products Service Manual 1997-10-21 Return...
  • Page 98 S2.0 2550 Transmission Disassembly / Assembly Version noT-code OE35 46. Install dowel pins in gear case. 47. Carefully install the gear case cover. Take care to line up the three brake springs and the brake separator plate retaining shaft with the appropriate holes in the cover.

  • Page 99: Installation

    4. Attach hoist to transmission with a chain through the pivot tube. 5. Raise and block the front of the truck about 12 in. off the ground. © BT Products Service Manual 1997-10-21 Return...
  • Page 100 S2.0 2550 Transmission Disassembly / Assembly Version noT-code OE35 6. Set transmission into truck from the top. 7. Bolt the pivot mount to the truck frame with three bolts. Torque to 75 ft-lb. 8. Adjust transmission steering ring guide rollers snug, but not tight, against the guide ring (+0.0156...

  • Page 101: Drive Wheel

    3. Hoist machine and securely block truck with drive tire about 1 in. off floor. 4. Remove lug bolts and remove tire and wheel assembly. Lug Bolts 5. Press drive tire (2) from wheel hub (3). © BT Products Service Manual 1997-10-21 Return...
  • Page 102 C-code S3.1 3500 Drive Wheel Version noT-code OE35 5.2. Installation 1. Press drive tire (2) onto wheel hub (2). This is usually done while pressing off old tire. Press hub to center of tire. 2. Install drive tire and hub on axle. The drive tire lug bolts should be torqued to 125 ft-lb.

  • Page 103: Load Wheels

    3. Drive roll pin (5) further in support arm to allow nut (6) to be removed. 4. Remove nut (6), axle (7), and load wheel assembly from support arm. 5. Drive roll pin (5) from support arm. 6. Inspect bearings (10). © BT Products Service Manual 1997-09-15 Return...
  • Page 104 C-code S3.2 3550 Load Wheels Version no T-code OE35 7. Install new load wheel (11) and bearing (10) as needed. 7. Install load wheel assembly in support arm. Slide axle (7) in support arm from outside and install nut (6).

  • Page 105: Stabilizing Caster Spring Loaded

    Bearing, thrust Screw Bearing, ball Seal Spring, inner Wheel Frame Spring, outer Frame, wheel Plate, spring Washer, spacer Washer Bushing Screw Nut, slotted Washer, shim Bearing, roller Fitting, grease Cap, hub Axle, caster © BT Products Service Manual 1997-07-15 Return...

  • Page 106: Removal

    C-code S3.2 3560 Stabilizing Caster Spring Loaded Version no T-code OE35 1. Removal NOTE! CLEANLINESS! Perform procedures in a clean environment. Make sure all parts are cleaned before disassembly and kept clean during assembly. 1. Park the truck on a level surface and make sure parking brake is applied.
  • Page 107 3560 Stabilizing Caster Spring Loaded Version no T-code OE35 Compressed air used for cleaning MUST be WARNING reduced to less than 30 p.s.i., and then only with effective chip-guarding and personal protective equipment. © BT Products Service Manual 1997-07-15 Return...

  • Page 108: Inspection

    C-code S3.2 3560 Stabilizing Caster Spring Loaded Version no T-code OE35 2. Inspection NOTE! CLEANLINESS! Perform procedures in a clean environment. Make sure all parts are cleaned before disassembly and kept clean during assembly. 1. Thoroughly clean all parts and remove all nicks and burrs with emery cloth.

  • Page 109: Disassembly

    1. Install caster assembly under truck, and secure with cap screws and nuts. 2. Lift truck and remove all blocking. 3. Reconnect the negative wire to pump solenoid. 4. Connect battery to truck. 5. Close access door. © BT Products Service Manual 1997-07-15 Return...
  • Page 110 F-code Section C-code S3.2 3560 Stabilizing Caster Spring Loaded Version no T-code OE35 Service Manual 1997-07-15 Return...

  • Page 111: Torque Generator

    F-code Section C-code S4.0 4130 Torque Generator Version no T-code OE35 Torque Generator © BT Products Service Manual 1997-10-27 Return...
  • Page 112 F-code Section C-code S4.0 4130 Torque Generator Version no T-code OE35 POS. POS. POS. DESCRIPTION DESCRIPTION DESCRIPTION Hosing, valve Seal, quad Seal, shaft Plate, spacer Key, woodruff Washer Spacer Shaft, power end Ring, retainer Geroler Washer O ring Plate, spacer...

  • Page 113: Disassembly

    ACROSS PORT FACE SIDES ONLY. 2. With the torque generator firmly supported, use a 6 point drive (E10) socket wrench and remove seven cap screws (early production units used 12 point drive screws). © BT Products Service Manual 1997-10-27 Return...
  • Page 114 S4.0 4130 Torque Generator Version no T-code OE35 Cap Screw Housing and Shaft Assembly 3. Remove the housing (power end) and shaft assembly. 4. Turn the housing and shaft assembly over and remove the shaft with retaining ring in place.
  • Page 115 10. Remove the gerotor or Geroler. 11. Remove the spacer. 12. Using a small screwdriver or similar tool, remove the O ring from the spacer plate. 13. Remove spacer plate from the valve housing. © BT Products Service Manual 1997-10-27 Return...
  • Page 116 C-code S4.0 4130 Torque Generator Version no T-code OE35 14. Again using a small screwdriver or similar tool, remove O ring from the valve housing. 15. Remove the control end drive from the spool/sleeve assembly in the valve housing. Washer...
  • Page 117 NOTE! Valve housing with inlet relief valve has one O ring on the plug. After O ring replacement, install relief valve and plug into valve housing and torque plug to 30-34 ft-lb (41-46 N$m). © BT Products Service Manual 1997-10-27 Return...

  • Page 118: Assembly

    S4.0 4130 Torque Generator Version no T-code OE35 2. Assembly Replace all worn and damaged parts, also a good service policy is to replace all seals. Lubricate all seals with petroleum jelly, and also lubricate all mating surfaces with good clean hydraulic fluid for ease of reassembly and to provide instant lubrication between rotating parts at start-up.
  • Page 119 Lip), have been addressed in the steps below. 7. Quad Seal In preparation of installing the quad seal, first install the spool/sleeve assembly into the valve housing backwards, shaft end up. Carefully retain the © BT Products Service Manual 1997-10-27 Return...
  • Page 120 4130 Torque Generator Version no T-code OE35 spool/sleeve and washer assembly in the valve housing, and turn the assembly over, support it on a clean flat surface. Temporarily installing these shaft parts in the valve housing in the opposite direction...
  • Page 121 After engaging the gerotor or Geroler star with the marked drive, rotate the outer ring of the gerotor or Geroler to align with the threaded holes in the valve housing. © BT Products Service Manual 1997-10-27 Return...
  • Page 122 F-code Section C-code S4.0 4130 Torque Generator Version no T-code OE35 Spacer Plate Gerotor or Geroler Drive (power end) O ring 19. Lubricate and install the O ring into the gerotor or Geroler. 20. Install the spacer in the Geroler star.
  • Page 123 30. Install the cap screws and torque in a criss-cross sequence to 200 in-lb (23 N$m). 31. The torque generator is now ready for test and installation. © BT Products Service Manual 1997-10-27 Return...
  • Page 124 F-code Section C-code S4.0 4130 Torque Generator Version no T-code OE35 Service Manual 1997-10-27 Return...

  • Page 125: Steering System Pump

    F-code Section C-code S4.0 4150 Steering System Pump Version no T-code OE35 Steering System Pump 24 VOLT 36 VOLT © BT Products Service Manual 1997-10-29 Return...

  • Page 126: General Information

    F-code Section C-code S4.0 4150 Steering System Pump Version no T-code OE35 POS. POS. POS. DESCRIPTION DESCRIPTION DESCRIPTION Pump and motor Gasket Pump assembly Motor Pump, steering Kit, coupler Lockwasher Pump and motor Gasket Screw, cap Motor Pump assembly Pump assembly...

