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Master Service Manual


SMX45

Electric Walkie Low-Lift Pallet Truck


Effective Serial Number SMX__4533227001 - UP

Warning

Read and observe all warnings on this unit


before operating it.

Warning

DO NOT operate this equipment unless all


factory installed guards and covers are
properly secured in place.

Part no: 313084-000

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Date: December 12, 2006

BT Prime-Mover is a trademark of BT Prime-Mover Inc.,

2006 BT Prime-Mover Inc., Muscatine, Iowa.


All Rights Reserved.

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Section

C-code

Ordering Spare Parts

Version no

T-code

000

SMX

Ordering Spare Parts


Supply the following information will assure prompt, efficient
handling of the order:
1. Identify truck model and serial number.
2. Refer to Parts Book and locate page with the
exploded diagram.
3. Find item number for the part required. Select the
column for the actual truck model and serial
number.
4. The following is an explanation of a serial number:

SMX 00 3 6 045 001


Number of unit
for that day
Day of year (365)
Year (2006)
Decade (2000)
Capacity (3000lb)
Model (SMX)

CAUTION Although some trucks appear to be similar,


component
parts
may
not
be
interchangeable. If an incorrect part is
used, the truck may malfunction.
5. Note part number.
6. Call your local Prime-Mover Dealer and state part
number.
7. If the truck model, serial number, or article number
cannot be found on the truck, call your local PrimeMover Dealer for assistance.

BT Prime-Mover, Inc.

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Ordering Spare Parts
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000

SMX

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Section

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Standard Codes
Version no

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001

SMX

Standard Codes
B-Code

= Business area

F-Code

= Product family

T-Code

= Product type

C-Code

= Component function

Worksheet standard
W-Code = Working code
R-Code

= Reason code

SO-Code = Assortment
F-Code List
PT

Low-Lift Pallet Truck

T-Code List
No.

Model
SMX45

C-Code List
No Function Group

BT Prime-Mover, Inc.

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C-Code

Frame

0000

Motors

1000

Drive Gear / Transmission

2000

Brake / Wheel System

3000

Steering System

4000

Electrical System

5000

Hydraulic / Pneumatic System

6000

Operating Function-lifting Mast / Cylinders

7000

Peripheral / Installation Equipment

8000

Optionals / Attachments

9000

10

Tools

10000

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Standard Codes
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001

SMX

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Table of Contents
Table of Contents
Ordering Spare Parts .................................................................................... 1
Standard Codes ............................................................................................. 3
Warning Symbols ......................................................................................... 13
Warning Levels .................................................................................................... 13

Prohibitory Symbols .................................................................................... 14


Ordinance Symbols .............................................................................................. 14

Safety ............................................................................................................ 15
General Safety ..................................................................................................... 15

Battery Safety ............................................................................................... 20


Static Discharge Precautions ..................................................................... 25
Welding Safety ............................................................................................. 27
Introduction, Service Manual ...................................................................... 29
Contents, Section M ..................................................................................... 31
Machine Information ............................................................................................ 31

General Product Information ...................................................................... 33


Truck Presentation ............................................................................................... 33
Truck Side Views ..........................................................................................................
Intended Truck Application ...........................................................................................
Prohibited Truck Application .........................................................................................
Truck Data ....................................................................................................................
Dimensions ...................................................................................................................
Data Plate .....................................................................................................................

33
33
34
34
35
36

Main Components ................................................................................................ 37

Inch (SAE) and Metric Fasteners ................................................................ 39


Introduction ..........................................................................................................
Nomenclature, Threads ........................................................................................
Strength Identification ..........................................................................................
Truck Torque Specifications .................................................................................
Conversion of Metric and English Units ...............................................................

39
40
41
47
48

Technical Service Data ................................................................................ 51


Contents, Section P ..................................................................................... 55
Planned Maintenance .......................................................................................... 55

Introduction, Maintenance .......................................................................... 57

BT Prime-Mover, Inc.

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2004-05-17

Table of Contents
Jacking Truck Off The Floor ................................................................................. 58
Fork Section ................................................................................................................. 59
Tractor Section ............................................................................................................. 59

Lubricants ............................................................................................................ 59
Standard ....................................................................................................................... 59
Cold Storage ................................................................................................................ 59

Service Schedule ......................................................................................... 61


Planned Maintenance Schedule .......................................................................... 61
Planned Maintenance Procedures ....................................................................... 64
General .........................................................................................................................
Hardware .................................................................................................................
Noise .......................................................................................................................
Leaks .......................................................................................................................
Cables and Connections .........................................................................................
Grease Location Points ...........................................................................................
Services Performed Daily or Every 8 Operating Hours ................................................
Frame ......................................................................................................................
Brakes .....................................................................................................................
Wheels/Tires ...........................................................................................................
Steering Control Handle ..........................................................................................
Functions/Operations ..............................................................................................
Battery .....................................................................................................................
Battery Connector ...................................................................................................
Services Performed Every Two Months or Every 250 Operating Hours ......................
Frame ......................................................................................................................
Motors .....................................................................................................................
Drive Unit ................................................................................................................
Brake .......................................................................................................................
Electrical Control System ........................................................................................
Battery .....................................................................................................................
Electrical Panel .......................................................................................................
Hydraulic System ....................................................................................................
Lifting Devices .........................................................................................................
Services Performed Annually or Every 1500 Operating Hours ....................................
Drive Unit ................................................................................................................
Hydraulic System ....................................................................................................

64
64
64
64
65
65
65
65
65
65
65
66
66
66
67
67
67
67
67
67
68
68
68
68
68
68
69

Lubrication Chart ......................................................................................... 71


Oil and Grease Specifications .................................................................... 72
Lubricants ............................................................................................................ 72
Grease Location Points ........................................................................................ 72

Contents, Section S ..................................................................................... 73


Service Instructions .............................................................................................. 73

Frame ............................................................................................................ 75
Theory of Operation ............................................................................................. 75
Maintenance ........................................................................................................ 75
Inspection ..................................................................................................................... 75

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Table of Contents
Troubleshooting ................................................................................................... 76
Repair and Rebuild .............................................................................................. 76

Inspection Covers ........................................................................................ 83


Theory of Operation .............................................................................................
Maintenance ........................................................................................................
Troubleshooting ...................................................................................................
Repair and Rebuild ..............................................................................................

83
83
83
83

Decals ............................................................................................................ 85
Decal with Protective Sheet ................................................................................. 85
Decal without Protective Sheet ............................................................................ 85

Electric Motors ............................................................................................. 87


Theory of Operation .............................................................................................
Maintenance ........................................................................................................
Troubleshooting ...................................................................................................
Repair and Rebuild ..............................................................................................

87
87
88
89

Motor Brushes ..............................................................................................................


Drive Motor ..............................................................................................................
Pump Motor .............................................................................................................
Brush Inspection .....................................................................................................
Brush Replacement .................................................................................................
Pump Motor ..................................................................................................................
Removal ..................................................................................................................
Installation ...............................................................................................................
Drive Motor ...................................................................................................................
Drive Motor ...................................................................................................................
Removal ..................................................................................................................
Installation ...............................................................................................................

89
89
90
90
91
92
92
93
94
96
97
97

Transmission ................................................................................................ 99
Theory of Operation ............................................................................................. 99
Maintenance ........................................................................................................ 99
Fluid Changing ............................................................................................................. 99

Troubleshooting .................................................................................................. 100


Repair and Rebuild ............................................................................................. 100

Parking Brake System ................................................................................ 109


Theory of Operation ............................................................................................ 109
Maintenance ....................................................................................................... 111
Mechanical Brake Release .......................................................................................... 111
Brake Adjustment ........................................................................................................ 111

Troubleshooting .................................................................................................. 112


Repair and Rebuild ............................................................................................. 113

Drive Wheel .................................................................................................. 115


Theory of Operation ............................................................................................ 115
Maintenance ...................................................................................................... 115

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Table of Contents
Drive Wheel Nut Inspection ......................................................................................... 115

Troubleshooting .................................................................................................. 117


Repair and Rebuild ............................................................................................. 117

Load Wheels ................................................................................................ 121


Theory of Operation ............................................................................................
Maintenance .......................................................................................................
Troubleshooting ..................................................................................................
Repair and Rebuild .............................................................................................

121
121
121
122

Caster Wheel (Optional) ............................................................................. 125


Theory of Operation ............................................................................................ 125
Maintenance ....................................................................................................... 125
Inspection .................................................................................................................... 125

Troubleshooting .................................................................................................. 126


Repair and Rebuild ............................................................................................. 126

Steering Control Handle ............................................................................. 129


Theory of Operation ............................................................................................ 129
Maintenance ....................................................................................................... 129
Inspection .................................................................................................................... 129

Troubleshooting .................................................................................................. 129


Repair and Rebuild ............................................................................................. 130

Steering Control Head ................................................................................ 135


Theory of Operation ............................................................................................
Maintenance .......................................................................................................
Troubleshooting ..................................................................................................
Repair and Rebuild .............................................................................................

135
135
135
136

Steering Bearing ......................................................................................... 141


Theory of Operation ............................................................................................
Maintenance .......................................................................................................
Troubleshooting ..................................................................................................
Repair and Rebuild .............................................................................................

141
141
141
142

Electrical Functions .................................................................................... 145


Theory of Operation ............................................................................................ 145
Battery Plugged In With Keypad .................................................................................
Battery Plugged In With Key Switch ............................................................................
Main ON/OFF Switch/Keypad ON ...............................................................................
Travel, Low Speed ......................................................................................................
Travel, High Speed ......................................................................................................
Reverser ......................................................................................................................
Lift ................................................................................................................................
Lower ...........................................................................................................................

146
147
148
150
152
153
154
155

Maintenance ....................................................................................................... 156


Wiring .......................................................................................................................... 156
Definitions .............................................................................................................. 156

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Table of Contents
Shorts to Frame Test ............................................................................................. 157

Troubleshooting .................................................................................................. 161


Troubleshooting Flowchart ..........................................................................................
Main Harness Replacement ........................................................................................
Operator Display and Programming ............................................................................
Special Modes ........................................................................................................
Service Display ......................................................................................................
Digital Inputs/Outputs from Transistor Controller ...................................................
Transistor Controller System Mode ........................................................................
Changing Driver Accessible Parameters (P) ...............................................................
Changing Service Parameters ....................................................................................
Parameter Description ...........................................................................................
Operating Parameter Programming .......................................................................
Display Part Numbers (Pn) ....................................................................................
Error Codes (E) ...........................................................................................................
Error Code History .................................................................................................
Truck Fault Codes ..................................................................................................
Troubleshooting Chart Index .......................................................................................
Travel (Forward / Rearward) System .....................................................................
Wiring System ........................................................................................................
Other Possible Troubleshooting Issues .................................................................
Troubleshooting Charts ...............................................................................................
Electrical Schematic 1(2) .............................................................................................
Electrical Schematic 2(2) .............................................................................................

161
164
168
168
169
170
171
172
174
176
179
179
180
180
181
188
188
188
188
189
194
195

Battery .......................................................................................................... 199


Theory of Operation ............................................................................................ 199
Maintenance ....................................................................................................... 199
Inspection and Care ....................................................................................................
Exterior Cleaning .........................................................................................................
Charging ......................................................................................................................
Storage ........................................................................................................................
History Record .............................................................................................................

199
200
200
201
202

Troubleshooting .................................................................................................. 202


Repair and Rebuild ............................................................................................. 203

Swing Out Battery Pack .............................................................................. 205


Theory of Operation ............................................................................................ 205
Maintenance ....................................................................................................... 205
Electrical Testing ......................................................................................................... 205
Required Equipment .............................................................................................. 205
Instructions ............................................................................................................. 205

Troubleshooting .................................................................................................. 210


Repair and Rebuild ............................................................................................. 210

Battery Connector ....................................................................................... 215


Theory of Operation ............................................................................................ 215
Maintenance ....................................................................................................... 215
Inspection .................................................................................................................... 215

Troubleshooting .................................................................................................. 215


Repair and Rebuild ............................................................................................. 216

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Switches ....................................................................................................... 219
Theory of Operation ............................................................................................
Maintenance .......................................................................................................
Troubleshooting ..................................................................................................
Repair and Rebuild .............................................................................................

219
220
222
223

Main ON/OFF Switch ..................................................................................................


Arm Angle Switches ....................................................................................................
Lift Limit Switch ...........................................................................................................
Key Switch (Optional) ..................................................................................................
Horn Switch .................................................................................................................
Converting Keypad to Key Switch ...............................................................................

224
224
225
226
226
227

Fuses/Circuit Breakers ............................................................................... 229


Theory of Operation ............................................................................................ 229
Maintenance ....................................................................................................... 229
Wiring Harness ............................................................................................................
Power Cables ..............................................................................................................
Circuit Breaker .............................................................................................................
Master Control Relay ...................................................................................................

230
231
232
233

Troubleshooting .................................................................................................. 234


Repair and Rebuild ............................................................................................. 234

Contactor Panel ........................................................................................... 235


Theory of Operation ............................................................................................ 235
Maintenance ....................................................................................................... 235
Troubleshooting .................................................................................................. 235
Resistance Testing ...................................................................................................... 235

Repair and Rebuild ............................................................................................. 236

Transistor Controller .................................................................................. 239


Theory of Operation ............................................................................................ 239
Basics Of Circuit Operation .........................................................................................
Interface ......................................................................................................................
Control Features ..........................................................................................................
Motor Circuit ................................................................................................................
Control Circuit ..............................................................................................................
Definitions ....................................................................................................................

239
240
241
241
242
243

Maintenance ....................................................................................................... 244


Safety .......................................................................................................................... 244
Cleaning ...................................................................................................................... 244

Troubleshooting .................................................................................................. 245


Diagnostics and Troubleshooting ................................................................................ 245
Fault Codes ................................................................................................................. 245

Repair and Rebuild ............................................................................................. 247

Electronic Tiller Arm Card (ETAC) ............................................................. 249


Theory of Operation ............................................................................................
Maintenance .......................................................................................................
Troubleshooting ..................................................................................................
Repair and Rebuild .............................................................................................

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250
250
251

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Hydraulic System ........................................................................................ 253
Theory of Operation ............................................................................................ 253
Lift ................................................................................................................................ 254
Lower ........................................................................................................................... 255
Relief Pressure ............................................................................................................ 256

Maintenance ....................................................................................................... 257


Changing Hydraulic System Fluid ............................................................................... 257
Hydraulic Pump Pressure Relief Valve ....................................................................... 259

Troubleshooting .................................................................................................. 259


Troubleshooting Chart Index ....................................................................................... 260
Troubleshooting Charts ............................................................................................... 261

Repair and Rebuild ............................................................................................. 264


Hydraulic Unit ..............................................................................................................
Hydraulic Solenoid ......................................................................................................
Reservoir .....................................................................................................................
Filter Screen and Inlet Tube ........................................................................................
Lift Pump .....................................................................................................................

266
267
268
269
270

Lift Cylinder ................................................................................................. 271


Theory of Operation ............................................................................................ 271
Maintenance ....................................................................................................... 271
Inspection .................................................................................................................... 271

Troubleshooting .................................................................................................. 271


Repair and Rebuild ............................................................................................. 272

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Warning Symbols
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001

Warning Symbols
Always follow the warnings given in this Service Manual
and on the truck to avoid accidents from occurring.

1. Warning Levels
Warning levels
Warning text is given in four levels and provide information on
the risks, describe the consequences, and instruct how to
avoid accidents.
DANGER
Warns that an accident will occur if the instructions are not
followed.
The consequences are serious personal injury or possibly
death, and/or extremely large material damage.

WARNING
Warns that an accident can occur if the instructions are not
followed.
The consequences are serious personal injury or possibly
death, and/or large material damage.

CAUTION
Warns that an accident can occur if the instructions are not
followed.
The consequences are personal injury and/or material
damage.

NOTE!
Marks the risk of a accident or breakdown if the
instructions are not followed.

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Prohibitory Symbols
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Prohibitory Symbols
NO SMOKING
If smoking occurs in situations where a restriction against
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.

GENERAL PROHIBITION
If the prohibition is ignored, a serious accident can occur.

1. Ordinance Symbols

SAFETY SHOES
When the directive for safety shoes is given, safety shoes
shall always be worn to avoid personal injury.

PROTECTIVE GLASSES
When the directive for protective glasses is given,
protective glasses shall always be worn to avoid personal
injury.

14

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Safety
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Safety
1. General Safety
Do NOT operate or work on this truck unless trained,
qualified, and authorized to do so and have read the
Operators Manual.

Know the truck controls and what they do.

Do NOT operate truck if it needs repair or if it is in any way


unsafe.

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Safety
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001

Operate truck only from the position of the operator.

Before working on this truck always press the red OFF (O)
key on the keypad and disconnect the truck battery connector
(unless this manual states otherwise.)

Do NOT wear watches, rings, or jewelry when working on this


truck.

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Safety
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001

Follow the scheduled


inspection steps.

lubrication,

maintenance,

and

Follow exactly the safety and repair instructions in this


manual. Do NOT take shortcuts.

Do NOT Use an open flame near the truck.

Do NOT use gasoline or other flammable liquids for cleaning


parts.

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Safety
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001

Clean up any hydraulic fluid, oil, or grease that has leaked or


spilled on the floor.

Always operate and park truck indoors.

Do not park truck in a cold storage area overnight.

Do NOT wash truck with a hose.

18

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Safety
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001

Do NOT add to or modify truck without written approval from


BT Prime-Mover, Inc.

