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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.
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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...
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F-code Section C-code BT Standard Codes Version no T-code Service Manual 1997-07-15 Return...
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 ................
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.
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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.
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F-code Section C-code Introduction, Service Manual Version no T-code Service Manual 1997-07-15 Return...
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.
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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...
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”...
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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.
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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.
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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.
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.
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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...
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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...
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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...
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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.
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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...
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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.
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F-code Section C-code M3.0 Ordering Spare Parts Version no T-code Service Manual 1997-07-15 Return...
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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...
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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.
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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...
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.
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.
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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...
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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.
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.
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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...
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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.
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.
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.
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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.
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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.
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).
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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...
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.
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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.
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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.
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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.
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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...
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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.
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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).
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.
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.
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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.
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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...
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.
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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...
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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.
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...
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.
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...
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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”.
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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.
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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.
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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.
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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.
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.
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.
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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.
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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.
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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.
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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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.
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.
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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.
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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).
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.
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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.
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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.
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.
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.
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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.
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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.
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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.
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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.
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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.
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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.
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.
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.
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.
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.
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.
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.
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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.
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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.
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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.
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.
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.
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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.
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.
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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.
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.
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.
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.
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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.
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.
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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.
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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...
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.
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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.
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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.
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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.
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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.
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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.
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.
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.
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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.
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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...
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...
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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...
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.
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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.
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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.
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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.
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.
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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.
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.
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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.
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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...
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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.
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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.
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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).
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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.
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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.
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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.