  • Page 127: Installation

    9. Install the caps over the relief valve adjusting screws. © BT Products Service Manual 1997-10-29 Return...
  • Page 128 F-code Section C-code S4.0 4150 Steering System Pump Version no T-code OE35 POS. POS. POS. DESCRIPTION DESCRIPTION DESCRIPTION Shaft, drive Gear O ring Gasket O ring Housing, gear Ring, backup Ring, retainer Plug Plug Gear Housing, end gear Cap, hex...

  • Page 129: Disassembly

    12. Remove seal from front housing. 13. Clean all pump parts in safety solvent and dry with compressed air. WARNING Be extremely careful when working with solvent. Even a small explosion or fire could cause injury or death. © BT Products Service Manual 1997-10-29 Return...

  • Page 130: Inspection

    Section C-code S4.0 4150 Steering System Pump Version no T-code OE35 Compressed air used for cleaning MUST WARNING be reduced to less than 30 p.s.i., and then only with effective chip-guarding and personal protective equipment. 5. Inspection 1. Parts must be kept clean and dry for inspection.
  • Page 131 9. Install shaft seal in front housing. Outer face of seal should be recessed 0.5 in. from front edge of bore. 10. Install coupling half on front of input shaft. 11. Install solenoid valve and coil in end body. © BT Products Service Manual 1997-10-29 Return...
  • Page 132 F-code Section C-code S4.0 4150 Steering System Pump Version no T-code OE35 Service Manual 1997-10-29 Return...

  • Page 133: Steering System

    Both turn buckles must be adjusted an equal amount so that the steering remains centered. Adjust turn buckles so that tension springs are collapsed all but one full coil. © BT Products Service Manual 1997-10-29 Return...
  • Page 134 F-code Section C-code S4.0 4170 Steering System Version no T-code OE35 Service Manual 1997-10-29 Return...

  • Page 135: Electrical System With Tx And Tt Card

    Electrical System with TX and TT Card 1. Electrical Schematic Part 1 NOTE! Items represented with dashed lines are options that may not be present on all models. See Electrical Schematic Part 2 for further information. © BT Products Service Manual 1997-10-23 Return...

  • Page 136: Electrical Schematic Part 2

    F-code Section C-code S5.0 5000 Electrical System with TX and TT Card Version noT-code OE35 2. Electrical Schematic Part 2 See Electrical Schematic Part 1 for further information. Service Manual 1997-10-23 Return...

  • Page 137: Basics Of Circuit Operation

    (card terminal 14) is fully charged negative. This charge exceeds battery voltage by an amount which is a function of peak motor current, and 2REC turns off. The illustrates below shows the pulsing of current from the battery. © BT Products Service Manual 1997-10-23 Return...
  • Page 138 S5.0 5000 Electrical System with TX and TT Card Version noT-code OE35 Dash Line Shows Average Motor Current During the off time, the energy stored in the motor, by virtue of the motors inductance, will cause current to circulate through the motor around the loop formed by 3REC. Thus, providing what is called “flyback current”.

  • Page 139: Control Features

    “Controlled Acceleration”. The minimum time required to go from creep speed to 80-85% on time point may be varied by function 3, adjustable from approximately 0.1 seconds to 22.0 seconds. © BT Products Service Manual 1997-10-23 Return...
  • Page 140 S5.0 5000 Electrical System with TX and TT Card Version noT-code OE35 4.2. Current Limit This circuit monitors motor current by utilizing a sensor in series with the armature. The information detected across the sensor is fed back to the card so current may be limited to a pre-set value.
  • Page 141 1A contactor again. Using this feature will reduce the 1A contactor tip life, thus it should be used only where needed to protect the motor. © BT Products Service Manual 1997-10-23 Return...
  • Page 142 S5.0 5000 Electrical System with TX and TT Card Version noT-code OE35 4.9. Static Return to OFF This built-in feature of the control is set up to make the driver return the directional lever to neutral anytime he leaves the vehicle and returns.
  • Page 143 PMT with the key switch if the trip is due to random noise. When the PMT circuit prevents forward or contactors from closing, the PMT circuit can be reset only by opening the key switch. © BT Products Service Manual 1997-10-23 Return...
  • Page 144 S5.0 5000 Electrical System with TX and TT Card Version noT-code OE35 4.15. Thermal Protector - (TP) This temperature sensitive device is mounted on the 1REC heat sink. If the 1REC temperature begins to exceed the design limits, the thermal protector will lower the maximum current limit and not allow 1REC to exceed its temperature limits.
  • Page 145 Handset. There are currently over 75 status codes that are available with systems. The logic card is capable of reducing the current to the control to alert the operator of a critical fault condition. © BT Products Service Manual 1997-10-23 Return...
  • Page 146 S5.0 5000 Electrical System with TX and TT Card Version noT-code OE35 4.24. Battery Discharge Indication This feature uses the latest in microprocessor technology to provide accurate battery state of charge information and supplies passive and active warning signals to the vehicle operator.

  • Page 147: General Maintenance Instructions

    The truck should not be plugged when the truck is jacked up and the drive wheels are in a free wheeling position. The higher motor speeds can create excessive voltages that can be harmful to the control. © BT Products Service Manual 1997-10-23 Return...

  • Page 148: Trouble-Shooting Instructions

    S5.0 5000 Electrical System with TX and TT Card Version noT-code OE35 Do not hipot (or merger) the control. Unless the terminals of each semiconductor and card are connected together, the control may be damaged. Refer to control manufacturer before hipotting.
  • Page 149 Tools and test equipment required are: (a) 6-volt lamp, 6-volt battery, two A14 diodes (1 Amp 400 volts), clip leads, volt- ohm meter (20,000 ohms per volt) and general hand tools. © BT Products Service Manual 1997-10-23 Return...
  • Page 150 F-code Section C-code S5.0 5000 Electrical System with TX and TT Card Version noT-code OE35 Service Manual 1997-10-23 Return...

  • Page 151: Battery Controller / Hourmeter / Lift Interrupt

    0.1 hours or 6 minutes. Battery Display LED 2 Red, 3 Yellow, 5 Green Hourmeter LCD 2. Electrical 2.1. Voltage This instrument is supplied as a pin selectable dual voltage unit with the voltage of 12/48 VDC. © BT Products Service Manual 1997-04-15 Return...

  • Page 152: Battery Controller (Bc)

    F-code Section C-code S5.3 5230 Battery Controller / Hourmeter / Lift Interrupt Version no T-code 2.1.1. The Contact Voltage and Current Ratings for Switching Resistive Loads. Open Contact Voltage Closed Contact Current Volt Ampere Product 2.1.2. Memory Retention The instrument contains an internal battery (BC) which allows memory retention when external power is removed.
  • Page 153 1.63 1.84 1.68 1.86 1.73 1.91 1.78 1.93 DISCHARGE PIN NO: FUNCTION Hourmeter (-) Key switch (+) Relay arm (+) Relay NC (-) Battery (-) Hourmeter (+) 24 Volt (+) 48 Volt (+) © BT Products Service Manual 1997-04-15 Return...
  • Page 154 F-code Section C-code S5.3 5230 Battery Controller / Hourmeter / Lift Interrupt Version no T-code NOTE! The discharge adjustments can be made at any time during a working cycle before lift lockout. However, discharge potentiometer adjustments made late in a working cycle have little or no effect in delaying the lift lockout in that particular working cycle.

  • Page 155: Troubleshooting

    If it does its memory cell is depleted. This will not affect the discharge function of the instrument if it is always © BT Products Service Manual 1997-04-15...
  • Page 156 F-code Section C-code S5.3 5230 Battery Controller / Hourmeter / Lift Interrupt Version no T-code connected to a fully charged battery and allowed to track its discharge without break in power. NOTE! New instruments are shipped from the factory with a full reading in their memory. The first time the instrument is connected to the truck’s battery it will always show a full charge.
  • Page 157 7 or 8 and pin 5. If battery voltage is measured across these pins and the LCD does not turn on, the instrument is defective. 4.2.2. Hourmeter Glass Icon Does Not Flash If the icon does not flash, the hourmeter is not accumulating © BT Products Service Manual 1997-04-15 Return...
  • Page 158 F-code Section C-code S5.3 5230 Battery Controller / Hourmeter / Lift Interrupt Version no T-code time. The key switch pin 2 must be on at B+, pin 7 or 8 must be connected to B+, and one or both of the hourmeter lines must be active.