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Battery Safety
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Battery Safety
WARNING As a battery is being charged, an explosive
gas mixture forms within and around each
cell. If the area is not properly ventilated,
this explosive gas can remain in or around
the battery for several hours after charging.
Be sure there are no open flames or sparks
in the charging area. An open flame or
spark can ignite this gas, resulting in
serious damage or injury.
WARNING Battery electrolyte is a solution of sulfuric
acid and water. Battery acid causes burns.
Should any electrolyte come in contact with
clothing or skin, flush the area immediately
with cold water. Should the solution get on
your face or in the eyes, flush the area with
cold water and receive medical attention
immediately.
Read, understand and follow procedures, recommendations
and specifications available by the battery and battery
charger supplier.

20

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Battery Safety
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001

Wear personal protective equipment to protect eyes, face,


and skin when checking, handling, or filling batteries. This
equipment includes goggles or face shield, rubber gloves
(with or without arm shields) and a rubber apron.

Make sure a shower and eyewash station are nearby in case


there is an accident.

A battery gives off explosive gases. Never smoke, use an


open flame, or use anything that gives off sparks near a
battery.

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Battery Safety
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Keep the charger area well-ventilated to avoid hydrogen gas


concentration.

Press the red OFF (O) key on the keypad before


disconnecting the battery from the truck at the battery
connector. Do NOT break live circuits at the battery terminals.
A spark often occurs at the point where a live circuit is
broken.

Do NOT lay tools or metal objects on top of battery. A short


circuit or explosion could result.

Keep batteries clean. Corrosion causes shorts and possibly


sparks to the frame.

22

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Battery Safety
T-code

001

Keep plugs, terminals, cables, and receptacles in good


condition to avoid shorts and sparks.

Cable

Filler
Plugs

Keep filler plugs firmly in place at all times except when the
electrolyte level is checked, when water is added to the cells
or when the specific gravity is checked.
Make sure vent holes in filler plugs are open to allow gas to
escape from the cells.

Filler Plug

Vent Hole

Do NOT allow cleaning solution, dirt, or any foreign matter to


enter the cell.

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Battery Safety
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001

Make sure to install the correct size battery. A smaller or


lighter weight battery could seriously affect truck stability. See
the truck specification (data) plate for more information.

Never plug a battery charger into the truck battery connector.


Plug battery charger ONLY into battery connector from
battery.

Follow the charging procedures available by the supplier on


the Battery and Battery Charger.

24

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Static Discharge Precautions
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001

Static Discharge Precautions


Electronic circuit board and devices used on the truck can be
damaged by the discharge of static electricity, called
electrostatic discharge.
Static charges can accumulate from normal operation of the
truck as well as movement or contact between nonconductive materials such as plastic bags, synthetic clothing,
synthetic soles on shoes, styrofoam coffee cups, etc.
Accumulated static can be discharged through human skin to
a circuit board or component by touching the parts. Static
discharge is also possible through the air when a charged
object is placed close to another surface at a different
electrical potential. Static discharge can occur without
seeing or feeling it.
Whenever working on or near static-sensitive electronics,
always use static discharge precautions.
1. Static-sensitive items are to remain in their
protective containers except when actually in use
at the static-free station.
2. Before removing the item(s) from their protective
container, the operator should place the container
on the conductive grounded bench top. Make sure
the wrist strap fits snugly around the wrist and is
properly plugged in/attached to ground receptacle
or the truck. The operator should then touch hands
to the conductive bench top, workstation, or truck.
3. All operations should be performed with the items
in contact with the truck or grounded bench top.
4. Do not allow conductive magazine (static-sensitive
items) to touch hard-grounded test gear or bench
top.
5. Ordinary plastic solder-suckers and other plastic
assembly aids should not be used.
6. In cases where it is impossible or impractical to
ground the operator with a wrist strap, a conductive
shoe strap can be used along with conductive tile/
mats.

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Static Discharge Precautions
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7. When the operator moves from any other place to


the static-free station, the start-up procedure
should be the same as the preparation for working
at a static-free workstation.
8. Plastic snow polystyrene foam, peanuts, or other
high-dielectric materials should never come in
contact with or be used around electrostatic
sensitive items, unless they have been treated with
an antistatic compound. Such treatment is often
indicated by a pink color on the foam material.
9. Static-sensitive items should not be transported or
stored in trays, tote boxes, vials, or similar
containers made of untreated plastic material
unless items are protectively packaged in
conductive material.

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Welding Safety
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001

Welding Safety
WARNING Flame cutting or welding on painted
surfaces may produce potentially harmful
fumes, smoke and vapors. Prior to
performing flame cutting or welding
operations, it is recommended that the
coating be removed in the vicinity where the
operation(s) will be performed.
WARNING Coating removal may be by mechanical
methods, chemical methods or a
combination of methods. Flame cutting and/
or welding operations should be carried out
in well ventilated areas using local exhaust
if necessary.
Before working on the truck, make sure of the following:
Fire protection equipment is nearby.
Know where the nearest eyewash station is located.

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Welding Safety
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001

CAUTION Disconnect battery before attempting to


inspect, service or repair truck. Discharge
residual charge in the transistor controller
by connecting a load across the transistor
controllers B+ and B- terminals (such as a
contactor coil or by pressing the horn
button.)

Check for shorts to frame. If any shorts are detected,


remove before proceeding with the welding operation.
Clean the area to be welded.
Protect all truck components from heat, weld spatter and
debris.
Attach the ground cable as close to the weld area as
possible.
Disconnect all electrical cards before any type of electric
resistance welding is done.
Only trained, qualified, and authorized personnel should
weld on the truck.
Do not perform any welding operations near the electrical
components.
If welding must be done, remove the battery from the truck.
When welding is completed, perform all ground tests and
electrical inspections before the truck is operated.

28

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Introduction, Service Manual
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Introduction, Service Manual


The information in this service manual covers model SMX45.
Federal and State laws require that operators be completely
trained in the safe operation of lift trucks in accordance with
OHSA regulation 1910.178.
An operators manual is sent with every Prime-Mover truck
when it is manufactured. If the operators manual is missing
from the truck, a new manual may be obtained by contacting:
BT Prime-Mover, Inc.
3305 N Highway 38
Muscatine, Iowa

52761-8800

(563) 262-7700
The information contained in this service manual is intended
as a guide to help trained, qualified, and authorized
technicians safely service the truck.
The service manual is divided into four separate sections
which cover needed information for servicing the truck types.
The main subject for each of these sections is described
below.

BT Prime-Mover, Inc.

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SECTION

SUBJECT

MACHINE INFORMATION

PLANNED MAINTENANCE

SERVICE INSTRUCTIONS

OPTIONS

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Contents, Section M
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Contents, Section M
1. Machine Information

BT Prime-Mover, Inc.

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M1.0

GENERAL PRODUCT INFORMATION

M2.0

TECHNICAL SERVICE DATA

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General Product Information
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General Product Information


1. Truck Presentation
The SMX45 is a battery powered walkie low-lift pallet truck.
The truck is intended solely to be operated indoors carrying
pallets or similar load carriers. The truck is equipped with a
steering control handle with all the controls for operating
within easy access. The trucks lifting capacities can be found
on the trucks data plate.
The SMX45 truck is equipped with a 24 volt electrical system.
Speed is regulated by means of a transistor controller to
provide infinite control of acceleration and speed while
driving.
The forks are raised by means of a hydraulic unit. The control
of the lift/lower is done electrically with push buttons on the
steering control handle.

1.1. Truck Side Views


The terms right-hand and left-hand used indicate the right
and left side of the truck as viewed from the operators line of
sight for proper operation of the truck. Use this view when
ordering parts to assure proper selection of parts.
Left Side

Forward
(Tractor-first)

Rearward
(Forks-first)

Right Side

1.2. Intended Truck Application


The trucks are solely designed and manufactured to handle
goods. The trucks should be fitted with the appropriate
accessories relevant to the application.

BT Prime-Mover, Inc.

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General Product Information
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1.3. Prohibited Truck Application


The trucks are designed for handling goods indoors. It is not
permitted to use the trucks for other purposes including the
following:

As a towing tractor for trailers.

To tow other trucks.

To transport/lift passengers.

To drive on gravel or grass.

1.4. Truck Data


The following table provides information regarding technical
data which is of value with daily use of the trucks. Lifting
capacity and weight can be found on the trucks data plate
(see page 36.)
Metric dimensions and capacities are shown in parenthesis
and have been rounded for convenience.
Truck Data
Lifting capacity rated load, lb (kg)

4500 (2241)

Lift height, inch (mm)

5.0 (127.0)

Operating speed without load, mph (kph)

3.6 (5.8)

Operating speed with load, mph (kph)

3.4 (5.5)

Service weight without battery, lb (kg)

640 (290)

Service weight including battery


Minimum battery weight is 200 lbs (91 kg) 24 volt

34

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Above + battery
weight

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General Product Information
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1.5. Dimensions
The following diagram shows external dimensions for the
SMX45 truck in its standard design.

68.6 inch
(1742 mm)
23.0 inch
(585 mm)

Battery Compartment 27.0 inch


(685 mm)

26.6 inch

E (675 mm)

28.0 inch
(711 mm)

6
(15 0 inch
25
mm
)

6.8 inch
(172 mm)

6
Battery Compartment 7.8 inch
(198 mm)
47.9 inch
(1216 mm)

40

33

48.0 inch Nominal


(1220 mm)

5.4 inch
(137 mm)

3.25 inch
(83 mm)

31.2 inch
(792 mm)

3.1 inch
(79 mm)

53.0 inch
(1346 mm)
Full Load Gradeability: 6%
2500 lbs (1133 kg) Load Gradeability: 10%
Dimensions shown in parentheses are metric, others are standard U.S. measure.

BT Prime-Mover, Inc.

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2006-12-12

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General Product Information
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Use only batteries that meet the following specifications:


Battery Pack Dimension Specifications
24 Volt Battery Pack

Amp Hour

Length

Width

Height

Max Weight

Swing-out Upper Trays


with 15 amp charger

152

26.5 inch
(675 mm)

7.5 inch
(192 mm)

26.45 inch
(672 mm)

300 lbs (136 kg)

GNB PalletPro
with 25 amp charger

195

26.5 inch
(675 mm)

7.5 inch
(192 mm)

26.25 inch
(665 mm)

300 lbs (136 kg)

1.6. Data Plate


The illustration shows the data plate used on this truck.

4
7

8
10

Legend

36

Return

Truck model number

Truck voltage DC

Truck serial number

Battery type UL class

Truck type

Battery maximum AMP hours

Truck lifting capacity

Minimum battery weight

Truck weight (less battery)

10

Maximum battery weight

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General Product Information
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2. Main Components
1. Steering Control Handle:
The truck is to be controlled by the operator with 180 degree
steering angle. The truck has the ability to right-angle stack.
The brake is applied in the upper and lower position of the
steering control head.

2. Hydraulic unit:
Pump motor, pump, electric valve and oil tank integrated in a
compact unit.

3. Hydraulic lowering valve:


For controlling lifting and lowering functions with hydraulic
lowering valve.

4. Battery:
24 volt with different capacities and weights.

5. Drive unit with brake:


Drive unit with a electromagnetic brake assembly, drive motor,
drive wheel, and transmission assembly. The steering bearing
is located at the top of the drive unit.

6. Steering pivot point.


7. Data plate:
See data plate on page 36.

8. Operator Display:
Display includes hourmeter, error codes, parameters, hardware
and software part numbers.

9. Electrical panel:
24 volt electrical system. Truck speed is regulated by means of
a transistor controller.

10. Fuse/Circuit breaker:


10A, Fuse Keypad and ETAC (supplied with main harness)
10A, Fuse Main ON/OFF (supplied with main harness)
110A, Power Circuit Breaker

11. Load wheel:


Lubricate load wheels to prevent wheels from locking up. Load
wheels with sealed bearings.

12. Keypad:
Enter PIN-key code in the keypad and press green key (I) on
the keypad starts truck. Press red OFF (O) on the keypad to
shut off electrical power to the control system. Up to 10
operators can be assigned their own individual PIN-key code
for access to the truck.

BT Prime-Mover, Inc.

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2006-12-12

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General Product Information
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13. Main ON/OFF switch


The main ON/OFF switch will cut off all electrical power to the
control functions on the truck when pressed.

14. Travel speed / direction selection


To select direction, rotate thumb controls in the direction of
travel. The further you rotate in that direction the faster the
travel.

15. Fork lower switch


Forks will lower when switch is pressed or until lower stops are
reached.

16. Fork raise switch


Forks will raise when switch is pressed until lift limit switch is
opened.

17. Horn switch


Activates horn to warn others of your position. Horn button is
also used to cycle through special truck mode displays (see
page 168.)

18. Battery disconnect


Disconnecting the battery connector will shut off all electrical
power to the truck.
17

16
1

12
1
4
7
O

2
5
8
0

3
6
9
I

14

15

13, 18
9, 10
8

2, 3

4
6
5
11

38

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M1.1
Inch (SAE) and Metric Fasteners
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SMX

Inch (SAE) and Metric Fasteners

10

10

1. Introduction
Threaded fasteners such as bolts, nuts, cap screws, and
studs are made to specifications that describe mechanical
strength and hardness of fastener. A fastener used in a
design application is selected in accordance with its
specifications. Parts used on this truck are purchased from
many countries. Many fasteners are similar but cannot be
used as direct replacements.
Service technicians must use replacement fasteners that
have the same specifications. Fasteners made to each
specification have identification marks for that specification.
This specification is commonly called grade for SAE
standards and property for metric standards. This section
describes identification of some common fasteners.
The metric system used is described as SI (International
System of Units, also called SI in all languages.) The SI
system of measurement is described in ISO Standard 1000,
1973.

BT Prime-Mover, Inc.

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2004-01-12

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Inch (SAE) and Metric Fasteners
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2. Nomenclature, Threads
The thread design is specified by a series of numbers and
letters for inch and metric fasteners (see figure below.) The
diameter of shank of fastener is shown first in the series, e.g.
M12=12 mm, M20=20 mm (1/2=1/2 inch, 3/4=3/4 inch.)

The number of threads per inch is normally not shown for inch
nomenclature and only UNC (Unified National Coarse) or
UNF (Unified National Fine) is shown. This number of threads
per inch is not shown because a UNC or UNF fastener has a
standard number of threads per inch for a specific diameter.
The length of a shank is often indicated as part of the
description of a fastener. This length is shown in inches for
inch fasteners and in millimeters for metric fasteners.
A cap screw will have the following description:
Inch

Metric

1/2 x 13 UNC x 1-1/2


A
B C
D

M12 x 1.75 x 50
A
B
C

A =Shank diameter
B =Number of threads per unit of length
C =Type of thread
D =Shank length

40

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A =Thread size
B =Pitch
C =Length

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Inch (SAE) and Metric Fasteners
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3. Strength Identification
The most common property classes for metric fasteners are
8.8 and 10.9. The property class is marked with a number on
the head of the cap screw or on a nut. Property classes less
then 8.8 are often not marked. Grades for inch bolts go from 2
to 8. Grade 2 fasteners normally do not have marks. The
following tables show marks that identify grades and property
classes for different fasteners.
WARNING When fasteners must be replaced new
fasteners must be of same strength or
greater than original fasteners. The new
fasteners must also be the correct size.
NOTE!

BT Prime-Mover, Inc.

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Identification marks are according to bolt


strength. The higher the number, or
increase in number of marks, indicates
increased bolt strength.

2004-01-12

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Inch (SAE) and Metric Fasteners
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Table 1. Bolt and Screw Designations

Types of
Fasteners

Metric Fasteners

Inch Fasteners

Strength Levels: Property Classes

Strength Levels: SAE Grades

5.2

* Markings Not Required


8

Hex Head Bolts


& Cap Screws
5

4.6*

4.8*

5.8*

8.8

4.6

4.8

5.8

8.8

9.8

10.9

12.9

9.8

10.9

12.9

Markings
for size
M5 and
Larger

Same As Above

Hex Head
Flange Screws
5

12 Point
Flange Screws
Markings Not Required

8.8

12.9

8.8

12.9

Hex Socket Head


Cap Screws
5.1

4.8*

9.8

4.8

9.8

Sems

42

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Inch (SAE) and Metric Fasteners
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Table 2. Stud and Nut Designations

Types of
Fasteners

Inch Fasteners

Metric Fasteners

* Markings Not Required

Strength Levels: SAE Grades

Strength Levels: Property Classes

Markings Not Required

5*

5.2*

8*

4.6*

4.8*

5.8*

8.8

4.6

4.8

5.8

8.8

9.8

10.9

12.9

9.8

10.9

12.9

Markings
for size
M5 and
Larger

8.1
or

Studs

Optional Geometric Symbols for


Size M5 through M11.

or

or

10

Hex Nuts

Markings Not Required

Hex Slotted Nuts

12

10

12

10

12

10

10

10

10

12

12
12

Markings Not Required

Hex Flange Nuts

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Inch (SAE) and Metric Fasteners
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Table 3. Torque Nut Designations

Types of
Fasteners

Inch Fasteners

Strength Levels: SAE Grades

B
B

C
C

Metric Fasteners

Strength Levels: Property Classes

10
10

or
All Metal Prevailing
Torque Nuts

G
9

10

10

or
All Metal Prevailing
Torque Flange Nuts

or

44

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Inch (SAE) and Metric Fasteners
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SMX

Table 4. Torque Nut with Nylon Insert Designations

Types of
Fasteners

Inch Fasteners

Strength Levels: SAE Grades

Metric Fasteners

Strength Levels: Property Classes

10

10

or

Nylon Insert Prevailing Torque


Nuts

Markings Not Required

or
or

Markings Not Required

10

10

or

Nylon Insert Prevailing Torque


Flange Nuts

BT Prime-Mover, Inc.

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2004-01-12

45

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Inch (SAE) and Metric Fasteners
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Table 5. Fastener Torque Values

Size and
Pitch

Property, Class
8.8*

Property, Class
10.9**

Property, Class
12.9***

Nm

in-lbs

Nm

in-lbs

Nm

in-lbs

5-6
8-10
20-25

44-53
71-88
177-221

7-8
12-14
30-35

62-71
106-124
265-309

8-10
14-16
------------

71-88
124-142
------------

Nm

ft-lbs

Nm

ft-lbs

Nm

ft-lbs

M8 x 1.25
M10 x 1.5

-----------40-45

-----------30-33

29-35
60-65

22-26
44-48

34-40
70-75

26-30
52-55

M12 x 1.75
M14 x 2

70-80
110-125

30-33
52-59

100-110
155-180

74-81
114-133

115-130
180-210

85-96
133-155

M16 x 2
M20 x 2.5

170-190
340-380

125-140
251-280

240-270
450-500

177-199
332-369

280-320
550-600

207-236
406-443

M24 x 3

580-650

428-479

800-900

590-664

900-1050

664-774

M30 x 3.5

1150-1300

848-959

1600-1800

1180-1328

1850-2100

1364-1549

M36 x 4

2000-2250

1479-1660

2800-3150

2065-2323

3250-3700

2397-2729

M5 x 0.8
M6 x 1
M8 x 1.25

Size and
Pitch

Property class 8.8, Protective Treatment CMHC


Specification H (zinc phosphate), applies also to
internally threaded fasteners made of property
class 8 material.

** Property class 10.9, Protective Treatment CMHC


Specification H (zinc phosphate), applies also to
internally threaded fasteners made of property
class 10 material.
*** Property class 12.9, Protective Treatment CMHC
Specification H (zinc phosphate), applies also to
internally threaded fasteners of property class 12
material.

46

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Inch (SAE) and Metric Fasteners
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4. Truck Torque Specifications


Description

BT Prime-Mover, Inc.

Return

Torque Specification

Drive motor end cover bolts

70.5 - 77.3 ft-lbs (95.6 - 104.8 Nm)

Gear case cover mounting bolts

30 ft-lbs (42 Nm) (sealant, see page 72)

Drive wheel axle nut

55 ft-lbs (74.6 Nm)

Drive wheel studs

23 - 28 ft-lbs (32 - 38 Nm)

Friction disk mounting bolts

50 in-lbs (5.6 Nm)

Hydraulic motor contactor coil nut


Hydraulic reservoir clamp

48 - 60 in-lbs (5.5 - 7 Nm)

Hydraulic filter screen fitting

245 - 275 in-lbs (27 - 31 Nm)

Lift motor mounting bolts

40 - 45 in-lbs (4.5 - 5 Nm)

Cylinder retention screw

71 - 88 in-lbs (8 - 10 Nm)

Hydraulic adapter body

204 - 240 in-lbs (23-27 Nm)

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Inch (SAE) and Metric Fasteners
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5. Conversion of Metric and English


Units
Area
Multiply

By

To Get

Multiply

By

To Get

inches

6.451

centimeters (cm)

centimeters

0.155

inches (in)

feet

0.093

meters (m)

meters

10.764

feet (ft)

Linear
Multiply

By

To Get

Multiply

By

To Get

inches

25.4

millimeters(mm)

millimeter

0.03937

inches (in)

feet

0.305

meters (m)

meter

3.280

feet (ft)

yards

0.914

meters (m)

meter

1.094

yards (yd)

miles

1.609

kilometers (km)

kilometer

0.621

miles (mi)

Mass
Multiply

By

To Get

Multiply

By

To Get

ounces (oz)

28.49

grams (g)

grams

0.035

ounces (oz)

pounds (lb)

0.454

kilograms (kg)

kilograms

2.205

pounds (lb)

tons (2000 lb)

907.18

kilograms (kg)

kilograms

0.001

tons (2000 lb)

tons (2000 lb)

0.907

metric ton (t)

metric ton

1.102

tons (2000 lb)

Power
Multiply

By

To Get

Multiply

By

To Get

horsepower

0.746

kilowatts (kW)

kilowatts

1.34

horsepower (hp)

Pressure

48

Multiply

By

To Get

Multiply

By

To Get

pounds/in

6.895

kilopascal (kPa)

kilopascals

0.145

pounds/in (psi)

pounds/in

0.007

megapascal (MPa)

megapascals

145.04

pounds/in (psi)

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Inch (SAE) and Metric Fasteners
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Temperature
Multiply

By

To Get

Multiply

By

To Get

(Fahrenheit
-32)

0.56

Celsius (C)

(Celsius x 1.8)

+32

Fahrenheit (F)

Torque
Multiply

By

To Get

Multiply

By

To Get

inch pound

0.113

Newton meter (Nm)

Newton meter

8.851

inch pounds
in-lbs

feet pound

1.356

Newton meter (Nm)

Newton meter

0.738

foot pounds
ft-lbs

Velocity
Multiply

By

To Get

Multiply

By

To Get

miles/hour

1.609

kilometer/hour
(km/h)

kilometer/hour

0.621

miles/hour
(mph)

Volume
Multiply

By

To Get

Multiply

By

To Get

inches

16.387

centimeters (cm)

centimeters

0.061

inches (in)

inches

0.016

liters

liters

61.024

inches (in)

quarts, U.S.

0.946

liters

liters

1.057

quarts, U.S. (qt)

quarts, U.S.

0.83

quarts, Imp. (qt)

quarts, Imp.

1.205

quarts, U.S. (qt)

gallons, U.S.

3.785

liters

liters

0.264

gallons, U.S.
(gal)

gallons, U.S.

0.83

gallons, Imp. (gal)

gallons, Imp.

1.205

gallons, U.S.
(gal)

ounces

29.57

milliliters (ml)

milliliters

0.034

ounces (oz)

BT Prime-Mover, Inc.

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Inch (SAE) and Metric Fasteners
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Technical Service Data

Version no

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SMX

Technical Service Data


NOTE!

When the battery is fully charged,


performance may vary due to motor and
system efficiency tolerance. Technical
service data represents nominal values
obtained under typical operating conditions.
Specifications are subject to change
without notice.

Drive Unit
Type

Shunt wound

Power - horsepower [hp] (kilowatts [kW])

1.2 (0.90)

Duty factor

1 hour

Min carbon brush length - inch (mm)

0.59 (15)

Min commutator diameter - inch (mm)

1.85 (47)

Min brush spring tension - ounce-force foot (Nm)

44.8 (3.8)

Gear ratio

22:1

Oil volume, oz (liter)

13.5 (0.4)
Drive Gear Ambient Temperatures

Standard operation (see page 59) temperature down


down to 32 F (0 C)

Mobil-1 Synthetic Gear Lube 75W-90


or Texaco Synstar GL 75W-90

Cold Storage Conditioning (see page 59)


temperatures down to 5 F (-15 C) or down to -13 F
(-25 C) for intermittent operation

Mobil-1 Synthetic Gear Lube 75W-90


or Texaco Synstar GL 75W-90

Wheels
Drive wheel - inch (mm)

10.0 x 5.0 (255 x 125)

Drive wheel weight without load with battery - lb (kg)

710 (322)

Drive wheel weight with rated load and battery - lb (kg)

1650 (748)

Torque drive axle nut, ft-lbs (Nm)

55 (74.6)

Load wheel - inch (mm)

3.25 x 4.50 (82 x 115)

Load wheel weight with rated load - lb (kg)


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Technical Service Data
Version no

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Hydraulic Unit
Power - horsepower [hp] (kilowatts [kW])

1.9 (1.4)

Duty factor

10% on 5 min. cycles

Minimum brush length - inch (mm)

0.35 (9)

Minimum commutator diameter - inch (mm)

1.13 (28.8)

Minimum brush spring tension - ounce-force (newton)


Relief pressure - psi (kPa) at rated load
at operating load

17.98 (5)
3000 (20684)

Pump flow

1.0 cc

Tank volume

Approximately 1 quart
Hydraulic Ambient Temperatures

Standard operation (see page 59) temperature down


down to 32 F (0 C)

Sunoco TH

Cold Storage Conditioning (see page 59)


temperatures down to 5 F (-15 C) or down to -13 F
(-25 C) for intermittent operation

AFT

Fuses/circuit Breaker
Keypad and ETAC Fuse

10 Amp

Control circuit Fuse

10 Amp

Drive/Pump circuit breaker

110 Amp
Batteries

Compartment Dimension L x W - inch (mm)


Capacity (recommended Max. Amp-hrs.)
Weight (Minimum) - lbs (kg)

52

Return

27.0 x 7.8 (685 x 195)


330
200 (91)

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Technical Service Data

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Operating Speeds
Without load - mph (kph)

3.6 (5.8)

With rated load - mph (kph)

3.4 (5.5)
Lifting/lowering Time

Lift empty, high speed (seconds)

2.3

Lift rated load, low speed (seconds)

3.0

Lower with rated load, low speed (seconds)

2.8

Current Readings
Driving without load (amps taken at steady state)

14 Amp

Driving with rated load (amps taken at steady state)

42 Amp

Lifting without load (amps are peak when read on motor)

38 Amp

Lifting with rated load (amps are peak when read on


motor)

95 Amp

BT Prime-Mover, Inc.

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Technical Service Data
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Contents, Section P
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Contents, Section P
1. Planned Maintenance

BT Prime-Mover, Inc.

Return

P1.0

INTRODUCTION, MAINTENANCE

P2.0

SERVICE SCHEDULE

P3.0

LUBRICATION CHART

P4.0

OIL AND GREASE SPECIFICATIONS

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Introduction, Maintenance

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Introduction, Maintenance
The schedule of maintenance and lubrication given in this
section of the service manual cover up to one years
operation of the truck. These schedules are based on hourly
usage and can be adapted to suit most schedules. The
following hourly usage figures have been used when
calculating the schedule:
Single shift, 30 hours per week usage
Double shift, 60 hours per week usage
Triple shift, 90 hours per week usage
The Planned Maintenance Schedule on page 61 is
based on the single shift schedule. The schedules are
intended only as a guide, not as a rigid structure. Owners of
the trucks may wish to adapt to local requirements; but it is
emphasized that the schedules represent minimum
manufacturer requirements, and all items should be included
in a service program to ensure minimum downtime and a high
status of the equipment.

BT Prime-Mover, Inc.

Return

Use spare parts approved by BT Prime-Mover.


For ordering parts see page 1.
Always clean the equipment and carry out a full
check after service.

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1. Jacking Truck Off The Floor


To perform maintenance that requires the truck to be lifted
from the floor, observe the proper precautions as follows:
1. Lower the forks completely. Remove any load.
2. Position all controls in neutral
3. Block the wheels to prevent movement of the truck.

Blocking Fork Section

4. Press the red OFF (O) key on the keypad.


Disconnect the battery connector from the truck.
Jack only in these areas

WARNING Use extreme care whenever the truck is


jacked up for any reason. Keep hands and
feet clear from beneath the truck while
jacking. After the truck is jacked, position
solid blocks beneath it to support it. DO
NOT rely on the jack alone to support the
truck.
5. Position the jack under the designated jacking
points.

58

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Introduction, Maintenance

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1.1. Fork Section


1. Using the lift button, raise the forks to maximum
height.
2. Block the fork section. The tractor section will
remain on the floor.
3. Lower the forks on the blocks.
4. Press the red OFF (O) key on the keypad.
Disconnect the battery connector from the truck.

1.2. Tractor Section


1. Place jack in the designated jacking position.
2. Jack one side of the truck so that the drive tire is off
the floor no more than 1.0 inch (25.4 mm).
3. Block that side of the truck in place.
4. Jack the other side of the truck level with the first
side.
5. Block that side of the truck in place.

2. Lubricants
2.1. Standard
The standard conditioning truck is designed for operation in
temperatures down to 32 degrees F (0 degrees C).

2.2. Cold Storage


Trucks supplied with a cold storage conditioning package are
designed to operate in temperatures down to 5 degrees F (15 degrees C) in a continuous duty cycle or down to -13
degrees F (-25 degrees C) for intermittent operation. When a
truck is installed in a cold storage environment, change the
fluid in the hydraulic reservoir. (See Lubricants on
page 72.)

BT Prime-Mover, Inc.

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Service Schedule

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Service Schedule
1. Planned Maintenance Schedule
WORK REQUIRED
ITEM

1
2
3
4
5
0300
0300.1
0300.2
1700
1700.1
1700.2
1700.3
1700.4
2550
2550.1
2550.2
3300
3300.1
3300.2
3300.3
3500
3500.1
3500.2
4100
4100.1
5000
5000.1
5000.2
5000.3
5000.4
5000.5
5000.6
5000.7

250

1500

Interval in Days/Weeks/Months

1d

2m

12 m

General
Check for loose hardware. Tighten if necessary.
Note any unusual noise during operation
Check for leaks around drive unit and hydraulic system.
Visually inspect all cables for damage.
Check grease location points (see page 72.)
Frame
Check truck data plate and decals for legibility.
Check for crack formation and damage.
Motors
Check connections for proper contact.
Clean motor of dirt and dust.
Check condition of brushes, springs, and holders.
Check brush length. Replace brushes if necessary (see page 91.)
Drive Unit
Check oil in drive housing. Check for contamination in the oil (see
page 100.)
Change transmission oil (see page 99.)
Brake
Check brake operation.
Clean dust and debris.
Check brake disk for wear.
Wheels
Remove all string, wrapping, and debris.
Check all wheels for wear.
Steering Control Handle
Check return of control handle to upper rest position.
Electrical Control System
Check operation of horn button.
Check speed and thumb controls.
Check tiller arm/angle switches for adjustment.
Check steering operation.
Check lift/lower functions.
Check operation of main ON/OFF switch.
Check for electrical shorts in chassis.

BT Prime-Mover, Inc.

Return

Interval in Hours

Master Service Manual

2006-08-03

X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X

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WORK REQUIRED
ITEM
5000.8
5110
5110.1
5110.2
5110.3
5110.4
5110.5
5111
5111.1
5400
5400.1
5400.2
5400.3
6000
6000.1
6000.2
6000.3
6000.4
6000.5
6420
6420.1
6420.2
6420.3

62

Return

Interval in Hours

250

1500

Interval in Days/Weeks/Months

1d

2m

12 m

Check operation of reverse button.


Battery
Check cleanliness and exterior conditions.
Check the battery charge.
Check the battery weight.
Check all connections; battery, battery and charger plugs.
Check battery mounting bolt for freeplay.
Battery Connector
Check battery connector. Make sure all powered functions shut down
when disconnected.
Electrical Panel
Clean and check mounting to frame.
Check contactors for welded conditions.
Check contactor tips for free movement.
Hydraulic System
Check hose for wear and damage.
Check reservoir for cracks, leaks and mounting.
Check correct oil level.
Check hydraulic connections and mounting.
Change hydraulic oil. Clean filters.
Lift devices
Check lift cylinder for leaks.
Check play on pull rods.
Check forks for wear and cracks.

Master Service Manual

X
X
X
X
X
X
X

X
X
X
X
X
X
X
X
X
X
X

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Service Schedule

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5110
5400

5111

0300
6420

5000

3550

4100

0300

6420
5700
1700

3300
3500
1700

6000

2550

BT Prime-Mover, Inc.

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2. Planned Maintenance Procedures


This section describes how to perform the services listed in
the Schedule of Planned Maintenance Operations. As with
the Schedule, this section is subdivided into service
intervals.

2.1. General
The following general inspections are to be made by the
operator. It is the operators responsibility to report any
problems with the truck to the appropriate personnel. The
truck should not be operated until it has been inspected and
repaired by a trained, qualified, and authorized technician.
The operator is ultimately responsible for the safe operation
of the truck.
2.1.1. Hardware
Inspect the truck for loose, damaged, or missing parts. All
shields and covers must be in place and functional. Inspect
truck for missing data plate or decals and make sure they are
legible. Report any problems to the appropriate personnel.
DO NOT operate the truck until it has been inspected and
repaired by a trained, qualified, and authorized technician.
Check all fasteners and connections, torque as required (see
page 47.) Check the drive wheel studs. Ensure that the lug
nuts and studs are tightened to the proper torque
specification (see page 47.) Check torque on motor end cap
bolts.
2.1.2. Noise
Check for any abnormal noise coming from the truck.
2.1.3. Leaks
Inspect the entire truck for leaks, especially around the
hydraulic pump assembly and the lift cylinder. Any sign of oil
on the floor under the truck is an indication that the truck may
be leaking hydraulic oil or transmission fluid. Report any
problems to the proper authorities. DO NOT operate the truck
until it has been inspected and repaired by a trained,
qualified, and authorized technician.
Check for proper fluid level in the drive unit. When the truck is
level, oil must be up to the bottom of the plug opening. If fluid
is low, check for leaks (see page 99.)
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2.1.4. Cables and Connections


Tighten connections. Check all cable insulation for damage.
Check that all electrical connections are clean and tight. Plugin connectors should be unplugged and plugged back in to
clean terminals.
2.1.5. Grease Location Points
For location of the grease points see page 72.