  • Page 159: Dash Display

    Connections are made to the dash display by means of five 22 gauge wires to plug “Y” of each SCR control. In some cases, shielded cable must be required to eliminate signal interference. Back View of display © BT Products Service Manual 1997-12-15 Return...

  • Page 160: Location

    S5.3 5230 Dash Display Version no T-code OE35 2. Location The dash display is physically located on the cross member on the mast upright. The display is viewed through windshield when platform is in the fully lowered position. 3. Operational Checks 3.1.

  • Page 161: Status Codes

    Status code will change to -03 if rearward directional switch or -02 if forward directional switch is closed. Status Code -05 Indicates brake foot switch is not closed. Make sure brake foot switch is closed. © BT Products Service Manual 1997-12-15 Return...
  • Page 162 F-code Section C-code S5.3 5230 Dash Display Version no T-code OE35 Service Manual 1997-12-15 Return...

  • Page 163: Ev100 Lx Control Status Codes

    F-code Section C-code S5.7 5410 EV100 LX Control Status Codes Version no T-code OE35 EV100 LX Control Status Codes © BT Products Service Manual 1997-10-22 Return...
  • Page 164 F-code Section C-code S5.7 5410 EV100 LX Control Status Codes Version no T-code OE35 DESCRIPTION MEMOR STATUS CODE RECALL No display on Dash Display or Handset. - BLANK DISPLAY CIRCUIT Traction SYMPTOM Key Switch Display screen on dash display or handset is blank.
  • Page 165 * Disconnect wire at TB6; measure voltage at TB6, should be STATUS INDICATION CRITERIA less than 60% of battery volts. This status code will be displayed when TB6 is greater than 60% battery volts at initial power up. © BT Products Service Manual 1997-10-22 Return...
  • Page 166 F-code Section C-code S5.7 5410 EV100 LX Control Status Codes Version no T-code OE35 DESCRIPTION MEMOR STATUS CODE RECALL Switch input low after initial start up. CIRCUIT Traction SYMPTOM Gate Switches Key Switch Foot Sw. Forward or reverse contactor will not pick-up.
  • Page 167 3.7 volts for solid state type accelerator input. This status code will be displayed when the accelerator input voltage at TB1 is higher than 3.7 volts, and a directional contactor is picked up. © BT Products Service Manual 1997-10-22 Return...
  • Page 168 F-code Section C-code S5.7 5410 EV100 LX Control Status Codes Version no T-code OE35 DESCRIPTION MEMOR STATUS CODE RECALL Accelerator input voltage too low on power up after initial key switch closure. CIRCUIT Traction SYMPTOM Forward or reverse contactor does not pick up.
  • Page 169 Connector Figure 1. STATUS INDICATION CRITERIA This status code is displayed when the battery volts are greater than 2.40 volts per cell at initial start up (see Table A in figure). © BT Products Service Manual 1997-10-22 Return...
  • Page 170 F-code Section C-code S5.7 5410 EV100 LX Control Status Codes Version no T-code OE35 DESCRIPTION MEMOR STATUS CODE RECALL Invalid card type selection CIRCUIT Traction SYMPTOM Forward or reverse contactor will not close. POSSIBLE CAUSE Invalid card type selection * Review function 17 in the Handset Instruction sheets.
  • Page 171 Defective 1A contactor * Check 1A contactor for binding or slow operation when dropping out. Figure 1. STATUS INDICATION CRITERIA This status code is displayed when 1A contactor drop out time exceeds .060 seconds. © BT Products Service Manual 1997-10-22 Return...
  • Page 172 F-code Section C-code S5.7 5410 EV100 LX Control Status Codes Version no T-code OE35 DESCRIPTION MEMOR STATUS CODE RECALL Shorted coil driver for SP contactor CIRCUIT Traction SYMPTOM SP contactor picks up immediately when key switch is closed. POSSIBLE CAUSE Defective coil driver internal to logic card * Replace logic card.
  • Page 173 PZ3 on logic card. Current Sensor Yellow NEG. Figure 1. STATUS INDICATION CRITERIA This status code is displayed when voltage between PY7 and negative is less than 0.84 volts with no current flowing in motor circuit. © BT Products Service Manual 1997-10-22 Return...
  • Page 174 F-code Section C-code S5.7 5410 EV100 LX Control Status Codes Version no T-code OE35 DESCRIPTION MEMOR STATUS CODE RECALL 1REC did not turn off properly. CIRCUIT Traction SYMPTOM Forward or reverse contactors open and close, then can only be closed by opening and closing the key switch.
  • Page 175 * Check that power tips on F and R contactor power tips do not bounce open during operation (ie: travel over speed 2REC bumps or dockplates). Figure 1. STATUS INDICATION CRITERIA This status code is displayed when the 2REC fails to turn on. © BT Products Service Manual 1997-10-22 Return...
  • Page 176 F-code Section C-code S5.7 5410 EV100 LX Control Status Codes Version no T-code OE35 DESCRIPTION MEMOR STATUS CODE RECALL Look ahead test for T2 volts (less than 12% battery volts). CIRCUIT Traction SYMPTOM Forward or reverse contactor will not pick up.
  • Page 177 * Check for shorted armature winding. Current Sensor NEG. Figure 1. STATUS INDICATION CRITERIA This status code is displayed when capacitor volts exceed 225 volts and motor current is greater than 300 amps. © BT Products Service Manual 1997-10-22 Return...
  • Page 178 F-code Section C-code S5.7 5410 EV100 LX Control Status Codes Version no T-code OE35 DESCRIPTION MEMOR STATUS CODE RECALL Excessive capacitor voltage when motor current is low. CIRCUIT Traction SYMPTOM Forward or reverse contactors open and close, then can only be closed by opening and closing the key switch.
  • Page 179 NEG and the motor A2 cable connects to SCR A2. Sensor Yellow NEG. Figure 1. STATUS INDICATION CRITERIA This status code is displayed when the voltage input to PZ4 and PZ3 is the wrong polarity. © BT Products Service Manual 1997-10-22 Return...
  • Page 180 F-code Section C-code S5.7 5410 EV100 LX Control Status Codes Version no T-code OE35 Service Manual 1997-10-22 Return...

  • Page 181: Scr Component Checks

    Remove the two mounting screws and lift card box. NOTE! Do not attempt to remove circuit broad from card box. Reverse procedure to install new control card. Z Plug Y Plug B Plug Terminal 1-6 A Plug Mounting Screw © BT Products Service Manual 1997-04-15 Return...

  • Page 182: Capacitor 1C

    F-code Section C-code S5.3 5230 SCR Component Checks Version no T-code 2. Capacitor 1C Disconnect the battery and discharge the capacitor. Measure ohms Through the capacitor using the Rx10,000 scale. Meter should read zero and the swing slowly to above 100,000 ohms.
  • Page 183 Some SCR’s will operate correctly even if the lamp dose not remain on, particularly with a weak battery. 3. If the lamp cannot be lit under step 2 the SCR is open and must be replaced. © BT Products Service Manual 1997-04-15 Return...

  • Page 184: Rectifiers (3Rec, 4Rec, Diode Blocks)

    F-code Section C-code S5.3 5230 SCR Component Checks Version no T-code NOTE! If you do not have a test light to check the SCR’s as described above, they may be checked for shorts and opens by use of the VOM. NOTE! Measure resistance from anode to cathode (Rx100 scale.

  • Page 185: Filter Block (23Fil, Etc.)

    Rx1 scale, measure choke or reactor winding. Reading should be less then 1 ohm. 11. Replacement of EV100 Components When replacing stud semiconductors such as 3REC and 4REC, it is not necessary to torque these devices to a specific valve. © BT Products Service Manual 1997-04-15 Return...
  • Page 186 F-code Section C-code S5.3 5230 SCR Component Checks Version no T-code NOTE! The use of heat-transfer grease (such as GE Versilube G-350-M or equivalent) is recommended. When replacing module semiconductors such as: 11.1. 1REC, 2REC or 5REC 1 Remove all module connections. (As required) 2 Remove module by backing out the two screws at the device sides.

  • Page 187: Instructions - Ev100 Plugs

    Referring to Figure 1, insert the terminal removal tool into the plug body (which depresses the terminal locking lance). With a gentle push-pull motion on the wire, remove the wire. Figure 1 USE AMP REMOVAL TOOL - 91065-1. © BT Products Service Manual 1997-04-15 Return...
  • Page 188 F-code Section C-code S5.3 5230 SCR Component Checks Version no T-code To insert a terminal into the plug body. Orient Plug Check lance height Referring to Figure 2, orient the plug body as shown with the latch up, and terminal locking lance up. Check that the locking lance protrudes .030 to .060 inches (.8 to 1.5mm).

  • Page 189: Direction Contactor

    Coil Insulation Lockwashe Frame, magnet Locknut Tip, contact Spring Clamp Clamp Armature Tip, contact Washer, flat Base, bus Cover Seat Tip, contact Lockwasher Carrier Tip, contact Screw Bushing Tip, movable Screw Tip, contact © BT Products Service Manual 1997-07-15 Return...

  • Page 190: General Information

    F-code Section C-code S5.7 5440 Direction Contactor Version no T-code 1. General Information 1. Check armature and movable contacts for freedom of movement by depressing movable arm with a screwdriver or small rod. Check for any restrictions to movement and for return of parts by action of spring.
  • Page 191 If parts are found to be damaged, they should be replaced with new ones. 21. Inspect springs for damage. Replace damage parts with new ones. 22. Inspect spring seats for damage (cracks, breaks, etc.). Replace damaged parts with new. © BT Products Service Manual 1997-07-15 Return...
  • Page 192 F-code Section C-code S5.7 5440 Direction Contactor Version no T-code 23. Inspect the thin washer located on the armature for cracks, etc., and security of mounting. Material on the armature stem has been “up set” in four places to retain the washer. Inspect all four places to be certain this thin washer is properly retained and free to rotate about the armature stem.
  • Page 193 Be certain the notches in each bar fit properly to the screw guides of each support. 34. Position Insulators (13) over the bus bar/contacts and supports as shown in illustration on opposite page. Be © BT Products Service Manual 1997-07-15 Return...
  • Page 194 F-code Section C-code S5.7 5440 Direction Contactor Version no T-code certain the openings in the bottom of the insulators face downward and that the insulators are properly seated in the slots of the supports. 35. Assemble spacer, upper bus bar/contacts over the insulators.

  • Page 195: Speed Contactor

    1A Speed Contactor POS. POS. POS. DESCRIPTIO DESCRIPTION DESCRIPTION Base, magnet Bushing Clamp Coil Carrier Lockwashe Frame, magnet Tip, movable Screw, machine Spring Suppression Armature Spring Seat Base, bus Washer, flat Tip, contact Nut, lock © BT Products Service Manual 1997-10-29 Return...

  • Page 196: General Information

    Section C-code S5.7 5450 1A Speed Contactor Version no T-code OE35 1. General Information 1. Check armature and movable contacts for freedom of movement by depressing movable arm with a screwdriver or small rod. Check for any restrictions to movement and for return of parts by action of spring.
  • Page 197 14. Inspect coil for damage. Inspect alignment holes to be certain they are perfectly round and not “egg” shaped (damaged). Inspect coil terminals for damage. Replace damaged parts with new ones. © BT Products Service Manual 1997-10-29 Return...

  • Page 198: Assembly

    C-code S5.7 5450 1A Speed Contactor Version no T-code OE35 3. Assembly 1. Install coil on contactor base. Terminal connections must point outward away from base. Be certain the coil is properly located over the base alignment pins. 2. Locate Bracket (3) on coil and on the base. Be certain the bracket alignment pins properly seat in the holes on the top side of each coil.
  • Page 199 9. Use a bar or rod to move contacts. Be sure movement is free of binding and that tips are in correct orientation and tips contact correct mating parts. 10. Install contactor assembly to panel base plate. © BT Products Service Manual 1997-10-29 Return...
  • Page 200 F-code Section C-code S5.7 5450 1A Speed Contactor Version no T-code OE35 Service Manual 1997-10-29 Return...

  • Page 201: Electrical System Troubleshooting

    “Forward” direction refers to travel with forks trailing. “Reverse” direction refers to travel in the fork direction. © BT Products Service Manual 1996-10-15 Return...
  • Page 202 5460 Electrical System Troubleshooting Version no T-code OE35 After the final test is completed the truck should be repaired and operating properly. If it is not then you must verify your test results and possibly re-evaluate the failure symptoms. If you still have not repaired the truck then you should call your local dealer for assistance.

  • Page 203: Control Circuits And Power Circuits

    2.5 MPH. Function 12 controls the speed at lift heights above 150 inches when travelling in a straight line. The top of the truck must be 1.0 MPH. © BT Products Service Manual 1996-10-15 Return...
  • Page 204 5460 Electrical System Troubleshooting Version no T-code OE35 Function #13 controls the speed at lift heights above 150 inches when the truck is steered beyond 10 degrees off center and when above 226 inches. The truck must not travel although contactors will close.

  • Page 205: Electrical System Troubleshooting Charts

    0 volts, repair open wiring from fuse 3 to key switch. 4. Negative side of key switch, wire #14 (ON position). 0 volts, replace key switch. 5. Positive side of start switch 0 volts, repair open wiring from key switch to © BT Products Service Manual 1996-10-15 Return...
  • Page 206 F-code Section C-code S5.4 5460 Electrical System Troubleshooting Charts Version no T-code OE35 start switch. 6. Negative side of start switch (push button engaged). 0 volts, replace start switch. 7. Positive side emergency disconnect contactor coil. 0 volts, repair open wiring from push button to contactor coil.
  • Page 207 0 volts, repair faulty negative connection between SCR panel negative stand off terminal and battery negative. Possible failure - Emergency disconnect contactor tips. 2. Negative side of 300 AMP power fuse, fuse 2. © BT Products Service Manual 1996-10-15 Return...
  • Page 208 S5.4 5460 Electrical System Troubleshooting Charts Version no T-code OE35 0 volts, replace 300 AMP fuse. 3. Negative side of 400 AMP power fuse, fuse 1. 0 volts - replace 400 AMP fuse. 1.2 Steering and Brake Release Pump 1.2.1 Steering pump will not run, contactor does not close.
  • Page 209 Test for battery voltage at: 1. Positive side of brake interlock switch. 0 volts, repair open wire #17 from staging chain tension to brake switch. © BT Products Service Manual 1996-10-15 Return...
  • Page 210 S5.4 5460 Electrical System Troubleshooting Charts Version no T-code OE35 2. Negative side of brake interlock switch. 0 volts, replace brake interlock switch. 3. Positive side of directional switches. 0 volts, repair open wiring from brake switch to directional switches.
  • Page 211 Battery volts - repair open wiring to battery negative. 1.4.2 No high speed lift, low speed lift okay. Condition for test: Battery plugged in, key switch in “on” position, start button pushed and released, emergency disconnect contactor closed, foot pedal © BT Products Service Manual 1996-10-15 Return...
  • Page 212 S5.4 5460 Electrical System Troubleshooting Charts Version no T-code OE35 switch closed, gate switches closed, lift activated for high speed lift, lift platform raised minimum of 4 inches. Test for battery voltage at: 1. Positive side of platform lift chain tension switch, wire #19.
  • Page 213 “on” position, start button pushed and engaged, emergency disconnect contactor closed, foot pedal switch closed, gate switches closed, platform raised above 24 inches, slow speed lowering switch activated. Test for battery voltage at: © BT Products Service Manual 1996-10-15 Return...
  • Page 214 C-code S5.4 5460 Electrical System Troubleshooting Charts Version no T-code OE35 1. Positive side of slow speed lowering switch, wire #17. 0 volts - repair open wire #17 from mast column chain tension switch to slow speed lowering switches. 2. Negative side of slow speed lowering switch.
  • Page 215 0 volts - repair open wiring from 24 inch limit switch to #2 lowering valve coil. 6. Negative side of #2 lowering valve coil. Battery volts - repair open wire from lowering valve coil to battery negative, wire #22. © BT Products Service Manual 1996-10-15 Return...
  • Page 216 F-code Section C-code S5.4 5460 Electrical System Troubleshooting Charts Version no T-code OE35 Service Manual 1996-10-15 Return...