2.2. Services Performed Daily or Every 8


Operating Hours
Daily inspection is to be made by the operator prior to each
operating shift. It is the operator's responsibility to report any
problems with the truck to the appropriate personnel. The
truck should not be operated until it has been inspected and
repaired by a trained, qualified, and authorized technician.
The operator is ultimately responsible for the safe operation
of the truck.
2.2.1. Frame
Check truck data plate and decals to see that data is legible.
2.2.2. Brakes
Check operation of brakes.
2.2.3. Wheels/Tires
Inspect wheels and tires for wear and damage. Remove any
steel chips and foreign material to prevent damage to the
wheels. Check for gouging and chunking of the surface.
Trash that is wrapped around wheels and axles will cause
premature tire wear and bearing damage. The floors should
be kept clear of trash to prevent damage to the wheels and
tires.
2.2.4. Steering Control Handle
Check return of control handle to upper rest position.

BT Prime-Mover, Inc.

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2.2.5. Functions/Operations
Test truck for the proper operation of all functions including
the speed and thumb controls (arm angle switches), lift and
lower functions, brakes, steering, reverser button, horn button
and the main ON/OFF switch. Devices must be operational.
Report any problems to the proper authorities. DO NOT
operate the truck until it has been inspected and repaired by a
trained, qualified, and authorized technician.
2.2.6. Battery
Contact your battery supplier for specific instructions on
care and maintenance of the battery. Determine if the
battery needs to be washed down. This can only be done by
a trained, qualified, and authorized technician.
An average battery will have a specific gravity of 1.170 at the
80 percent discharged level. However, there are many
different batteries on the market. The battery supplier can
accurately determine the fully charged and 80 percent
charged levels. Contact an authorized battery supplier to
determine the overall condition of the battery.
The Battery Discharge Indicator (BDI) indicates the current
state of charge of the trucks battery. (See Parameter 21
on page 178.)
1
1/2
0

Full charge battery


Half charged battery
Discharged battery

When the battery has reached a charge level equivalent to 70


percent discharge, a warning signal is given via flashing
lights. A further 10 percent of the batterys capacity can then
be used before the battery discharge cuts out the lift function.
2.2.7. Battery Connector
Inspect the negative and positive cables for breaks and wear.
Check connectors for damage and to ensure proper
connections of cables.

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2.3. Services Performed Every Two Months


or Every 250 Operating Hours
The following inspections are to be made by the operator
prior to each operating shift. It is the operator's responsibility
to report any problems with the truck to the appropriate
personnel. The truck should not be operated until it has been
inspected and repaired by a trained, qualified, and authorized
technician. The operator is ultimately responsible for the safe
operation of the truck.
2.3.1. Frame
Check frame for crack formation and damage. Check cover
screws and secure as necessary.
2.3.2. Motors
WARNING When using compressed air, wear effective
chip-guarding and personal protective
equipment. Compressed air used for
cleaning MUST be reduced to less than 30
psi (207 kPa).
Check motors for improper connections due to poor
connections. Check tightness on all connections. Blow
carbon, copper, and plastic particle accumulations out from
the motor using compressed air. Check for signs of oil on the
motor air vents. Check for any damage to the air vents. For
minimum brush lengths see page 51 or page 52.
2.3.3. Drive Unit
Check oil in the drive housing. Check for contamination in the
oil (see page 100.)
2.3.4. Brake
Check brake of dust and debris. Check brake disk for wear.
1. Remove brake coil, and inspect brake disk for
wear. If the brake disk is damaged or worn, replace
with a new disk.
2. Before replacing the brake disk see page 112.
2.3.5. Electrical Control System
Check control handle arm angle switches for adjustment (see
page 220.)
BT Prime-Mover, Inc.

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Check for electrical shorts to frame (see page 157.)


2.3.6. Battery
Check battery mounting bolt. Check freeplay in battery
mounting area.
2.3.7. Electrical Panel
Clean and check electrical panel mounting to frame. Check
for connections in harness connectors. Check contactors for
welded conditions. Check contactor tips for free movement.
Clean operation of contactors for proper operation (see
page 239.)
2.3.8. Hydraulic System
Check the fluid level in the hydraulic reservoir (see
page 258.) Check hoses and connections on the hydraulic
system for leaks. Repair or replace hoses if worn or
damaged. Check oil reservoir for cracks, leaks and mounting.
2.3.9. Lifting Devices
Inspect the forks and cylinder for wear.

2.4. Services Performed Annually or Every


1500 Operating Hours
The following inspections are to be made by the operator
prior to each operating shift. It is the operator's responsibility
to report any problems with the truck to the appropriate
personnel. The truck should not be operated until it has been
inspected and repaired by a trained, qualified, and authorized
technician. The operator is ultimately responsible for the safe
operation of the truck.
2.4.1. Drive Unit
Fluid from the drive unit should be drained once a year. The
drain port is the lower left hand bolt holding the side cover in
place. Remove bolt to drain transmission fluid. Flush
transmission case with a cleaning solution. Pour clean
solution into the level check plug in the side cover. With drive
tire off the floor, allow solution to run out of drain port while
the transmission is running. Stop flushing when the solution
runs clean. Allow the solution to drain well before replacing
filler/level plug. Replace drain screw. Refill transmission with
proper clean oil (see page 72) before operating truck.

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2.4.2. Hydraulic System


The hydraulic system should be drained, flushed and refilled.
Clean the hydraulic filters when hydraulic fluid is changed.
The pressure relief valve setting should be checked.
WARNING Before siphoning oil from the reservoir,
make certain siphon is clean.
To drain reservoir, disconnect and remove the hydraulic
pump assembly (see page 257.)

BT Prime-Mover, Inc.

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Lubrication Chart

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Lubrication Chart
Pos. No
1
2
3
4

Interval/Running Hours

Service Point

360 h

Wheel bearings
Hydraulic system
Drive gear
Drive gear drain

720 h

L
C
C

L= Lubrication

1440 h

Lubricant
(See Lubricants
on page 72)

A
B
C
A

O
O
O
C = Check

O = Oil change

2
1

3
4

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Oil and Grease Specifications
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Oil and Grease Specifications


1. Lubricants

Location

Lubricant Specifications

Lubricant

A Grease
B Hydraulic oil
C Drive gear oil
D Sealant

Standard
Operation
Down To
32 F
(0 C)

Cold Storage
Continuous
Operation
Down To
5 F (-15 C)
Intermittent
Operation
Down To
-13 F (-25 C)

Mystik JT-6
Sunoco TH
ATF
Mobil-1 Synthetic Gear Lube 75W-90
or Texaco Synstar GL 75W-90
GE Weicon Silmate

Application area

Bearings and bushings


Hydraulic system
Gears
Gear case cover

2. Grease Location Points


Optional
B

72

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Contents, Section S
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Contents, Section S
1. Service Instructions

BT Prime-Mover, Inc.

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NO FUNCTION GROUP

C-CODE

FRAME

0000

MOTORS

1000

DRIVE GEAR / TRANSMISSION

2000

BRAKE / WHEEL SYSTEM

3000

STEERING SYSTEM

4000

ELECTRICAL / PNEUMATIC SYSTEM

5000

HYDRAULIC SYSTEM / CYLINDERS

6000

10

TOOLS

10000

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Contents, Section S
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Frame

Frame
1. Theory of Operation
The carrier frame is the body section of the truck that contains
the drive motor, drive unit, drive wheel, controls, and steering
control handle (with electronic tiller arm card [ETAC.]) The lift
frame is the section of the truck that contains the battery, pull
rods, and load wheels, along with the hydraulic and electrical
systems.

2. Maintenance
See Planned Maintenance Schedule on page 61.

2.1. Inspection
WARNING When using compressed air, wear effective
chip-guarding and personal protective
equipment. Compressed air used for
cleaning MUST be reduced to less than 30
psi (207 kPa).
NOTE!

CLEANLINESS! Perform procedures in a


clean environment. Make sure all parts are
cleaned before disassembly and kept clean
during assembly.

NOTE!

Call-outs in the following procedure refers


to illustration on page 78.

1. Thoroughly clean all parts and remove all nicks


and burrs with emery cloth.
2. Inspect pull rods (27) for excessive wear or
bending. No cracks are allowed in pull rods (27)
and should be replaced as a pair. If heavy wear or
bending is found replace both pull rods (27).
3. Inspect wheel fork assemblies (1) for excessive
wear or cracks. If cracks are found replace both
wheel forks.
4. Inspect all pins for nicks, scratches, or scoring. If
heavy scoring is found, or scratches that can not
be removed with emery cloth, replace pin.
BT Prime-Mover, Inc.

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5. All bushings are to be replaced with new.

3. Troubleshooting
Inspect carrier frame and lift frame for crack formation and
damage.

4. Repair and Rebuild


NOTE!

CLEANLINESS! Perform procedures in a


clean environment. Make sure all parts are
cleaned before disassembly and kept clean
during assembly.

NOTE!

Call-outs in the following procedure refers


to illustration on page 78.

Extensive damage to carrier frame, lift frame, or truck in any


weldment must be reported to BT Prime-Mover, Inc. Do not
attempt to weld the frame without permission from BT PrimeMover.

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Frame

Truck Serial Numbers 33227001 - 34271000

3
4

8
6

32
31
29
30
20

28

19
18

17

28

27

11

16

10

15

13

15
26

12

14

25

21

24
23

22

Item
No.

Description

Item
No.

Description

Item
No.

1
2
3
4
5
6
7

Wheel fork assembly


Load wheel
Fork, wheel
Bushing
Screw, set
Pin
Fitting, grease (optional)

12
13
14
15
16
17
18

Screw
Bracket, lift limit
Frame, carrier
Screw
Link assembly, upper
Bushing
Nut

23
24
25
26
27
28
29

Bushing
Pin
Pin
Screw
Pull rod assembly
Bushing
Screw

Frame, lift

19

Pin

30

Screw

9
10
11

Lift cylinder
Screw
Nut

20
21
22

Screw
Screw
Link

31
32

Pin
Pin

BT Prime-Mover, Inc.

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Truck Serial Numbers 34271001 - Up


1
2

3
4

32
35
31
29
30

20

19

10

33 34

28
18
17
27

16

11

15

28
13 12

15
26
25

14
21

24
23

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0300

Frame

Description

Item
No.

Description

Item
No.

2
3
4
5
6
7
8
9

Wheel fork assembly


Load wheel
Fork, wheel
Bushing
Screw, set
Pin
Fitting, grease (optional)
Frame, lift
Lift cylinder

13
14
15
16
17
18
19
20
21

Bracket, lift limit


Frame, carrier
Screw
Link assembly, upper
Bushing
Nut
Pin
Screw
Screw

25
26
27
28
29
30
31
32
33

Pin
Screw
Pull rod assembly
Bushing
Screw
Screw
Pin
Pin
Spring, retainer

10
11
12

Screw
Nut
Screw

22
23
24

Link
Bushing
Pin

34
35

Nut
Washer

Description

Removal
NOTE!

To replace pull rods and/or bushings it is


easiest to work with the truck on its side.
Remove battery before turning truck over
on its side.

To eliminate hydraulic leaks, remove the breather (0.6875


inch [17.46 mm] and install a plug. The bushings on the upper
links of the carrier frame can be replaced by removing the
links and lift cylinder.
1. Park truck on a level surface and make sure
parking brake is applied and load wheels are
blocked to prevent accidental movement.
2. Release pressure in hydraulic system by pressing
the lowering button on steering control handle.
3. Lower the forks completely. Remove any load.
4. Press red OFF button O on the keypad. Depress
main ON/OFF switch to the OFF position.
5. Disconnect the battery connector from the truck. If
applicable, remove bolts securing the battery to the
truck. Remove battery from the truck.

BT Prime-Mover, Inc.

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Master Service Manual

2006-08-03

79

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PT
Frame

S0.1

0300

Version no

T-code

001

SMX

6. Remove truck cover(s) [see page 84.]


WARNING When using compressed air, wear effective
chip-guarding and personal protective
equipment Compressed air used for
cleaning MUST be reduced to less than 30
psi (207 kPa).
7. Before disassembly, thoroughly clean exterior to
remove all contamination.
NOTE!

Turn truck on its side where the pull rod is


to be repaired.

8. Turn truck on its side.


9. Remove set screw (29) and pin (32) connecting
wheel fork assembly (1) to lift frame (8). This
allows the wheel fork and pull rod (27) to drop.

Wheel Fork
Set Screw
(Top View)

10. Remove set screws (30) and pin (31) connecting


the pull rod (27) to wheel fork assembly (1).
11. Remove screw (20) from pin (19). Remove pin
(19).
12. Separate link (22) by removing setscrew (26) and
pin (25).
13. Remove bushings (28) and (23) and discard.

80

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F-code

Section

PT

S0.1

Version no

T-code

001

SMX

C-code

0300

Frame

Installation
WARNING When using compressed air, wear effective
chip-guarding and personal protective
equipment Compressed air used for
cleaning MUST be reduced to less than 30
psi (207 kPa).
1. All parts should be cleaned and dried thoroughly.
Metal parts should be lightly oiled prior to
reassembly.
2. Press new bushing (23) into link (22). Push new
bushing (28) in pull rod (27).
3. Assemble pull rods (27) on links (22) to fit in frame
channel.
4. Install pins (19) and screws (20) in link (22).
5. Install pin (31) connecting pull rod (27) to wheel
fork assembly (1). Secure with set screws (30).
6. Install pins (32) in wheel fork assembly (1) and lift
frame (8). Secure with set screws (29).
7. If applicable, lubricate grease fitting (see page 72)
before turning truck back upright.
8. Return truck to the upright position.
9. Install battery on truck. If applicable, secure battery
bolts to the truck. Install truck cover(s) [see
page 84.]
10. Connect the battery connector to the truck.
WARNING DO NOT use your hands to check for
hydraulic leakage. Use a piece of
cardboard or paper to search for leaks.
Escaping fluid under pressure can
penetrate the skin causing injury. Relieve
pressure before disconnecting hydraulic or
other lines. Tighten all connections before
applying pressure. Keep hands and body
away from pinholes and nozzles which
eject fluids under high pressure.

BT Prime-Mover, Inc.

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2006-08-03

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Frame

S0.1

0300

Version no

T-code

001

SMX

11. Turn the main ON/OFF switch to the ON position.


Enter key code and press the green ON button I
on the keypad. Test truck for proper operation
before returning to service.

Cylinder Retention
Trucks with serial numbers 34271001 - Up are equipped with
the retainer spring (33), nut (34), and washer (35, see
page 78.) To install these parts on trucks prior to these serial
numbers, see drawing below.
Retainer

0.25 inch
(6.5 mm)

5.118 inch
(130 mm)

Drill & Tap M6 x 1, MIN 12 mm Deep


Use M6 Screw
Hex Locking with Lock Washer
Torque screw to
71-88 in-lbs (8-10 Nm)

Cylinder Retention Kit

82

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PT

Section

C-code

S0.2
0340
Inspection Covers

Version no

T-code

000

SMX

Inspection Covers
1. Theory of Operation
The truck covers are easily removed for access to the
components. During operation of the truck, the covers must
be secured to the truck.

2. Maintenance
See Planned Maintenance Schedule on page 61.

3. Troubleshooting
Inspect covers for damage. Damaged covers should be
replaced.

4. Repair and Rebuild


When the covers become damaged and do not fit properly,
replace with new as necessary.

BT Prime-Mover, Inc.

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Master Service Manual

2004-01-30

83

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C-code

PT
S0.2
Inspection Covers
Version no

T-code

000

SMX

0340

Item
No.

84

Return

Description

Clip

Cover, upper

Screw

Cover, lower

Bumper

Lockwasher

Screw

Master Service Manual

2004-01-30

F-code

Section

PT

S0.3

Version no

T-code

000

SMX

C-code

0851
Decals

Decals
Remove and replace any decals that are damaged or
missing. Remove a damaged decal by using a sharp edge to
peel the decal from the surface. Use caution not to scratch or
damage the paint on the truck when removing the decal. New
warning decals are free from BT Prime-Mover. Refer to truck
parts book for location and quantities of the decal.
Using a cleaning solution, thoroughly clean the surface of the
truck before applying a new decal. Allow the surface to dry
completely, be sure that there is no residue. Touch up the
paint in area of the decal, as required.

1. Decal with Protective Sheet


To install this style, peel off the backing, place the decal into
position, and press the decal into place. Do not wrinkle the
decal. Rub over the protective over-sheet with a firm, straight,
plastic edge to remove air bubbles and any wrinkles. Peel off
the over-sheet.

2. Decal without Protective Sheet


To install this style, peel off the backing, place the decal into
position, and press the decal into place. Do not wrinkle the
decal. Smooth the decal into place using clean fingers. Be
sure all the edges are secured to the surface.

BT Prime-Mover, Inc.

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Master Service Manual

2004-01-30

85

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PT
Decals

S0.3

0851

Version no

T-code

000

SMX

This page is intentionally left blank.

86

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2004-01-30

F-code

Section

PT

S1.0
1700
Electric Motors

Version no

T-code

001

SMX

C-code

Electric Motors
Electric motors provide power to the transmission and
hydraulic systems. Motor speed and direction are controlled
by the transistor controller or contactor with inputs from the
operator controls.