  • Page 217: Pump Contactor

    Pump Contactor POS. POS. POS. DESCRIPTIO DESCRIPTION DESCRIPTION Base, magnet Bushing Clamp Coil Carrier Lockwashe Frame, magnet Tip, movable Screw, machine Spring Suppression Armature Spring Seat Base, bus Washer, flat Tip, contact Nut, lock © BT Products Service Manual 1997-10-29 Return...

  • Page 218: General Information

    Section C-code S5.7 5610 Pump Contactor Version no T-code OE35 1. General Information 1. Check armature and movable contacts for freedom of movement by depressing movable arm with a screwdriver or small rod. Check for any restrictions to movement and for return of parts by action of spring.
  • Page 219 14. Inspect coil for damage. Inspect alignment holes to be certain they are perfectly round and not “egg” shaped (damaged). Inspect coil terminals for damage. Replace damaged parts with new ones. © BT Products Service Manual 1997-10-29 Return...

  • Page 220: Assembly

    C-code S5.7 5610 Pump Contactor Version no T-code OE35 3. Assembly 1. Install coil on contactor base. Terminal connections must point outward away from base. Be certain the coil is properly located over the base alignment pins. 2. Locate Bracket (3) on coil and on the base. Be certain the bracket alignment pins properly seat in the holes on the top side of each coil.
  • Page 221 9. Use a bar or rod to move contacts. Be sure movement is free of binding and that tips are in correct orientation and tips contact correct mating parts. 10. Install contactor assembly to panel base plate. © BT Products Service Manual 1997-10-29 Return...
  • Page 222 F-code Section C-code S5.7 5610 Pump Contactor Version no T-code OE35 Service Manual 1997-10-29 Return...

  • Page 223: Steering Pump Contactor

    Steering Pump Contactor POS. POS. POS. DESCRIPTIO DESCRIPTION DESCRIPTION Base, magnet Bushing Clamp Coil Carrier Lockwashe Frame, magnet Tip, movable Screw, machine Spring Suppression Armature Spring Seat Base, bus Washer, flat Tip, contact Nut, lock © BT Products Service Manual 1997-10-29 Return...

  • Page 224: General Information

    Section C-code S5.7 5610 Steering Pump Contactor Version no T-code OE35 1. General Information 1. Check armature and movable contacts for freedom of movement by depressing movable arm with a screwdriver or small rod. Check for any restrictions to movement and for return of parts by action of spring.
  • Page 225 14. Inspect coil for damage. Inspect alignment holes to be certain they are perfectly round and not “egg” shaped (damaged). Inspect coil terminals for damage. Replace damaged parts with new ones. © BT Products Service Manual 1997-10-29 Return...

  • Page 226: Assembly

    C-code S5.7 5610 Steering Pump Contactor Version no T-code OE35 3. Assembly 1. Install coil on contactor base. Terminal connections must point outward away from base. Be certain the coil is properly located over the base alignment pins. 2. Locate Bracket (3) on coil and on the base. Be certain the bracket alignment pins properly seat in the holes on the top side of each coil.
  • Page 227 9. Use a bar or rod to move contacts. Be sure movement is free of binding and that tips are in correct orientation and tips contact correct mating parts. 10. Install contactor assembly to panel base plate. © BT Products Service Manual 1997-10-29 Return...
  • Page 228 F-code Section C-code S5.7 5610 Steering Pump Contactor Version no T-code OE35 Service Manual 1997-10-29 Return...

  • Page 229: Ev100 Handset Operation

    The Handset is a multi-functional tool to be used with the EV100 LX and LXT SCR controls. The Handset consist of a Light Emitting Diode (LED) display and a keyboard for data entry. © BT Products AB Service Manual 1997-09-15 Return...

  • Page 230: Purpose

    F-code Section C-code S5.5 5710 EV100 Handset Operation Version no T-code 2. Purpose The purpose of the Handset is to allow authorized personal to perform the following functions: Monitor existing system fault codes for both traction SCR systems. Monitor intermittent random status code. Monitor battery state of change on LXT systems.

  • Page 231: Operation

    Display traction hourmeter for four seconds NOTE! The truck can be operated with the handset connected, however, the adjustment knob must be set fully clockwise to insure the control operates at top speed. © BT Products AB Service Manual 1997-09-15 Return...

  • Page 232: Function Set-Up Procedures

    F-code Section C-code S5.5 5710 EV100 Handset Operation Version no T-code 4. Function Set-Up Procedures Before making any adjustments to the WARNING control you must consult the operating and maintenance instructions supplied by the vehicle manufacturer. Failure to follow proper set up instructions could result in mis-operation or damage to the control system.
  • Page 233 EV100 Handset Operation Version no T-code disconnected before operation. NOTE! You can return to the segment check mode at any time, by holding down the ESC key until 8888 appears in the display. © BT Products AB Service Manual 1997-09-15 Return...

  • Page 234: Description And Location

    F-code Section C-code S5.5 5710 EV100 Handset Operation Version no T-code 5. Description and Location Service Manual 1997-09-15 Return...

  • Page 235: Function Numbers For Controllers

    0.5 volts or less then 50 ohms. Range 0.1 to 22.0 seconds 0 to 255 Resolution 0.084 seconds per set unit Example: Setting of 20 = 1.8 seconds C/A and 2.0 1A time. © BT Products AB Service Manual 1997-09-15 Return...
  • Page 236 F-code Section C-code S5.5 5710 EV100 Handset Operation Version no T-code 6.4. Function 4 Current Limit (Push 4) This function allows for the adjustment of the current limit of the control. The rating of the control will determine the range of adjustment for this function.
  • Page 237 Speed Limit 2 (SL2) (Push 12) Same as function 11 except using SL2 limit switch for input. 6.9. Function 13 Speed Limit 3 (SL3) (Push 13) Same as function 11 except using SL3 limit switch for input. © BT Products AB Service Manual 1997-09-15 Return...
  • Page 238 F-code Section C-code S5.5 5710 EV100 Handset Operation Version no T-code 6.10. Function 14 Internal Resistance Compensation (Push 14) This function is used when the Battery Discharge Indicator is present. Adjustment of this function will improve the accuracy of the BDI. In order to make this setting the voltage drop of the battery under load must first be determined by following the steps listed below.
  • Page 239 Example: If plug distance current Function 5 is set at 500 amps, then set pedal plug current at 500 amps. With this setting pedal position will have no effect on plugging distance. © BT Products AB Service Manual 1997-09-15 Return...
  • Page 240 F-code Section C-code S5.5 5710 EV100 Handset Operation Version no T-code 6.13. Function 17 Card Type Selection (Push CONT and 2) This function allows for the selection of the card type used for your vehicle's application. The table below shows the setting to select card application type depending on which control card is used.
  • Page 241 Pick up on foot pedal switch closure and time delay drop out on foot pedal switch opening. Range 1.5 to 65 seconds Setting Between 0 and 128 Resolution .5 seconds per set unit Example: Setting of 20 = 10.5 seconds © BT Products AB Service Manual 1997-09-15 Return...
  • Page 242 F-code Section C-code S5.5 5710 EV100 Handset Operation Version no T-code Service Manual 1997-09-15 Return...