1. Theory of Operation
The lift pump motor assembly consists of the pump motor,
pump assembly and lift valve assembly. The pump motor and
pump are an integrated unit. The drive unit assembly consists
of the electromagnetic brake assembly, drive motor,
transmission assembly and drive wheel. The drive motor is
part of the drive unit. The steering bearing is mounted on top
of the drive unit assembly.

2. Maintenance
A routine maintenance schedule with recorded findings is the
best way to reduce costly shut-downs and repair of
equipment during operating hours. The goal of any
maintenance program, long-life and trouble-free operation, is
related to time spent making inspections and correcting minor
problems as they occur.
Inspect the motor more frequently when working in an
abnormally severe or corrosive environment or if in a rigorous
duty cycle. Set up and maintain a strict inspection schedule to
obtain the maximum efficiency from the electrical equipment.
Operating environments of truck motors varies widely.
The following recommendations should be applied as actual
conditions dictate:
Normal Service:

Basically an eight hour day of indoor


material handling.

Severe Service:

Extended operating hours, or constant


usage.

Extreme Service:

Chemical processing
Cold storage operation
Processing plants (poultry, meat)

BT Prime-Mover, Inc.

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2006-08-04

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S1.0
Electric Motors

1700

Version no

T-code

001

SMX

Each partial inspection of the motor must include:


1. Inspect the brushes for wear and for correct
contact with the commutator. Record the level of
wear on the brushes. This history will indicate
whether a brush must be changed or if it can wait
until the next inspection. For acceptable brush
length see page 51 or page 52.
NOTE!

Overloading a unit is ultimately reflected in


the motor and brush wear. Therefore, take
this into account when considering brush
replacement.

2. Check the brush spring tension. For acceptable


brush spring tension see page 51 or page 52.
3. Clean the brushes and holders. Wipe the
commutator with a dry, lint-free cloth. Do not use
lubricants of any kind on or around the
commutator.
4. Check the brush holders for solid connection to the
mounting support. Tighten the mounting screws as
necessary.
5. Check the cap screws holding the brush cross
connectors to the brush holder body.
6. Make sure the motor terminals are secured tightly
to the motor frame. Do not strip the threads or
crush the insulating parts.
7. Check all the cap screws around the frame for
tightness.
8. Keep the outside frame of the motor clean and free
from dirt. Maintain a free air passage around the
motor to permit heat radiation.

3. Troubleshooting
When a motor has trouble in operation, a reasonable decision
has to be made as to the proper corrective course of action.

88

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S1.0
1700
Electric Motors

Version no

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001

SMX

C-code

4. Repair and Rebuild


4.1. Motor Brushes
4.1.1. Drive Motor
1. Park truck on a level surface and make sure
parking brake is applied and load wheels are
blocked to prevent accidental movement.
2. Press red OFF button O on the keypad. Depress
main ON/OFF switch to the OFF position.
3. Disconnect the battery connector from the truck.
4. Remove truck cover(s) [see page 84.]
5. Remove any shields around the motor end cover to
expose the brushes. See Figure 1-1.

Brush
Shield
Figure 1-1: Drive Motor Brush Shield

6. Drive motor brushes are accessible by turning


transmission. Remove screws holding brush lead.
Lift spring off brush. Remove brush from holder.
Follow the brush inspection and replacement
procedures (see page 90 and page 91.)

BT Prime-Mover, Inc.

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2006-08-04

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PT
S1.0
Electric Motors

1700

Version no

T-code

001

SMX

4.1.2. Pump Motor


Pump Motor

Motor End Cover

Brushes

Brushes
Figure 1-2: Pump Motor

1. The pump motor will need to be removed from the


hydraulic assembly before inspecting brushes.
Remove screws from motor end cover. Remove
motor end cover to expose the pump motor
brushes.
2. Push brush back into holder to disengage the
spring. Disengage the spring on remaining
brushes. To remove brush assembly, remove nuts
and washers from the side of the drive end head.
Remove brush from holder and replace with new
brush. Follow the brush inspection below and
replacement procedures (see page 91.)

Spring

90

Return

4.1.3. Brush Inspection


Brushes should be inspected for uneven wear and signs of
Brush
overheating such as discolored brush shunts and brush
Brush springs. Check the brush holders for physical damage and
Shunts make sure they are not loose on the end head or the brush
holder plate. Check the brush springs for correct alignment on
the brush. A brush spring that does not apply equal pressure
on the center of the brush will cause the brush to wear
unevenly. Check for correct clearance and freedom of brush
movement in the holder. If the brushes are worn to the point
that replacement is necessary, the complete brush set should
be replaced (see page 91.)
Master Service Manual

2006-08-04

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S1.0
1700
Electric Motors

Version no

T-code

001

SMX

C-code

4.1.4. Brush Replacement


Do not replace just one or two brushes. When brush service
is required on the motor, lift brush spring over holding bracket
before removing brush (see the following drawing.)

Put Spring In This


Position For Brush Removal

Figure 1-3: Motor Brush Removal

WARNING When using compressed air, wear effective


chip-guarding and personal protective
equipment. Compressed air used for
cleaning MUST be reduced to less than 30
psi (207 kPa).
CAUTION Do not substitute brushes. The brushes are
matched to the motor type and application
to provide the best service. Substituting
brushes of the wrong grade can cause
commutator damage or excessive brush
wear.
NOTE!

Blow stone dust out with dry compressed


air.

After the installation of new brushes, the motor should be


operated at 12 Volts, no load and brushes seated to the
commutator with a dressing stone. Remove stone dust.
BT Prime-Mover, Inc.

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PT
S1.0
Electric Motors

1700

Version no

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001

SMX

4.2. Pump Motor


Pump Motor Mounting
Cylinder
Assembly

Contactor
Pump Motor

Reservoir
3
1
2

Item
No.

Description

1
2
3

Pump Motor Assembly


Kit, brush and spring
Bearing

4.2.1. Removal
1. Park truck on a level surface and make sure
parking brake is applied and load wheels are
blocked to prevent accidental movement.
2. Release pressure in hydraulic system by pressing
the lowering button on steering control handle until
lift cylinder is completely collapsed.
Hydraulic
Line
Pump
Assembly

3. Press red OFF button O on the keypad and


depress main ON/OFF switch to the OFF position.
4. Disconnect the battery connector from the truck. If
applicable, remove bolts securing the battery to the
truck. Remove battery from the truck.
5. Remove truck cover(s) [see page 84.]
6. Remove hydraulic line from hydraulic pump
assembly and cap end to prevent contaminants
from entering the hydraulic system.

92

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1700
Electric Motors

Version no

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001

SMX

C-code

7. Disconnect hydraulic motor power cables and mark


their positions. Disconnect contactor wiring, noting
their position.
8. Remove screws securing hydraulic pump and
motor assembly to frame. Remove pump/motor
assembly from truck.
9. Rebuild pump/motor as necessary.
4.2.2. Installation
WARNING When using compressed air, wear effective
chip-guarding and personal protective
equipment. Compressed air used for
cleaning MUST be reduced to less than 30
psi (207 kPa).
1. Thoroughly clean all parts with non-corrosive
cleaning fluid and air dry all parts.
2. Install pump/motor assembly in truck and secure
with screws to truck frame. (For torque values see
page 47.)

Power
Cables

3. Properly connect electrical power cables and


contactor wiring, noting their positions recorded
earlier.
4. Uncap and connect hydraulic hose to hydraulic
pump assembly.
5. Fill hydraulic reservoir with new clean oil (see
page 72.)
6. Remove blocks.
7. Install battery on truck. If applicable, secure battery
bolts to the truck.
8. Connect the battery connector to the truck.
9. Turn the main ON/OFF switch to the ON position.
Enter key code and press the green ON button I
on the keypad.
10. Check the reservoir fluid level. Operate the trucks
hydraulic system and check operation of system as
a whole. Look for leaks and tight places on the
lifting linkage.
11. Install truck cover(s) [see page 84.]

BT Prime-Mover, Inc.

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2006-08-04

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S1.0
Electric Motors

1700

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001

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4.3. Drive Motor


29
8
7
32
33

1 2

31

10

30
6

11

9
8

15

14
12

13

5
4

18

20

22

19

23
24

17 16

21

25

28

26

27

35

34
35

EE

94

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2006-08-04

Item No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18

BT Prime-Mover, Inc.

Return

Description
Ring, retainer
Gear
Key
Case
Terminal
Screw
Nut

Section

PT

S1.0
1700
Electric Motors

Version no

T-code

001

SMX

Item No.
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35

Washer
Field
Isolator
Bearing
Shim
Seal
Armature
Key
Ring, retainer
Hub
Band, cover E

Master Service Manual

F-code

2006-08-04

C-code

Description
Screw
Cover
Plate, brush
Spring
Brush
Nut
Ring, retainer
Bearing
Lockwasher
Screw
Shoe, pole
Washer
Screw
Lockwasher
Nut
Band Cover EE
Screw EE

95

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S1.0
Electric Motors

1700

Version no

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001

SMX

4.4. Drive Motor


Drive Motor Mounting

Steering Bearing
Carrier
Frame

Steering
Control Head

Drive Wheel

Drive Motor

bly
sem
s
A
e
Brak

Transmission
Assembly

96

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Section

PT

S1.0
1700
Electric Motors

Version no

T-code

001

SMX

C-code

4.4.1. Removal
WARNING There is no brake on the truck when the
drive motor is removed from the
transmission assembly. Block all wheels to
reduce the risk of truck movement.
1. Park the truck on a level surface and make sure
parking brake is applied and load wheels are
blocked to prevent accidental movement.
2. Press red OFF button O on the keypad. Depress
main ON/OFF switch to the OFF position.
3. Disconnect the battery connector from the truck.
4. Jack truck and block the frame (see page 58.)
5. Remove truck cover(s) [see page 84.]
6. Disconnect cable/wires from the terminal block on
the transmission.
7. Remove brake assembly from drive motor.
Terminal Block
Connections

8. Disassemble
assembly.

drive

motor

from

transmission

4.4.2. Installation
WARNING When using compressed air, wear effective
chip-guarding and personal protective
equipment. Compressed air used for
cleaning MUST be reduced to less than 30
psi (207 kPa).
1. Thoroughly clean all parts with non-corrosive
cleaning fluid and air dry all parts.
2. Reassemble
assembly.

drive

motor

on

transmission

3. Reinstall brake assembly on drive motor.


4. Install drive motor end cover and torque to 70.5 77.3 ft-lbs (95.6 - 104.8 Nm).
5. Unblock and lower the truck.
6. Ensure drive unit is filled to the correct level with
gear oil (see page 72.) Install fill/level plug.

BT Prime-Mover, Inc.

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2006-08-04

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Electric Motors

1700

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001

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7. Connect the battery connector to the truck.


8. Turn the main ON/OFF switch to the ON position.
Enter key code and press the green ON button I
on the keypad.
9. Test truck for proper operation before returning to
service.
10. Install truck cover(s) [see page 84.]

98

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S2.0
2550
Transmission

Version no

T-code

001

SMX

C-code

Transmission
1. Theory of Operation
This transmission is of the double reduction gear type. The
gears are a combination of helical and straight cut gears for
strength and low noise. The final drive gear is mounted on
opposing tapered roller bearings. The intermediate gear is
mounted on ball bearings. Gears and bearings are enclosed
in an oil filled case. The drive motor is mounted externally
with the drive motor pinion gear mounted on the armature
shaft. The brake is mounted on the drive motor.

2. Maintenance
See Planned Maintenance Schedule on page 61.

2.1. Fluid Changing


1. Lower forks.
2. Press red OFF button O on the keypad. Depress
main ON/OFF switch to the OFF position.
Disconnect the battery connector from the truck.
3. Remove drain plug to drain transmission oil.
4. Flush transmission case with a safe cleaning
solution and allow it to drain.
5. Clean and install drain plug.

Fill/Level Plug
Drain Plug

Figure 2-1: Fill and Drain Locations

NOTE!

BT Prime-Mover, Inc.

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Master Service Manual

When the truck is level, the oil must be up


to the bottom of the fill/level opening.

2006-08-04

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PT
S2.0
Transmission

2550

Version no

T-code

001

SMX

6. Fill transmission case with oil (see page 72)


through plug opening in transmission cover.

3. Troubleshooting
Because of the uncomplicated nature of the transmission,
troubleshooting is limited to identifying problems if they are
mechanical or electrical in nature. Fluid leaks are obviously
mechanical in nature and can be found by visual inspection.
Unusual noise and/or slow running could be mechanical or
electrical in nature. Generally, if the problem is caused
internally in the transmission, then metal contamination will
be evident in the oil. If there is a mechanical problem outside
of the transmission, then it will become evident by inspecting
the drive motor and brakes. See page 111 for instructions to
release the brake, if necessary.

4. Repair and Rebuild


Visually inspect outside of gear case for damage, wear or
cracks. Excessive damage, wear, or cracks in the gear case
indicate that the transmission needs to be replaced rather
than repaired or rebuilt.

100

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2006-08-04

3
1

F-code

Section

PT

S2.0
2550
Transmission

Version no

T-code

001

SMX

9
6

11 10

24

13
10

12

Item No.

11 14
15
16
17

18

19
20

23

21

BT Prime-Mover, Inc.

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Transmission
TransmissionMounting
Mounting

22

C-code

Master Service Manual

2006-08-04

Description

1
2
3
4
5
6
7
8
9
10

Screw
Cushion, upstop
Screw
Mount, stem
Screw
Clip
Stem, handle
Screw, set
Steering control head
Washer

11
12
13
14
15
16
17
18
19
20
21
22
23
24

Bushing
Spring
Sleeve
Washer
Screw
Lockwasher
Carrier frame
Drive unit
Drive motor
Brake assembly
Transmission assembly
Steering bearing
Drive wheel
Pin

101

F-code

Section

C-code

PT
S2.0
Transmission

2550

Version no

T-code

001

SMX

22
19

20

21

14 15
17

16

18

13
4
10

12
11
Item No.
1
2
3
4
5
6
7
8

102

Return

6
Transmission
Assembly

9
Description
Stud
Axle
Seal
Bearing
Spacer
O ring
Plug
Gear

Item No.
9
10
11
12
13
14
15

Description
Ring, retainer
Gear
Cover
Plug
Vent
Screw
Lockwasher

Master Service Manual

Item No.
16
17
18
19
20
21
22

Description
Bearing
Gear
Bearing
Retainer ring
Gear
Key
Case

2006-08-04

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S2.0
2550
Transmission

Version no

T-code

001

SMX

C-code

Removal
WARNING There is no brake on the truck when the
drive motor is removed from the
transmission assembly. Block all wheels to
reduce the risk of truck movement.
NOTE!

Call-outs in the following procedure refer to


illustration on page 101.

1. Lower forks.
2. Press red OFF button O on the keypad. Depress
main ON/OFF switch to the OFF position.
3. Disconnect the battery connector from the truck.
4. Remove truck cover(s) [see page 84.]
5. If applicable, remove bolts securing the battery to
the truck. Remove the battery from the truck.
6. Jack truck and block the frame (see page 58.)
7. Disconnect handle harness.

Bolts

Stem
Mount

Figure 2-2: Stem Mount

BT Prime-Mover, Inc.

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103

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PT
S2.0
Transmission

2550

Version no

T-code

001

SMX

Wiring Harness
Connector

Arm Angle Switches


Figure 2-3: Handle Harness

8. Disconnect arm angle switches.


9. Remove screws from stem mount securing
steering control handle assembly to the drive unit
assembly.
10. Disconnect cable/wires from the terminal block on
the transmission.
11. Remove bolts (15) and lockwashers (16) securing
transmission assembly and bearing assembly to
frame.
WARNING Transmission assembly may fall free from
mounting after bolts are removed causing
damage to assembly or injury to personnel.
12. Remove transmission and steering bearing
assembly by lowering it through the pivot-frame
mounting.
13. Feed the control wiring harness and power cables
through the transmission pivot mount.
14. Drain gear case lubricant.
15. Remove drive wheel (see page 117.)

104

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Section

PT

S2.0
2550
Transmission

Version no

T-code

001

SMX

C-code

Disassembly
NOTE!

Call-outs in the following procedures refer


to illustration on page 102.

Thoroughly clean the outside of the gear case with a noncorrosive cleaning fluid. Dry all parts and proceed as follows.
1. Remove screws (14) and lockwashers (15)
securing gear case cover (11). Remove gear case
cover (11).
2. Remove retaining ring (19) securing the top pinion
gear (20). Remove top pinion gear (20) and key
(21) attached to drive motor armature shaft.
NOTE!

If bearing (16) does not remove with cover


(11), then remove bearing (16) with a
bearing puller.

3. Remove the second stage gear set (10) and (17)


from the gear case (22).
4. Remove retaining ring (9) from the drive axle (2).
Remove output gear (8).
5. Press drive axle (2) through the inner and outer
gear case bearings.
6. Remove old bearings (4), spacer (5), and seal (3)
from the gear case (22).

Reassembly
NOTE!

Call-outs in the following procedure refer to


illustration on page 102.

1. Thoroughly clean gear case (22).


2. Install new bearings (4), spacer (5), and seal (3) in
the gear case (22) for the drive axle (2).
3. Place the gear case (22) in a fabricated assembly
base and carefully press the drive axle (2) in the
gear case (22).
4. Position transmission on a work bench with gear
case (22) side up. Install output gear (8) in the gear
case (22) and secure with retaining ring (9).
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S2.0
Transmission

2550

Version no

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001

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5. Install second stage gear set (10) and (17).


NOTE!