  • Page 243: Hydraulic System

    Hydraulic System Version no T-code OE35 Hydraulic System 1. Hydraulic Schematic Component Enclosure Reservoir (Vented) Hydraulic Lines Joining Cylinder (Single Acting) Motor (Electric) Cylinder (Double Acting) Hydraulic Pump Check Valve Hydraulic Lines Crossing Filter © BT Products Service Manual 1997-10-23 Return...

  • Page 244: General Information

    C-code M6.0 6000 Hydraulic System Version no T-code OE35 2. General Information The hydraulic system consists of a compact hydraulic pump unit, including a electric solenoid valve, pressure relief valve and a cylinder(s) for lifting the platform. 2.1. Lift/lower During lifting the duplex pump is turned by a single electric motor.
  • Page 245 With the pump rotating and the solenoid valve closed, oil pressure is directed to the pump outlet. This oil pressure operates the brake release cylinder and pushes the brake actuator arm © BT Products Service Manual 1997-10-23 Return...

  • Page 246: Maintenance

    6000 Hydraulic System Version no T-code OE35 inside the transmission to release the brakes. A pressure relief valve holds the oil pressure at 180 psi. When the pump motor is turned off the solenoid is de- energized and opens back up. This allows oil pressure in the cylinder to be released and brakes are applied by springs inside the transmission.

  • Page 247: Hydraulic Troubleshooting

    The pressure gauge should be reading the set pressure of the relief valve. Remove pressure on the system by actuating the solenoid operated release valve. © BT Products Service Manual 1997-10-23 Return...
  • Page 248 6000 Hydraulic Troubleshooting Version no T-code OE35 The normal troubles that may occur with the pump assembly have been grouped under three headings: Failure to (A) Raise (B) Hold (C) Lower the load. One or more of the listed trouble sources may be causing improper operation. Refer to the proper heading (i.e.
  • Page 249 2. Internal damage in pump. Repair or replace pump. C. No low speed lift Pump motor runs, high speed lift appears okay. 1. Check lift solenoid valve. Repair or replace solenoid valves. 2. Check adjustable restrictor. © BT Products Service Manual 1997-10-23 Return...
  • Page 250 F-code Section C-code M6.0 6000 Hydraulic Troubleshooting Version no T-code OE35 Service Manual 1997-10-23 Return...

  • Page 251: Lift Pump Assembly

    POS. POS. DESCRIPTION DESCRIPTION DESCRIPTION Seal, shaft Plate, wear Washer, flat Body Gear, drive Screw, cap Pin, dowel Plate, thrust Plug, pipe Nylatron Seal, gasket Gear, driven Spacer, rubber Cover-side, port Kit, seal © BT Products Service Manual 1997-12-15 Return...

  • Page 252: Removal

    M6.1 6140 Lift Pump Assembly Version no T-code OE35 1. Removal The hydraulic pump and motor assembly must be removed from the truck in order to separate the pump and motor. The platform must be fully lowered before removing pump.

  • Page 253: Disassembly

    7. Scribe a line on both body and base of pump to aid when reassembling. 8. Secure pump in vise (with soft jews use light clamping pressure) with shaft end down, remove screws (12) and washers (11). © BT Products Service Manual 1997-12-15 Return...
  • Page 254 6140 Lift Pump Assembly Version no T-code OE35 NOTE! During disassembly, take special note of the wear patterns on wear plate (8), thrust plate (6), and body (2). Relate these patterns th the inlet and outlet sides of the pump. The large port in the rear cover (10) always corresponds to the inlet side of the pump.
  • Page 255 13. Invert pump body with shaft seal up. Remove shaft seal (1) by prying it out with a large screwdriver. WARNING Care should be taken not to damage (gouge the shaft seal bore, this will result in shaft seal leakage. © BT Products Service Manual 1997-12-15 Return...

  • Page 256: Inspection

    C-code M6.1 6140 Lift Pump Assembly Version no T-code OE35 3. Inspection NOTE! CLEANLINESS! Perform procedures in a clean environment. Make sure all parts are cleaned before disassembly and kept clean during assembly. 1. Thoroughly clean all parts and remove all nicks and burrs with emery cloth.
  • Page 257 F-code Section C-code M6.1 6140 Lift Pump Assembly Version no T-code OE35 usable, remove wipe burr with suitable de-burring tool. © BT Products Service Manual 1997-12-15 Return...

  • Page 258: Assembly

    C-code M6.1 6140 Lift Pump Assembly Version no T-code OE35 4. Assembly NOTE! CLEANLINESS! Perform procedures in a clean environment. Make sure all parts are cleaned before disassembly and kept clean during assembly. 1. All parts should be cleaned and dried thoroughly.
  • Page 259 (3), aline scribe marks on cover and body. 10. Insert cap screws (12) and washers in pump body. Torque screws to 34 to 38 ft-lb. 11. Check that drive shaft turns with adjustable wrench without evidence of mechanical bind. © BT Products Service Manual 1997-12-15 Return...
  • Page 260 F-code Section C-code M6.1 6140 Lift Pump Assembly Version no T-code OE35 Service Manual 1997-12-15 Return...

  • Page 261: Mast, 2 Stage

    F-code Section C-code S7.0 7110 Mast, 2 Stage Version no T-code OE35 Mast, 2 Stage POS. POS. DESCRIPTION DESCRIPTION Platfor Pin, dowel Column, inner Screw, cap Screw, cap Column, outer Pin, cotte © BT Products Service Manual 1996-10-15 Return...

  • Page 262: Shimming Mast On Truck

    Section C-code S7.0 7110 Mast, 2 Stage Version no T-code OE35 1. Shimming Mast on Truck. When blocking mast columns to prevent WARNING lowering, always block both sides of the column. Otherwise, the truck could tip over on its side.
  • Page 263 Lower platform down and out of inner column. Set platform away from truck. 5. Attach a hoist to top of inner column and hoist to loosen lift chains. This will allow removal of lift chain anchor pins. © BT Products Service Manual 1996-10-15 Return...
  • Page 264 7110 Mast, 2 Stage Version no T-code OE35 6. Remove cap screw on top of inner column which secures lift cylinder. Once column is lifted with hoist, the lift cylinder is free to move or fall. Secure lift cylinder in place.
  • Page 265 Retighten locknuts on chain anchors. 17. Test operation of mast and check for tight or loose spots and reshim as needed. Check operation first with no load, then with capacity rated load. © BT Products Service Manual 1996-10-15 Return...

  • Page 266: Two Stage Mast

    C-code S7.0 7110 Mast, 2 Stage Version no T-code OE35 2. Two Stage Mast 2.1. Removal 1. Disconnect battery and remove from unit. 2. The truck will have to be hoisted and blocked about 6 inches off the floor. Always make sure unit is on level surface WARNING before work can begin.
  • Page 267 1/2 in. to 1 in. before platform raises slightly. 8. Retighten locknuts on chain anchors. 9. Grease all chain sheaves. 10. Bleed air from cylinder. 11. Install and connect battery and test operation of mast and unit. © BT Products Service Manual 1996-10-15 Return...
  • Page 268 C-code S7.0 7110 Mast, 2 Stage Version no T-code OE35 2.3. Disassembly 1. Lower mast assembly to a horizontal position before work can begin. 2. Remove lift chain anchors, lift chain, electrical cable and hydraulic hose from mast. 3. Remove a cap screw from top of inner column securing cylinder rod end.
  • Page 269 0.030 in. shim. Maximum clearance must not exceed 0.030 7. Install lift cylinder assembly. 8. Install grease fittings in pins, if removed. © BT Products Service Manual 1996-10-15 Return...
  • Page 270 S7.0 7110 Mast, 2 Stage Version no T-code OE35 9. Press roller bearings in lift chain sheaves, grease roller bearings, and slide inner races in roller bearings. 10. Install shim washers on either side of lift chain sheaves and install in inner column. Slide pins...

  • Page 271: Mast, 3 Stage

    F-code Section C-code S7.1 7110 Mast, 3 Stage Version no T-code OE35 Mast, 3 Stage POS. POS. DESCRIPTION DESCRIPTION Platfor Screw, cap Column, inner Column, intermediate Pin, cotte Column, outer © BT Products Service Manual 1996-10-15 Return...

  • Page 272: Shimming Mast On Truck

    Section C-code S7.1 7110 Mast, 3 Stage Version no T-code OE35 1. Shimming Mast on Truck. When blocking mast columns to prevent WARNING lowering, always block both sides of the column. Otherwise, the truck could tip over on its side.
  • Page 273 4. Remove chain anchor pins, steering wheel chain, and electrical cable. Hydraulically lift up inner column enough to remove platform. Lower platform down and out inner column. Place it away from truck. © BT Products Service Manual 1996-10-15 Return...
  • Page 274 S7.1 7110 Mast, 3 Stage Version no T-code OE35 5. Attach hoist to top of inner column and hoist to loosen lift chain. This will allow removal of lift chain anchor pins. 6. Before disconnecting hoses and fittings from inner column, thoroughly clean off all outside dirt around fittings.
  • Page 275 (wheel nut) and locknuts (jam nuts) torqued to 200 ft-lb. (271 N •m). Chains are to be centered on sheaves within 1/32 in. 21. Connect electrical cable and attachment hydraulic hoses. © BT Products Service Manual 1996-10-15 Return...
  • Page 276 7110 Mast, 3 Stage Version no T-code OE35 22. Remove hoist from mast and lower unit to floor. 23. Install and connect battery to unit. 24. Loosen locking nuts on lift chain anchors. Adjust nuts until both chains are free of twists and of equal tension.

  • Page 277: Three Stage Mast

    After disconnecting hose, immediately cap ports on both cylinder and hoses. 7. Disconnect electrical cable attachment hydraulic hoses from mast. 8. Remove four mast mounting bolts and hoist to remove mast from unit. © BT Products Service Manual 1996-10-15 Return...
  • Page 278 C-code S7.1 7110 Mast, 3 Stage Version no T-code OE35 2.2. Installation 1. Install mast on unit using four mast mounting bolts securing mast in place. Torque to 260 ft-lb. (350 N•m). 2. Connect hydraulic hoses to lift cylinders. 3. Hydraulically raise inner column enough to get platform in.
  • Page 279 8. Pull intermediate column straight forward until it stops (hits bearings) and then 90 degrees straight up from outer column. 9. Remove mast bearings and shim washers from all columns. 10. Thoroughly clean all parts. © BT Products Service Manual 1996-10-15 Return...
  • Page 280 Section C-code S7.1 7110 Mast, 3 Stage Version no T-code OE35 2.4. Assembly 1. Thoroughly clean all parts and air dry WARNING Be extremely careful when working with solvent. Even a small explosion or fire could cause injury or death.
  • Page 281 16. Install electrical sheave on intermediate column and secure with a cap screw and lockwasher. 17. Push intermediate and outer columns together and install cap screw in intermediate column to secure staging lift cylinder. © BT Products Service Manual 1996-10-15 Return...
  • Page 282 S7.1 7110 Mast, 3 Stage Version no T-code OE35 18. Install lift chain anchors through outer column and thread wheel nut on anchors and secure with jam nut. 19. Install lift chain on chain anchors and secure with chain pins. After chain pins have been installed, run lift chain over chain sheaves, making sure chain and sheaves are properly aligned.

  • Page 283: Lift Cylinder, 2 Stage

    NO seals on the lower end of the cylinder rod. The lift cylinder can be resealed without removing from the truck. NOTE! CLEANLINESS! Perform procedures in a clean environment. Make sure all parts are cleaned before disassembly and kept clean during assembly. © BT Products Service Manual 1997-12-15 Return...

  • Page 284: Cylinder Repair

    C-code S7.3 7310 Lift Cylinder, 2 Stage Version no T-code OE35 1. Cylinder Repair 1.1. Removal 1. Park the truck on a level surface and apply the brake. 2. Fully extend the cylinder to inspect the rod (8) for gouges or pits. If gouges or pits are detected, then the cylinder must be removed for repair.
  • Page 285 3. Check hydraulic oil level in tank and fill if needed. 4. Connect battery. 5. Test for proper operation. 6. Recheck hydraulic oil level in tank after air is removed from hydraulic system and fill if needed. © BT Products Service Manual 1997-12-15 Return...
  • Page 286 F-code Section C-code S7.3 7310 Lift Cylinder, 2 Stage Version no T-code OE35 Service Manual 1997-12-15 Return...

  • Page 287: Freelift Cylinder, 3 Stage

    250/300 ft./lbs. POS. POS. POS. DESCRIPTION DESCRIPTION DESCRIPTION Retainer Rod, cylinder Wiper, cylinder O ring Tube, cylinder Ring, backup Spring Screw Ball, steel Bearing Washer, seal Kit, seal Piston Ring, wear Seal Ring, wear © BT Products Service Manual 1997-12-15 Return...

  • Page 288: Freelift Cylinder Repair

    Freelift Cylinder, 3 Stage Version no T-code OE35 The lift cylinders are the positive displacement type, meaning there are NO seals on the lower end of the cylinder rod. The lift cylinder can be resealed without removing from the truck.
  • Page 289 The “lip” of the wiper must face outward. It is not necessary to replace wear ring (6), unless the rod was removed for repair. 1.4. Installation 1. Install crosshead, chains, hoses and electric cables. 2. Connect battery. 3. Test for proper operation. © BT Products Service Manual 1997-12-15 Return...
  • Page 290 F-code Section C-code S7.3 7310 Freelift Cylinder, 3 Stage Version no T-code OE35 Service Manual 1997-12-15 Return...

  • Page 291: Staging Cylinder, 3 Stage

    POS. DESCRIPTION DESCRIPTION Screw Ring, wear Washer, seal Piston Cylinder tube, 1 Port Ring, retainer Cylinder tube, 2 Port Rod, cylinder Plugger assembly O ring Spring Bearing Plug Seal, rod O ring Wiper © BT Products Service Manual 1997-07-15 Return...
  • Page 292 S7.4 7310 Staging Cylinder, 3 Stage Version no T-code OE35 1.1. Removal 1. Park the truck on a level surface and apply the brake. 2. Fully extend the cylinders to inspect the rod (12) for gouges or pits. If gouges or pits are detected, then the cylinder must be removed for repair.
  • Page 293 F-code Section C-code S7.4 7310 Staging Cylinder, 3 Stage Version no T-code OE35 1.4. Installation 1. Install crosshead, chains, hoses, and electric cables. 2. Test for proper operation. © BT Products Service Manual 1997-07-15 Return...
  • Page 294 F-code Section C-code S7.4 7310 Staging Cylinder, 3 Stage Version no T-code OE35 Service Manual 1997-07-15 Return...

  • Page 295: Micro 70 Wire Guidance Important Information

    1. Disconnect battery from truck. 2. Remove 1A & 20A fuse from holder. 3. On the center relay move wire #84 from relay terminal position #4 to relay terminal position #1. 4. Connect temporary battery to truck. © BT Products Service Manual 1997-10-24 Return...
  • Page 296 F-code Section C-code S8.0 8200 Micro 70 Wire Guidance Important Information Version no T-code OE35 Move wire #84 from Position #1 to Position #4 1A Fuse 1A Fuse 20A Fuse 20A Fuse Drawing showing location of fuses and wire Service Manual...

  • Page 297: Micro 70 Wire Guidance

    Micro 70 Wire Guidance 1. Electrical Schematic Part 1 NOTE! Items represented with dashed lines are options that may not be present on all models. See Truck Electrical Schematic Part 2 for further information. © BT Products Service Manual 1997-10-24 Return...

  • Page 298: Electrical Schematic Part 2

    F-code Section C-code S8.0 8200 Micro 70 Wire Guidance Version no T-code OE35 2. Electrical Schematic Part 2 See Electrical Schematic Part 2 for further information. Service Manual 1997-10-24 Return...
  • Page 299 F-code Section C-code S8.0 8200 Micro 70 Wire Guidance Version no T-code OE35 3. Electrical Schematic Part 3 © BT Products Service Manual 1997-10-24 Return...