The seal must be installed correctly with its


open side and seal ring positioned towards
the bearing.
Ensure the motor end cap is installed
before proceeding to the next step.

6. Install pinion gear (20), woodruff key (21), and


retaining ring (19) on the armature shaft.
7. Apply sealant (GE Weicon Silmate) on the mating
surface and install gear case cover (11). Install
lockwashers (15) and screws (14). Torque cover
screws (14) to 30 ft-lbs (42 Nm).

Installation
CAUTION Make sure the main ON/OFF switch is OFF
and the battery connector is removed from
truck before proceeding.
NOTE!

Call-outs in the following procedure refer to


illustration on page 101.

1. If removed earlier,
assembly (22).

install

steering

bearing

2. Reinstall drive unit assembly through the pivot


frame while feeding the harness and cables
through the pivot frame mount.
3. Secure assembly
lockwashers (16).

with

screws

(15)

and

4. Connect cables/wire to terminal block on the


transmission.
5. Connect arm angle switches.
6. Connect stem harness to main harness and slide
the connector back onto the metal support tab.
NOTE!

Replace any wire ties that were removed


during reassembly.

7. Install stem mount.

106

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S2.0
2550
Transmission

Version no

T-code

001

SMX

C-code

8. Ensure drive unit contains the correct gear oil level


(see page 72.) Install fill/level plug.
9. With the truck still blocked and drive unit off the
ground, connect the truck to a battery. (Do not
install battery on the truck at this time.)
10. Test ease of steering. Test to make sure truck
powers ON and all functions on the handle head
are functional. Move handle up and down to test
arm angle switches.
11. Disconnect battery.
12. Install drive wheel (see page 118.)
13. Unblock and lower truck.
14. Install the battery on the truck. If applicable, secure
battery bolts to the truck.
15. Install truck cover(s) [see page 84.]
16. Connect the battery connector to the truck.
17. Turn the main ON/OFF switch to the ON position.
Enter key code and press the green ON button I
on the keypad.

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S2.0
Transmission

2550

Version no

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001

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108

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PT

Section

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S3.0
3300
Parking Brake System

Version no

T-code

001

SMX

Parking Brake System


1. Theory of Operation
The parking brake is an electrically released disk brake
mounted on the drive motor armature for increased braking
force through the transmission. The parking brake is applied
when the control handle is returned to the upper rest position
or in the bottom 8 degrees of the operating range. The brake
may be released when the control handle is moved as little as
6 degrees and travel request is made to allow for reduced
speed operation with the handle in near-vertical position for
greater maneuverability. Normal stopping during truck
operation is accomplished by reversing the travel controls
(plugging) and activating the inductive, regenerative braking
through the motor.
Electromagnetic
Brake

Figure 3-1: Electromagnetic Brake

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S3.0
3300
Parking Brake System
Version no

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001

SMX

When the steering control handle is in the upper rest position,


the parking brake is engaged. When the handle is within 6 to
41 degrees of the upper rest position and travel request is
made, the brake disengages, allowing the truck to operate in
slow speed. When the handle is placed beyond 41 degrees
from the upper rest position, the truck can operate in fast
speed. When the handle is placed in the bottom 8 degrees of
the operating range, the parking brake is engaged.

40
33
8

Figure 3-2: Handle Positions

110

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Section

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S3.0
3300
Parking Brake System

Version no

T-code

001

SMX

2. Maintenance
See Planned Maintenance Schedule on page 61.

2.1. Mechanical Brake Release


If the brake can not be mechanically released, perform the
following procedures:
Mounting Bolts

1. Park truck on a level surface and load wheels are


blocked to prevent accidental movement.
2. Press red OFF button O on the keypad. Depress
main ON/OFF switch to the OFF position.
3. Remove truck cover(s) [see page 84.]
4. Loosen the mounting bolts four turns each to allow
the truck to roll.
5. Move truck to desired location.
WARNING Before truck is put back into service, the
mounting bolts will need to be tighten. DO
NOT OPERATE TRUCK WITHOUT THE
BRAKE.
6. Reinstall truck cover(s).

2.2. Brake Adjustment


WARNING Before adjustments are made, disconnect
the battery from the truck to prevent
accidental operation.
1. Park truck on a level surface and make sure
parking brake is applied and load wheels are
blocked to prevent accidental movement.
2. Press red OFF button O on the keypad. Depress
main ON/OFF switch to the OFF position.
3. Disconnect the battery connector from the truck.
4. Jack the truck and block the frame (see page 58.)
5. Remove truck cover(s) [see page 84.]

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PT
S3.0
3300
Parking Brake System
Version no

T-code

001

SMX

6. Loosen assembly mounting bolts on brake.


7. Turn the adjusting screws while checking the air
gap at several points with a 0.008 to 0.014 inch
(0.2 to 0.36 mm) feeler gauge.
8. Tighten the mounting bolts to 50 in-lb (5.6 Nm).
Recheck the gap with feeler gauge.
Adjusting
Screw

Air Gap
0.008 - 0.014 inch
(0.2 - 0.36 mm)

Mounting Bolt

Coil Housing
Friction disk

Pressure Plate

3. Troubleshooting
Check brake disk for wear. Replace friction disk if worn
unevenly or when its total thickness is reduced to 0.20 inch
(5.5 mm).

112

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Section

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C-code

S3.0
3300
Parking Brake System

Version no

T-code

001

SMX

4. Repair and Rebuild


2
6
3

1
8

Item
No.

Description

Item
No.

Transmission assembly

Disk

Brake assembly

Coil

Flange, friction

Screw

Hub

Retaining ring

Description

Removal
1. Park truck on a level surface and make sure
parking brake is applied and load wheels are
blocked to prevent accidental movement.
2. Press red OFF button O on the keypad. Depress
main ON/OFF switch to the OFF position.
3. Disconnect the battery connector from the truck.

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PT
S3.0
3300
Parking Brake System
Version no

T-code

001

SMX

4. Remove truck cover(s) [see page 84.]


5. Loosen and remove mounting bolts (7). Remove
brake coil (6) assembly.
6. Remove friction disk (5) from hub (4).
7. Remove retaining ring (8) from hub (4).
8. Remove friction flange (3).
7
Adjusting Screw

6
5

Figure 3-3: Brake Coil Assembly

Installation
1. Inspect friction flange (3) for wear, replace if the
surface is worn unevenly. Install friction disk (5) on
hub (4). Place friction flange (3) on motor.
2. Install brake coil assembly on the motor end.
Adjust gap (see page 111.) Torque mounting bolts
to 50 in-lbs (5.6 Nm).
3. Connect the battery connector to the truck.
4. Remove blocks. Turn main ON/OFF switch to the
On position and turn key switch ON.
5. Test truck for proper operation before returning to
service.
6. Install truck cover(s).

114

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PT

S3.1

Version no

T-code

001

SMX

C-code

3530
Drive Wheel

Drive Wheel
1. Theory of Operation
The drive wheel is mounted on the transmission drive axle.
The drive wheel is part of the drive unit assembly.
Drive Wheel Specifications
10 inch X 5 inch (255 X 125 mm)

2. Maintenance
See Planned Maintenance Schedule on page 61.

2.1. Drive Wheel Nut Inspection


1. Park truck on a level surface and make sure
parking brake is applied and load wheels are
blocked to prevent accidental movement.
2. Press red OFF button O on the keypad or turn
key switch OFF. Depress main ON/Off switch to
the OFF position.
3. Disconnect the battery connector from the truck.
4. Remove truck covers and bumper.
5. Hoist truck and securely block truck with drive tire
approximately 1 inch (25 mm) off the floor.
6. Visually inspect lug nuts for signs of being loose.
Inspect studs to see if one or more studs protrude
through the lug nut farther than the others. If either
condition exists, proceed as follows.
7. Loosen lug nuts to finger tight. If one or more studs
turn while loosening the lug nuts, proceed as
follows.
8. If any of the studs appear damaged, replace studs.

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S3.1
Drive Wheel

3530

Version no

T-code

001

SMX

NOTE!

The installation procedure of the studs,


wheel and lug nuts must be completed in
less than 0.50 hour to ensure the thread
locking compound does not start to set up
before the installation is complete.

9. Remove and clean studs.


10. Install two lug nuts, jammed together, to the end of
the stud. This will allow the tightening of the studs
using a torque wrench.
11. Apply Loctite 290 thread-locking compound to
studs.
12. Install studs and torque to 23 - 28 ft-lbs (32 - 38
Nm).
NOTE!

Do not overtighten studs. If studs are


tightened to more to 30 ft-lbs (41 Nm) of
torque, the studs will start to cut new
threads and go too far hitting the lip seal. If
the lip seal is damaged due to studs being
installed too far, the axle will have to be
replaced.

13. Remove nuts on studs, making sure studs do not


rotate.
14. Install drive wheel and lug nuts. Torque lug nuts,
starting with a low torque (possibly 5 ft-lbs [75
Nm]), using a star pattern. This is to make sure
the lugs are centered in the mounting holes. On the
final pass, apply 55 ft-lbs (75 Nm) of torque to
nuts.
15. Remove blocking.
16. Connect the battery connector to the truck.
17. Turn the main ON/Off switch to the ON position.
Enter key code and press the green On button I
on the keypad or turn key switch ON.
18. Check operation of drive wheel.
19. Install truck covers and bumper.

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001

SMX

C-code

3530
Drive Wheel

3. Troubleshooting
Inspect wheel and tire for wear and damage. Trash that is
wrapped around the wheel and axle will cause premature tire
wear and bearing damage. The floors should be kept clean of
trash to reduce risk of damage to wheel and tire.

4. Repair and Rebuild


1

Item No.
1
2
3
4

Description
Wheel assembly
Tire
Hub
Nut

Removal
The drive wheel can be removed without removing the
transmission by the following steps:
1. Park truck on a level surface and make sure
parking brake is applied and load wheels are
blocked to prevent accidental movement.

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S3.1
Drive Wheel

3530

Version no

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001

SMX

2. Press red OFF button O on the keypad. Depress


main ON/OFF switch to the OFF position.
3. Disconnect the battery connector from the truck.
4. Remove truck cover(s) and bumper (see page 84.)
5. Hoist truck and securely block truck with drive tire
approximately 1 inch (25 mm) off floor.
6. Remove hub (3) and nuts (4). Pull tire and wheel
from transmission drive axle.

Installation
1. Install new tire and hub (3) on transmission drive
axle and secure with nuts (4). In a crossing pattern,
torque nuts to 55 ft-lbs (74.6 Nm).
2. Attach bumper with bolts, apply Loctite 243 to
bolts, and tighten.
3. Remove blocking. Connect the battery connector
to the truck.
4. Turn the main ON/OFF switch to the ON position.
Enter key code and press the green ON button I
on the keypad.
5. Check operation of drive wheel.

118

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S3.1

Version no

T-code

001

SMX

C-code

3530
Drive Wheel

Tire Pressing Procedure


1. Check the inside surface of metal insert on the new
tire. Remove any scaling or rust with sandpaper.
Clean the inside of metal insert and lubricate with a
soap solution.
Outside of Hub
and Tire Assembly

2. Place a circular ram on press table. The length of


ram must be longer than the width of the old tire to
allow complete removal of old tire. The outside
diameter of ram must be small enough to fit loosely
in the insert of tire, but large enough to rest
squarely on the flat surface on the outer edge of
hub.

Circular
Ram

3. If the outside edge of the hub is not flush with the


edge of the metal insert in old tire, measure how far
hub is recessed inside tire. The new tire must be
placed in the same position the old tire was
installed on the hub. A spacer (slightly smaller in
diameter than the inside diameter of tire insert and
the same thickness as the depth of the recess) can
be used to obtain proper amount of recession.

New
Tire
Worn
Tire

Press
Table

4. Position hub assembly with the old tire on the top


of circular ram so the outside of the wheel is
positioned upward. The outside edge of hub has a
chamfer to help guide the new tire onto the wheel.
The chamfered edge must always be the leading
edge when a tire is pressed onto hub.
5. Center hub assembly on the top of the ram and
make sure they mate squarely.
6. Position new tire with its chamfered insert facing
hub. Align new tire and hub so they are concentric.

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S3.1
Drive Wheel

3530

Version no

T-code

001

SMX

CAUTION Any misalignment of tire and hub while tire


is being pressed onto hub can cause
damage to hub. For this reason, chamfers
have been provided on the outside edge of
hub and on the end of the inside diameter
of tires metal insert. The chamfers help to
center hub and tire during the pressing
operation and reduce the possibility of
misalignment. To prevent damage, hub
must be installed on circular ram with its
chamfered side up.
NOTE!

If new tire does not press on with a


minimum of 5 tons (68,947 kPa) force,
replace hub.

7. Begin pressing new tire onto hub and old tire off
wheel. Run press slowly for the first few inches of
travel, because this is the critical stage of the
operation. If tire begins to cock to one side, stop
press and realign tire. A sharp jar with a softheaded mallet will usually realign tire on hub.
8. Release press. Remove wheel, tire assembly, and
old tire from press table. Inspect wheel and tire
assembly.
9. Install wheel assembly following the procedure for
the specific type of wheel.

120

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S3.2

Version no

T-code

001

SMX

C-code

3550
Load Wheels

Load Wheels
1. Theory of Operation
The load wheels are mounted on the pallet forks to support
the rated load at the forks fully raised height. Load wheels
contain sealed bearings on both sides.
Load Wheel Specifications
3.25 inch X 4.50 inch (82 X 115 mm)

2. Maintenance
Inspect the wheels for wear and debris wrapped around the
wheels. Check load wheel bearings for binding or excessive
play. See Planned Maintenance Schedule on page 61.

3. Troubleshooting
Inspect load wheel bearings for chunking, bond failure, and
excessive or uneven wear. Make sure wheels are functioning
smoothly and sufficient grease is applied to load wheel
bearings and linkage.

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121

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PT
S3.2
Load Wheels

3550

Version no

T-code

001

SMX

4. Repair and Rebuild


1

Item
No.
1
2

Description
Bearing
Wheel, load

Removal
1. Park the truck on a level surface.
2. Lift forks to maximum height and block (see
page 58.)
3. Press red OFF button O on the keypad. Depress
main ON/OFF switch to the OFF position.
4. Disconnect the battery connector from the truck.
5. Remove axle set screw.

Axle Set Screw

Figure 3-4: Load Wheel Setscrew

122

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S3.2

Version no

T-code

001

SMX

C-code

3550
Load Wheels

6. Drive the axle out of the load arm casing with a


hammer and brass drift pin.
7. Push the wheel out.
8. If bearings are to be reused, insert a brass drift pin
into each of the load wheel and knock bearings
out.

Installation
1. Install bearings in the new load wheel with seal
side out.
2. Place the new load wheel upright on a level
surface. Position the bearing over the load wheel.
Put a flat metal plate over the bearing and tap the
bearing in place with a plastic mallet. Make sure
the bearing is fully seated in the load wheel.
3. Align the wheel with the holes in the load arm
casting.
4. Install the axle through the load arm hole and
wheel. Align the dimple in the axle with the set
screw hole.
5. Install and tighten the set screw.
6. Lower truck and remove blocks.
7. Connect the battery connector to the truck.
8. Turn main ON/OFF switch to the ON position.
Enter key code and press the green ON button I
on the keypad.
9. Test truck for proper operation before returning to
service.

BT Prime-Mover, Inc.

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PT
S3.2
Load Wheels

3550

Version no

T-code

001

SMX

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124

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PT

Section

C-code

S3.3
3560
Caster Wheel (Optional)

Version no

T-code

001

SMX

Caster Wheel (Optional)


1. Theory of Operation
The caster assembly is mounted on the truck bumper to
provide truck maximum stability.

2. Maintenance
Normal maintenance includes lubricating the grease fittings
on the caster assembly periodically. (See Planned
Maintenance Schedule on page 61.)

2.1. Inspection
Caster
Assembly

1. Park truck on a level surface and make sure


parking brake is applied and load wheels are
blocked to prevent accidental movement.
2. Press red OFF button O on the keypad. Depress
main ON/OFF switch to the OFF position.
3. Disconnect the battery connector from the truck.
WARNING When using compressed air, wear effective
chip-guarding and personal protective
equipment. Compressed air used for
cleaning MUST be reduced to less than 30
psi (207 kPa).
NOTE!

CLEANLINESS! Perform procedures in a


clean environment. Make sure all parts are
cleaned before disassembly and kept clean
during assembly.

4. Thoroughly clean all parts and remove all nicks


and burrs with emery cloth.
5. Inspect all bearings and replace as necessary.
6. Inspect wheel(s) for flat spots or pieces of material
missing from tire.
7. Fill caster wheel with grease (see page 72.)

BT Prime-Mover, Inc.