  • Page 300: Electrical Schematic Part 3

    F-code Section C-code S8.0 8200 Micro 70 Wire Guidance Version no T-code OE35 4. Electrical Schematic Part 4 Service Manual 1997-10-24 Return...

  • Page 301: Cautions And Warnings

    Stay clear of raised platforms or forks and WARNING rotating or moving parts. Failure to do so could result in personal injury or property damage. © BT Products Service Manual 1997-10-24 Return...
  • Page 302 If a test indicates a failed Micro controller it is recommended that the remaining tests be completed and all test results written down. After the tests are completed call the BT Prime-Mover service department before replacing the Micro 70 controller. Service Manual 1997-10-24 Return...

  • Page 303: Operation Information

    6. Operation Information 6.1. Modes of operation. There are two modes of operation for the N.D.C Micro 70 wire guided steering system on the BT OE35 order selector. 1. Automatic mode Used for on-wire guidance of the truck in the guided aisle.
  • Page 304 8200 Micro 70 Wire Guidance Version no T-code OE35 NOTE! The approach angle of the truck must not be greater than 20 degrees when acquiring the guidewire. If the truck approaches the guidewire at too great an angle or too high a speed the Micro 70 system may not acquire the guidewire.
  • Page 305 Drive the truck along the guided aisle allowing the Micro 70 system to control the steering. The truck © BT Products Service Manual 1997-10-24 Return...
  • Page 306 S8.0 8200 Micro 70 Wire Guidance Version no T-code OE35 must be moved at least two truck lengths after the "on wire" light has turned on before the travel direction can be reversed. 6.3. Daily operational checks Operational checks are performed for operator safety and to prevent damage to the facility or truck.

  • Page 307: Component Function And Relationship

    Micro 70 controller. The FTI 7 also selects the multiplier for the feedback signal to the controller. When the system is in the acquisition mode the feedback signal is amplified to the © BT Products Service Manual 1997-10-24 Return...
  • Page 308 8200 Micro 70 Wire Guidance Version no T-code OE35 controller at a 1X gain for better wire acquisition. After the system has acquired the wire this signal is amplified to a 10X gain for better guidance while on wire. The FSA Mobicon Steering Servo Amplifier and the steer motor are the output components of the Micro 70 guidance system.

  • Page 309: Truck Set Up On Site

    T-code OE35 8. Truck Set Up On Site New trucks delivered from the BT factory with N.D.C Micro 70 guidance systems have been fully assembled, test run, and adjusted at the factory. The load wheel antenna and mounting bracket has been removed for shipping.
  • Page 310 S8.0 8200 Micro 70 Wire Guidance Version no T-code OE35 Potentiometer to FTI 7 connector K2. 11. Reconnect battery and restart truck. 12. Connect volt meter between battery negative and FTI 7 connector K3, pin 3. 13. Loosen set screw on Feed-back Potentiometer to unlock potentiometer shaft.
  • Page 311 For instance, if the truck runs to the left side of the guidewire in the load wheel direction of travel then move the load wheel antenna towards the left side of the truck. © BT Products Service Manual 1997-10-24 Return...

  • Page 312: Troubleshooting Information

    8200 Micro 70 Wire Guidance Version no T-code OE35 9. Troubleshooting Information To use this troubleshooting guide go to the appropriate chart that best describes the symptoms of the failure. Perform the checks indicated to trace the possible causes of the failure.
  • Page 313 1. A digital multimeter (DVOM) such as a Fluke 8060A or equivalent. 2. Common mechanic's hand tools. 3. Wiring diagrams and repair manual. 4. A functioning line driver and guide path. © BT Products Service Manual 1997-10-24 Return...
  • Page 314 Micro 70 Wire Guidance Version no T-code OE35 The following is a list of operating symptoms of failed trucks. Find the symptom that best describes the operation of the failed truck and then follow the instructions for testing in the chart.

  • Page 315: Troubleshooting Charts

    If not battery volts, repair open wire 94 between fuse 1 and emergency disconnect contactor interlock switch. d. Check for battery volts at wire 96 connected to emergency disconnect contactor interlock switch. If © BT Products Service Manual 1997-10-24 Return...
  • Page 316 8 of #2 control relay. If not zero volts, repair open wire 13 from 2 control relay to truck negative wire 13. Replace #2 control relay. m. Re-check truck symptoms and continue with other test. Call BT Prime-Mover service department with Service Manual 1997-10-24 Return...
  • Page 317 Make the following tests with the Micro 70 system in the auto mode and the truck over the guidewire so that the green "on wire" light is on. The foot pedal must be depressed so that the © BT Products Service Manual 1997-10-24...
  • Page 318 8200 Micro 70 Wire Guidance Version no T-code OE35 power steering motor is running. c. Check for battery volts at wire 2 on fuse 2, 20 amp slow blow control fuse. If not battery volts, repair open wire 2 between battery positive and fuse 2.
  • Page 319 (2 in.) of total movement. Measure the voltage between terminals MO and M1 on the FSA. It does not matter which wire the positive lead or negative lead of the volt meter is © BT Products Service Manual 1997-10-24 Return...
  • Page 320 8200 Micro 70 Wire Guidance Version no T-code OE35 connected to. As the antenna is moved across the guidewire check for the voltage between MO and M1 to change from positive to negative up to battery volts. If the voltage does not change as stated replace the FSA.
  • Page 321 (2 in.) of total movement. Measure the voltage between terminals K8-11, S+ red wire, and K8-15, S-black wire, on the Micro 70. It © BT Products Service Manual 1997-10-24 Return...
  • Page 322 8200 Micro 70 Wire Guidance Version no T-code OE35 does not matter which wire the positive lead or negative lead of the volt meter is connected to. As the antenna is moved across the guidewire check for the voltage between S+ and S- to change from positive ten volts (+10 volts) to negative ten volts (- 10 volts).
  • Page 323 Check for 5 volts between the red wire on terminal 1 of the steering feedback potentiometer and the black wire on terminal 3 of the steering feedback potentiometer. If not 5 volts repair open red or black © BT Products Service Manual 1997-10-24 Return...
  • Page 324 Section C-code S8.0 8200 Micro 70 Wire Guidance Version no T-code OE35 wire between FTI 7 and steering feedback potentiometer. The following tests use K1-2 on the Micro 70 controller for the volt meter negative connection e. With the steering in the straight ahead position check for 5 volts on the white wire on terminal 2 of the steering feedback potentiometer.
  • Page 325 75 to 150 milliamps. c. Check for damaged antennas and properly mounted antennas. If damaged, replace antennas. The following tests are to be made with the truck power © BT Products Service Manual 1997-10-24 Return...
  • Page 326 8200 Micro 70 Wire Guidance Version no T-code OE35 turned on and the Micro 70 system in auto mode. d. Check for negative (-) 12 volts between K4-1 and K4-4 on the Micro 70 controller. The positive lead of the volt meter should be on K4-1 and the negative lead on K4-4.
  • Page 327 Check for 5 volts at K1-2 on the FTI 7. If not 5 volts, +/- 0.1 volts, disconnect K1 on FTI 1 and retest. If still not 5 volts, replace FTI 7 and readjust system. © BT Products Service Manual 1997-10-24...
  • Page 328 8200 Micro 70 Wire Guidance Version no T-code OE35 b. Check for 5 volts at the black wire on terminal 1 of the tachometer. If not 5 volts, +/- 0.1 volts, repair open black wire between FTI 7 and tachometer.
  • Page 329 If the truck runs off the wire with the antennas on opposite sides of the guidewire the problem is likely in the adjustment of the antennas. © BT Products Service Manual 1997-10-24 Return...
  • Page 330 F-code Section C-code S8.0 8200 Micro 70 Wire Guidance Version no T-code OE35 Service Manual 1997-10-24 Return...
  • Page 331 Return...
  • Page 332 BT Prime-Mover, Inc., 3305 N. Highway 38, Muscatine, Iowa 52761-8800 U.S.A • Tel (319) 262-7700 Fax (319) 262-7600 Return...

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