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S3.3
3560
Caster Wheel (Optional)
Version no

T-code

001

SMX

3. Troubleshooting
Lubricate caster swivel as necessary.

4. Repair and Rebuild


1
2
3
4
5
6

20
7
8
7
19
9

10

11

18

10

12

17
15

14

13

14
13
16

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PT

Item
No.
1
2
3
4
5
6
7

Description
Caster Assembly
Fitting, grease
Pin
Cap
Bearing cup
Plate
Washer, thrust

Item
No.
8
9
10
11
12
13
14

Description
Bearing, thrust
Arm
Washer assembly
Nut
Nut
Washer, flat
Bearing

C-code

S3.3
3560
Caster Wheel (Optional)

Version no

T-code

001

SMX

Item
No.
15
16
17
18
19
20

Description
Wheel
Screw
Screw
Block, torsion
Housing
O Ring

Removal
1. Park truck on a level surface and make sure
parking brake is applied and load wheels are
blocked to prevent accidental movement.
2. Press red OFF button O on the keypad. Depress
main ON/OFF switch to the OFF position.
3. Disconnect the battery connector from the truck.
4. Hoist truck so caster wheel is approximately 2
inches (50 mm) off the floor and securely block.
5. Before disassembly thoroughly clean exterior of
the caster assembly in a cleaning solution to
remove all contamination.
6. Remove caster assembly screws from bumper.
Remove caster assembly and take to a suitable
work area.
7. Remove nuts (11) and (12) and washers (10) from
screws (16) and (17). Remove screws (16) and
(17) from assembly. Remove arms (9).
8. Remove flat washers (13) and bearings (14) from
wheel (15). Inspect bearings (14).
9. Disassemble housing (19) by removing pin (3), cap
(4), and plate (6). Remove bearing (5) from plate
(6). Remove O ring (20), thrust washers (7), and
thrust bearing (8) from housing (19). Inspect
bearings (5) and (8).

BT Prime-Mover, Inc.

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PT
S3.3
3560
Caster Wheel (Optional)
Version no

T-code

001

SMX

Installation
WARNING When using compressed air, wear effective
chip-guarding and personal protective
equipment. Compressed air used for
cleaning MUST be reduced to less than 30
psi (207 kPa).
1. All parts should be cleaned and dried thoroughly.
Metal parts should be lightly oiled prior to
reassembly.
2. Pack all bearings with grease (see page 72.)
3. Install O ring (20), thrust bearing (8), and thrust
washers (7) in housing (19).
4. Install bearing (5) and cap (4) in plate (6). Install
plate (6) on housing (19) and secure with pin (3).
5. Install bearings (14) and flat washers (13) in new
wheel (15).
6. Install arms (9) on housing (19) and secure with
screws (16) and (17), washer (10), and nuts (11)
and (12).
7. Install caster assembly to bumper and secure with
screws.
8. Connect the battery connector to the truck.
9. Remove blocks. Turn main ON/OFF switch to the
ON position. Enter key code and press the green
ON button I on the keypad.
10. Test truck for proper operation before returning to
service.

128

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F-code

PT

Section

C-code

S4.0
4100
Steering Control Handle

Version no

T-code

001

SMX

Steering Control Handle


1. Theory of Operation
The steering control head fastens to the handle stem and
mounts on the carrier frame. Ease of operator steering and
the ability to right-angle stack is provided by the handle
assembly.

2. Maintenance
See Planned Maintenance Schedule on page 61.

2.1. Inspection
WARNING When using compressed air, wear effective
chip-guarding and personal protective
equipment. Compressed air used for
cleaning MUST be reduced to less than 30
psi (207 kPa).
NOTE!

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.
2. Inspect all parts for excessive wear or scoring. If
heavy scoring is found replace part(s).
3. Inspect handle stem for nicks or rust; clean with
emery cloth or replace handle stem.
4. Inspect head harness for wear or broken wiring(s).

3. Troubleshooting
Check fasteners and the ease of steering.

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PT
S4.0
4100
Steering Control Handle
Version no

T-code

001

SMX

4. Repair and Rebuild


3
1

9
6

4
8

11 10

24

13
10

12

11 14
15
16
17

18

19
22

20
23

21

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PT

Item
No.

Description

Section

Version no

T-code

001

SMX

Item
No.

C-code

S4.0
4100
Steering Control Handle

Description

1
2
3
4
5
6
7
8
9

Screw
Cushion, upstop
Screw
Mount, stem
Screw
Clip
Stem, handle
Screw, set
Steering control head

13
14
15
16
17
18
19
20
21

Sleeve
Washer, plastic
Screw
Lockwasher
Carrier frame
Drive unit
Drive motor
Brake assembly
Transmission assembly

10
11
12

Washer
Bushing
Spring

22
23
24

Steering bearing
Drive wheel
Pin

Removal
1. Park truck on a level surface and make sure
parking brake is applied and load wheels are
blocked to prevent accidental movement.
2. Release pressure in hydraulic system by pressing
the lowering button on steering control handle.
3. Press red OFF button O on the keypad. Depress
main ON/OFF switch to the OFF position.
4. Disconnect the battery connector from the truck.
5. Remove screws (1) securing lower steering control
handle cover (4).

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S4.0
4100
Steering Control Handle
Version no

T-code

001

SMX

Cover

Screw

Figure 4-1: Control Handle Cover

6. Lift cover (4) off assembly and lay to one side.

Wiring Harness
Connector

Arm Angle Switches


Figure 4-2: Wiring Harness

NOTE!

Make note locations of cable ties on handle


harness before disconnecting wiring.

7. Disconnect wiring harness connector.


CAUTION The steering control handle stem will be
free to fall when cap screws are removed.
8. Remove set screw (8) located at the base of the
steering control handle stem (7) and drive out pin
(24) using a hammer and a brass drift pin. Hold
stem securely to prevent it from dropping.
9. Carefully remove steering control handle stem (7).
132

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PT

Section

C-code

S4.0
4100
Steering Control Handle

Version no

T-code

001

SMX

10. Inspect stem harness and washer (10), bushing


(11), spring (12), sleeve (13), and washer (14) for
excessive wear. Replace if necessary.

Installation
NOTE!

Make sure brake release cam assembly is


in the correct position before proceeding
with installation procedures.

1. Position steering control handle stem (7) on the


pivot assembly. Secure with screw (5).
2. Thread wiring harness through handle base.
3. If removed, reattach steering control handle head.
4. Connect handle harness connector and arm angle
switch connections. Install cable ties in their
original locations on the handle harness.
5. Install lower steering control handle cover (4).
Secure with screws (1).

Plastic Washer

Harness

Sleeve

Spring

Figure 4-3: Control Handle

6. Remove blocks.
7. Connect the battery connector to the truck.

BT Prime-Mover, Inc.

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2006-08-07

133

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Section

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PT
S4.0
4100
Steering Control Handle
Version no

T-code

001

SMX

8. Turn main ON/OFF switch to the On position and


enter key code and press green ON button I on
the keypad.
9. Test operation of all steering control handle
functions before returning to service.

134

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2006-08-07

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PT

Section

C-code

S4.1
4100
Steering Control Head

Version no

T-code

001

SMX

Steering Control Head


1. Theory of Operation
The steering control head is mounted to the steering control
handle. For functions of the control handle assembly see
Changing Driver Accessible Parameters (P) on
page 172 or Changing Service Parameters on page 174.

2. Maintenance
See Planned Maintenance Schedule on page 61.

3. Troubleshooting
Check fasteners and ease of steering.

BT Prime-Mover, Inc.

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2006-08-07

135

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S4.1
4100
Steering Control Head
Version no

T-code

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SMX

4. Repair and Rebuild


12

13

46

14
15

45

16

44

17

43
42

20

19

18

21

41

22
25

17
29 28

26

27

24
23

30

32 31
35
38
34

38

34 33

37 36

39

31 32 40
1
3

5
6

11
8
10

136

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BT Prime-Mover, Inc.

Return

T-code

001

SMX

Description

Item
No.

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23

Screw
Plate
Handle
Screw
Cover (option)
Pad, key
Screw
Screw
Relief, strain
Plate
Handle assembly, control
Insert, blank
Button, no function
Button, reverser
Button, horn (right)
Housing
Switch, horn
Display
Electronic Tiller Arm Card (ETAC)
Spring
Housing
Screw
Gasket

24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46

2006-08-07

C-code

S4.1
4100
Steering Control Head

Version no

Item
No.

Master Service Manual

Section

Description
Spring
Screw
Screw
Tie, cable
Screw
Tie, cable
Thumb control assembly
Screw
Washer
Switch, right
Bearing
Stop lug
Arm
Axle
Support
Spring
Switch, left
Button, horn (left)
Seal
Cap, transparent plastic
Button, lift / lower
Insert, lower
Insert, lift

137

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S4.1
4100
Steering Control Head
Version no

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001

SMX

Removal
1. Park truck on a level surface and make sure
parking brake is applied and load wheels are
blocked to prevent accidental movement.
2. Release pressure in hydraulic system by pressing
the lowering button on steering control head.
3. Press red OFF button O on the keypad. Depress
main ON/OFF switch to the OFF position.
4. Disconnect the battery connector from the truck.
5. Remove screw (7) from key pad. Unplug and
remove key pad (6) from handle (3).
6. Holding the top cover (16) firmly, remove screws
(4) and (8).
7. Disconnect the cable connected to ETAC (19).
8. Remove screws (22) from housing (21) to gain
access to ETAC (19).
NOTE!

Place finger between housing (21) and


reverser button (14) to hold right switch (33)
in place while removing housing (21).

9. Carefully lift off housing (21).

Horn Button Removal

10. Remove horn button (15) and (41).


11. Disconnect the connection for the switch on the
ETAC (19).
12. Press switch out from its mounting in the top cover
assembly.
13. Remove thumb wheel assembly (30).
A

14. Remove lift/lower button (44) by placing a


screwdriver in the hole.

Lift/Lower Button Removal

138

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Section

C-code

S4.1
4100
Steering Control Head

Version no

T-code

001

SMX

Installation
NOTE!

Place finger between housing (21) and


reverser button (14) to hold right rocker (33)
in place while installing housing (21).

1. Install thumb wheel assembly (30).


2. Install lift/lower button (44).
3. Install horn button (15) and (41).
NOTE!

Do not force housing (21). Install carefully.

4. Install housing (21) and secure with screws (22).


5. Connect the stem harness to ETAC (19).
NOTE!

Make sure stem harness is properly routed


before installing top cover.

6. Install top cover (16) and hold firmly in place while


securing with screws (4) and (8).
7. Plug in key pad (6) in handle (3). Secure with
screws (7).
8. Remove blocks.
9. Connect the battery connector to the truck.
10. Turn main ON/OFF switch to the ON position.
Enter key code and press the green ON button I
on the keypad.
11. Test truck for proper operation before returning to
service.

BT Prime-Mover, Inc.

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2006-08-07

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4100
Steering Control Head
Version no

T-code

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This page is intentionally left blank.

140

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S4.2
4180
Steering Bearing

Version no

T-code

000

SMX

C-code

Steering Bearing
1. Theory of Operation
The steering bearing is part of the drive unit assembly. The
vertical and horizontal loads are carried by the steering
bearing.

2. Maintenance
Inspect for wear or damage.

3. Troubleshooting
Probable Cause
Worn or damaged
steering bearing

BT Prime-Mover, Inc.

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Master Service Manual

2004-02-13

Required Action
Replace bearings

141

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Section

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PT
S4.2
Steering Bearing

4180

Version no

T-code

000

SMX

4. Repair and Rebuild


1
2
3

4
5

Item No.

142

Return

Description

Screw

Lockwasher

Bearing

Stop, steering

Transmission assembly

Master Service Manual

2004-02-13

F-code

Section

PT

S4.2
4180
Steering Bearing

Version no

T-code

000

SMX

C-code

The steering bearing can not be repaired or rebuilt. Replace


steering bearing with new as necessary.

Removal
1. Park truck on a level surface and make sure
parking brake is applied and load wheels are
blocked to prevent accidental movement.
2. Release pressure in hydraulic system by pressing
the lowering button on steering control head.
3. Press red OFF button O on the keypad. Depress
main ON/OFF switch to the OFF position.
Disconnect the battery connector from the truck.
4. Jack truck and block the frame (see page 58.)
5. Remove truck cover(s) [see page 84.]
6. Disconnect all electrical connections on drive
motor and brake assembly.
7. Remove transmission (see page 103.)
8. Remove screws (1) and lockwashers (2) from
bearing (3). Remove bearing (3) from transmission
assembly (5).

BT Prime-Mover, Inc.

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2004-02-13

143

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PT
S4.2
Steering Bearing

4180

Version no

T-code

000

SMX

Installation
1. Install new bearing (3) and secure with
lockwashers (2) and screws (1) on transmission.
2. Install transmission (see page 106.)
3. Connect all electrical connections.
4. Refill transmission with fluid as needed (see
page 72.)
5. Install truck cover(s) [see page 84.]
6. Remove blocks.
7. Connect the battery connector to the truck.
8. Turn main ON/OFF switch to the ON position.
Enter key code and press the green ON button I
on the keypad. Operate the trucks hydraulic
system and check operation of system as a whole.
Look for leaks and tight places on the lifting
linkage.

144

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S5.0
5000
Electrical Functions

Version no

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SMX

Electrical Functions
1. Theory of Operation
The travel control system on the truck is electrically controlled
and monitored. The lift/lower systems are electrically
controlled and hydraulically operated. All circuits are
protected against overload with automatic resetting circuit
breakers. Refer to the following detailed electrical circuit
schematics as they apply. The complete electrical circuit
schematics can be found starting on page 194. When starting
the truck, the transistor controller checks the closing
sequence of the micro switches in the circuit. For information
on the transistor controller see page 239.
Normal Operation
1. When the truck is first powered on, it displays an
hourmeter (see parameter 20 on page 178) for the
first five seconds. Then, it normally displays the
battery state-of-charge throughout operation.
2. While a Caution error code is tripped, it is
displayed 3.4 seconds out of every 5.1 seconds.
The other 1.7 seconds shows normal display.
3. When battery state-of-charge is zero percent, lift is
not allowed. When the battery state-of-charge is 10
percent or lower, the battery light blinks.

BT Prime-Mover, Inc.

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2006-12-12

145

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S5.0
Electrical Functions
Version no

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5000

1.1. Battery Plugged In With Keypad


With the battery connected to the truck, wire number 1
connects battery voltage to the positive side of the main
contactor (K10), control fuse (F50), positive of the key switch
jumper, electronic tiller arm card (ETAC) [A2] and positive
side of resistor (PTC R1.) From resistor (PTC R1), a voltage
of 1.0 to 1.5 volts less than battery voltage is provided to fuse
(F51) and positive side of the main ON/OFF switch (S21.)

Pressure Oil
Return Oil
B+ Circuit
B- Circuit
Signal
Pre-Charge Voltage

146

Return

Symbol

Designation

Symbol
M1

Designation

A1

Drive Transistor Controller

A2

Electronic Tiller Arm Card Transistor Controller

M3

Pump Motor

F50

Keypad/Tiller Arm Circuit Fuse

S18-1

Horn Switch

F51

Main Control Fuse

S18-2

H1

Horn

S21

Drive Motor

Horn Switch
Main ON/OFF Switch

J11

Handle Stem Base Wire Connection

S24

Arm Angle (A) Switch

J41

Service Key (CAN) Wire Connection

S25

Arm Angle (B) Switch

K4

Main Contactor Relay

S36

Lift Limit Switch

K10

Main Contactor

Y1

Brake Coil

K30

Pump Motor Solenoid

Y10

Lower Valve Coil

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2006-12-12

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Section

PT

C-code

S5.0
5000
Electrical Functions

Version no

T-code

002

SMX

1.2. Battery Plugged In With Key Switch


With the battery connected to the truck, wire number 1
connects battery voltage to the positive side of the main
contactor (K10), control fuse (F50), positive side of the key
switch and positive side of resistor (PTC R1.) From the
resistor (PTC R1), a voltage of 1.0 to 1.5 volts less than the
battery voltage is provided to fuse F51 and positive side of
the main ON/OFF switch (S21).

Pressure Oil

BT Prime-Mover, Inc.

Designation

Symbol
M1

Designation

Return Oil

A1

Drive Transistor Controller

A2

Electronic Tiller Arm Card Transistor Controller

M3

Pump Motor

B+ Circuit

F50

Keypad/Tiller Arm Circuit Fuse

S18-1

Horn Switch

F51

Main Control Fuse

S18-2

H1

Horn

B- Circuit

Return

Symbol

S21

Drive Motor

Horn Switch
Main ON/OFF Switch

J11

Handle Stem Base Wire Connection

S24

Arm Angle (A) Switch

Signal

J41

Service Key (CAN) Wire Connection

S25

Arm Angle (B) Switch

K4

Main Contactor Relay

S36

Lift Limit Switch

Pre-Charge Voltage

K10

Main Contactor

Y1

Brake Coil

K30

Pump Motor Solenoid

Y10

Lower Valve Coil

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2006-12-12

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S5.0
Electrical Functions
Version no

T-code

002

SMX

C-code

5000

1.3. Main ON/OFF Switch/Keypad ON


When the switches on wire number 22 connects to the battery
voltage to the ETAC (A2) pin J11-1, this powers up the ETAC
(A2) for start of communication to the transistor controller
(A1). A voltage of volts from the resistor (PTC R1) 1.0 to 1.5
volts less than battery voltage is provided to the positive side
of arm angle A switch (S24), arm angle B switch (S25), and
the normally closed lift limit switch (S36) to the transistor
controller (A1) pin J5-15.

Pressure Oil
Return Oil
B+ Circuit
B- Circuit
Signal
Pre-Charge Voltage

148

Return

Symbol

Designation

Symbol
M1

Designation

A1

Drive Transistor Controller

A2

Electronic Tiller Arm Card Transistor Controller

M3

Pump Motor

F50

Keypad/Tiller Arm Circuit Fuse

S18-1

Horn Switch

F51

Main Control Fuse

S18-2

H1

Horn

S21

Drive Motor

Horn Switch
Main ON/OFF Switch

J11

Handle Stem Base Wire Connection

S24

Arm Angle (A) Switch

J41

Service Key (CAN) Wire Connection

S25

Arm Angle (B) Switch


Lift Limit Switch

K4

Main Contactor Relay

S36

K10

Main Contactor

Y1

Brake Coil

K30

Pump Motor Solenoid

Y10

Lower Valve Coil

Master Service Manual

2006-12-12

F-code

PT

Section

C-code

S5.0
5000
Electrical Functions

Version no

T-code

002

SMX

This page is intentionally left blank.

BT Prime-Mover, Inc.

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2006-12-12

149

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S5.0
Electrical Functions
Version no

T-code

002

SMX

C-code

5000

1.4. Travel, Low Speed


When the steering control handle is within 6 to 41 degrees of
the upper rest position and the thumb controls are rotated
from neutral, the travel signal is detected via hall effect
sensors. This converts into a travel instruction in the ETAC
(A2) and transmitted via the CAN to the transistor controller
(A1). The ETAC (A2) verifies that the reverser button is not
activated before supplying the travel command to the
transistor controller. The ETAC (A2) verifies that arm angle B
switch (S25) is engaged for slow speed travel mode. The
transistor controller provides a negative pin J5-4 to the main
contactor coil (K10) closing the main contactor (K10) and to
the main contactor relay (K4). The main contactor relay (K4)
provides battery voltage to the positive side of pump
contactor coil (K30), brake coil (Y1), lower valve coil (Y10)
and horn (H1). The transistor controller provides a negative
pin J5-5 to the brake coil (Y1) releasing the brake. The
voltage at M- of the drive motor will vary from 24V to
approximately 20V. The voltage is proportional to the position
of the thumb controls. The drive wheel starts to rotate in the
selected direction at a speed proportional of the thumb
controls.

150

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C-code

S5.0
5000
Electrical Functions

Version no

T-code

002

SMX

Travel Low Speed

Pressure Oil

BT Prime-Mover, Inc.

Return

Symbol

Designation

Symbol
M1

Designation

Return Oil

A1

Drive Transistor Controller

A2

Electronic Tiller Arm Card Transistor Controller

M3

Pump Motor

B+ Circuit

F50

Keypad/Tiller Arm Circuit Fuse

S18-1

Horn Switch

F51

Main Control Fuse

S18-2

B- Circuit

H1

Horn

S21

Drive Motor

Horn Switch
Main ON/OFF Switch

J11

Handle Stem Base Wire Connection

S24

Arm Angle (A) Switch

Signal

J41

Service Key (CAN) Wire Connection

S25

Arm Angle (B) Switch

K4

Main Contactor Relay

S36

Lift Limit Switch

Pre-Charge Voltage

K10

Main Contactor

Y1

Brake Coil

K30

Pump Motor Solenoid

Y10

Lower Valve Coil

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PT
S5.0
Electrical Functions
Version no

T-code

002

SMX

C-code

5000

1.5. Travel, High Speed


When the steering control handle is between 41 to 79
degrees from the upper rest position, the ETAC (A2) verifies
that both arm angle switch (S24) and arm angle switch (S25)
are engaged for high speed travel mode. The voltage at M- of
the drive motor will vary from 24V to 0.5V. The voltage is
proportional to the position of the thumb controls. The drive
wheel rotates in the selected direction at a higher speed
proportional of the thumb controls.

Pressure Oil

Symbol

Return Oil

A2

Electronic Tiller Arm Card Transistor Controller

M3

Pump Motor

B+ Circuit

F50

Keypad/Tiller Arm Circuit Fuse

S18-1

Horn Switch

F51

Main Control Fuse

S18-2

Horn Switch

H1

Horn

S21

Main ON/OFF Switch

J11

Handle Stem Base Wire Connection

S24

Arm Angle (A) Switch

J41

Service Key (CAN) Wire Connection

S25

Arm Angle (B) Switch

K4

Main Contactor Relay

S36

Lift Limit Switch

K10

Main Contactor

Y1

Brake Coil

K30

Pump Motor Solenoid

Y10

Lower Valve Coil

Pre-Charge Voltage

Master Service Manual

M1

Designation

Drive Transistor Controller

Signal

152

Designation

A1

B- Circuit

Return

Symbol

Drive Motor

2006-12-12

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PT

Section

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5000
Electrical Functions

Version no

T-code

002

SMX

1.6. Reverser
Pressure Oil
Return Oil
B+ Circuit
B- Circuit
Signal
Pre-Charge Voltage

Symbol

Designation

Symbol
M1

Designation

A1

Drive Transistor Controller

A2

Electronic Tiller Arm Card Transistor Controller

M3

Pump Motor

F50

Keypad/Tiller Arm Circuit Fuse

S18-1

Horn Switch

F51

Main Control Fuse

S18-2

H1

Horn

S21

Drive Motor

Horn Switch
Main ON/OFF Switch

J11

Handle Stem Base Wire Connection

S24

Arm Angle (A) Switch

J41

Service Key (CAN) Wire Connection

S25

Arm Angle (B) Switch


Lift Limit Switch

K4

Main Contactor Relay

S36

K10

Main Contactor

Y1

Brake Coil

K30

Pump Motor Solenoid

Y10

Lower Valve Coil

BT Prime-Mover, Inc.

Return

When the reverser button is activated with the steering


control handle lowered in the travel mode, the control system
provides an immediate forks-first direction travel instruction.
Reverse signal is converted into a forks-first travel instruction
transmitted via the CAN to the transistor controller. Travel
and speed inputs are ignored. The transistor controller
provides maximum torque immediately after the reverser
button is pressed. Maximum rearward travel continues until
the reverser button is released.

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2006-12-12

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S5.0
Electrical Functions
Version no

T-code

002

SMX

C-code

5000

1.7. Lift
When the lift button is pressed, the transistor controller
provides a negative pin J5-4 to the main contactor coil (K10),
closing the main contactor (K10) to the main contactor relay
(K4). The main contactor relay (K4) provides battery voltage
to the positive side of pump contactor coil (K30). The
transistor controller provides a negative in J5-6 to the pump
contactor coil (K30) closing the pump contactor.

Pressure Oil
Return Oil
B+ Circuit
B- Circuit
Signal
Pre-Charge Voltage

154

Return

Symbol

Designation

A1

Drive Transistor Controller

Symbol
M1

Designation
Drive Motor

A2

Electronic Tiller Arm Card Transistor Controller

M3

Pump Motor

F50

Keypad/Tiller Arm Circuit Fuse

S18-1

Horn Switch

F51

Main Control Fuse

S18-2

Horn Switch

H1

Horn

S21

J11

Handle Stem Base Wire Connection

S24

Arm Angle (A) Switch

J41

Service Key (CAN) Wire Connection

S25

Arm Angle (B) Switch


Lift Limit Switch

Main ON/OFF Switch

K4

Main Contactor Relay

S36

K10

Main Contactor

Y1

Brake Coil

K30

Pump Motor Solenoid

Y10

Lower Valve Coil

Master Service Manual

2006-12-12

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Section

PT

C-code

S5.0
5000
Electrical Functions

Version no

T-code

002

SMX

1.8. Lower
When the lower button is pressed, the transistor controller
provides a negative pin J5-4 to the main contactor coil (K10),
closing the main contactor (K10) to the main contactor relay
(K4). The main contactor relay (K4) provides battery voltage
to the positive side of lowering valve coil (Y10). The transistor
controller provides a negative pin J5-2 to the lowering valve
coil (Y10), opening the hydraulic lowering valve.

Pressure Oil

BT Prime-Mover, Inc.

Return

Symbol

Designation

Symbol

Return Oil

Drive Transistor Controller

A2

Electronic Tiller Arm Card Transistor Controller

M3

Pump Motor

B+ Circuit

F50

Keypad/Tiller Arm Circuit Fuse

S18-1

Horn Switch

F51

Main Control Fuse

S18-2

Horn Switch

B- Circuit

H1

Horn

S21

J11

Handle Stem Base Wire Connection

S24

Arm Angle (A) Switch

Signal

J41

Service Key (CAN) Wire Connection

S25

Arm Angle (B) Switch

K4

Main Contactor Relay

S36

Lift Limit Switch

Pre-Charge Voltage

K10

Main Contactor

Y1

Brake Coil

K30

Pump Motor Solenoid

Y10

Lower Valve Coil

Master Service Manual

M1

Designation

A1

2006-12-12

Drive Motor

Main ON/OFF Switch

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Electrical Functions
Version no

T-code

002

SMX

C-code

5000

2. Maintenance
Connections must be kept clean and tight. The electrical
components should be protected from moisture. If the truck is
equipped with cold storage, or corrosive environment
application package, then the di-electric compound (part
number 302249-000) in the plug-in connectors should be
renewed periodically. This compound is available through the
parts department of your authorized Prime-Mover Dealer.

2.1. Wiring
Many electrical problems are caused by a bad or dirty battery.
Make sure battery is clean. Check the electrolyte level and
battery level.
CAUTION Unless otherwise directed, disconnect
battery connector when checking electrical
circuits or components with an ohmmeter.
Electrical current can damage the
ohmmeter.
Visually inspect all wiring and electrical components for the
following:

Loose connections or connectors

Loose or broken terminals

Damaged terminals, blocks, or strips

Broken wiring and shorted conditions


(especially those that are close to metal
edges or surfaces)

Use an ohmmeter to check for wiring continuity.

2.1.1. Definitions
Continuity. A continuous and uninterrupted path between
two or more locations in an electrical circuit, typically having a
resistance of less than 1 ohm.
Open Circuit. A lack of a continuous path between two or
more electrical connections. Generally, when such a circuit is
tested, it will have a resistance greater than one megohms.
Pulse Width Modulation. Pulse Width Modulation (PWM),
also called chopping, controls the speed of the motor by

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5000
Electrical Functions

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SMX

switching the battery voltage to the motor on and off very


quickly.
Overtemperature. Overtemperature of the transistor
controller is from 185 degrees F (85 degrees C) and above.
At overtemperature, the drive current limit is linearly
decreased from full set current down to zero. Plug current is
not reduced to provide full truck braking under all thermal
conditions.
Undertemperature. When the transistor controller is
operating at less than -13 degrees F (-25 degrees C), the
current limit is cut back resulting in reduced travel speed.
Short Circuit or Short. A short circuit is an unspecified
path in a circuit that provides unwanted full or partial
continuity between two or more locations in an electrical
circuit.
Example: Two insulated wires are physically next
to each other and the insulation has been worn off
each of the wires. Because the conductors inside
each wire are now touching each other, there is a
short circuit.
Example: A power cable from the battery to a
junction post in the truck has had the insulation
worn away. Because the wire conductors are
touching the frame, there is a short circuit of the
battery cable.
2.1.2. Shorts to Frame Test
Shorts to frame is an industry term for unintentional current
leakage paths between normally isolated electrical circuits
and their metal enclosures. Shorts to frame may be metallic
connections, such as a wire conductor contacting metal
through worn insulation. More often, shorts to frame are
resistive leakage paths caused by contamination and/or
moisture. These leakage paths can result in unwanted
electrical noise on the metallic truck structure and may result
in improper operation.
Shorts to frame can be caused by the following:

BT Prime-Mover, Inc.

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Accumulation of dirt

Battery electrolyte leakage

Motor brush dust

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Motor brush leads touching housing

Insulation breakdown

Bare wires

Pinched wiring harness

Circuit cards improperly mounted

Shorts to frame can occur at numerous locations on truck


including the following:

Batteries

Motors

Cables, wiring, and harnesses

Heat sinks

Bus bars

Solenoids

Contactors

Terminal strips

Switches

Power panel insulation

Circuit card mounts

To test for shorts from battery to frame:


1. Press red OFF button O on the keypad. Depress
main ON/OFF switch to the OFF position.
Disconnect the battery connector from the truck.
2. Using a voltmeter set on a 50Vdc scale, attach the
leads as follows:

Negative (-) lead to an unpainted, grounder


surface on the truck frame

Positive (+) lead to the positive battery


terminal.

The voltmeter must shown no more than 3V.


3. Attach the leads as follows:

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Negative (-) lead to the negative battery


terminal

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Positive (+) lead to an unpainted, grounded


surface on the truck frame.

The voltmeter must show no more than 3V.


4. If a reading of 3V or more is received in the
previous steps 2 or 3, proceed as follows:
a. If applicable, remove bolts securing the battery
to the truck. Remove battery from the truck (see
page 203.)
b. Thoroughly clean battery (see page 200.)
c. Reinstall battery. If applicable, securely fasten
bolts to battery box frame on the truck.
d. Repeat steps 2 and 3 to see if the problem has
been eliminated.
e. If excessive voltage is still found, check the
battery for internal leakage.
To test for shorts from components to frame:
1. Press red OFF button O on the keypad. Depress
main ON/OFF switch to the OFF position.
2. Disconnect the battery connector from the truck.
3. Using an ohmmeter and measure the resistance to
an unpainted, grounded surface on the frame at
B+, B-, and all fuses:
A resistance reading of less than 100,000 ohms
indicates a short to the frame. If this condition
exists, find the source of low resistance or short to
frame using the following step 6.
4. If applicable, remove bolts securing the battery to
the truck. Remove battery from the truck (see
page 203.)
The voltmeter must show no more than 3V.
5. Connect the battery lead to the truck.
6. Using an ammeter to measure the leakage current
to the unpainted, grounded surface on the frame at
B+, B-, all fuses and all motors. If the current is less
than 0.001 ampere (1 mA), the truck system
passes. If the current exceeds 1 mA, go to step 6.
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7. To find the cause of the low resistance, disconnect


the power cables from each motor or major
subassembly one at a time, to determine if that
item is causing the low resistance.

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3. Troubleshooting
3.1. Troubleshooting Flowchart
Troubleshooting

Truck Fault
Code

Yes

Find Code
(see page 181)

No

Transistor
Controller
Error
Code

Yes

Find Code
(see page 246)

No

Yes, Traction/Overall
Check
Troubleshooting
Chart

No

Go to charts
(see page 189)

Yes, Hydraulic

Go to charts
(see page 261)

General Troubleshooting
(see Service Display page 169)

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Troubleshooting can be broken down into two sections: (1)


mechanical and (2) electrical circuits. Electrical circuits can
be further broken down into control circuit and power circuit.
Many hours of troubleshooting time can be saved by knowing
the exact operational symptoms. Check the control switches;
if they test as operating properly, the problem most likely will
be in the power circuit of that function.
The travel functions are controlled by the transistor controller.
Lift, lower, and horn functions operate separately. To use this
troubleshooting guide locate the failure symptom in the index
(see Troubleshooting Chart Index on page 188.) Then go
to the expanded outline, and follow the testing procedures
described.
Voltage tests are made with the negative lead of the volt
meter connected to battery negative. If the negative lead is
connected to a negative terminal on the electrical panel, first
verify the negative connection to the battery by touching the
positive meter lead to the positive battery post. The battery
voltage must be at least 25.2 volts for a 24 volt system. If
the battery voltage is below 22 volts (no load), then the
transistor controller may not operate properly. Charge the
battery before starting the troubleshooting procedures.
When testing voltage, the POSITIVE SIDE of any
component refers to the terminal on that component that is
closest electrically to the battery positive terminal. The
NEGATIVE SIDE of any component refers to the terminal
on that component that is farthest electrically from the battery
positive terminal. It is possible and in many cases desirable to
measure battery voltage on the negative side of a
component.
Forward direction refers to travel in the direction of the
control handle with the tractor-first. Reverse direction refers
to travel with the forks-first.
The parking brake will automatically engage when the truck
has come to a stop while the control handle is in the operating
range and no travel speed is requested. Normal stopping
during travel operation is obtained by reversing the travel
direction controls (plugging) or moving the control handle to
either the braking positions shown on page 163. The control
handle and the direction control operate together to release
the brake. The line contactor will be open when either of the
parking methods are applied.
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40
33
8

Figure 5-1: Operating Range of Control Handle

After the final troubleshooting test is completed, the truck


should be repaired and operating properly. If it is not, then
verify test results and possibly re-evaluate the failure
symptoms. If the truck still has not been repaired, then call
your local Prime-Mover Dealer for assistance. When placing
a call, the following information is required: truck model and
serial number, information on hourmeter and error code,
actual battery voltage at open circuit and at hydraulic
operation under full load, the precise operating symptoms,
and the exact results of the testing you have done.
Authorized Prime-Mover Dealers may call the factory
directly if necessary.
The first steps of any troubleshooting procedure include:
1. Inspect truck for physical damage or mechanical
malfunction.
2. Check for ground faults from the electrical system
to the frame with an ohmmeter. A minimum of
100,000 ohms resistance from the frame to any
and all wiring is acceptable.
3. Check that the battery is fully charged and
connected.
4. Operate the truck in all modes to determine the
exact symptoms. DO NOT forget that systems are
equipped with circuits that reduce operation in the
event of improper operating procedures.

BT Prime-Mover, Inc.

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3.2. Main Harness Replacement


NOTE!

Before removal of harness, document wire


to terminal connections for main harness.
Control Wires/
Wire Guard

26

3
6

57

Power Cables
on Left Side
Figure 5-2: Terminal Block

1. Park the truck on a level surface and make sure


the parking brake is applied and load wheels are
blocked to prevent accidental movement
2. Press red OFF button O on the keypad. Depress
main ON/OFF switch to the OFF position.
3. Disconnect the battery connector from the truck.
4. Remove the truck covers and upstop (see see
Figure 5-5 on page 166) to gain access to the
wiring and cables.

NOTE!

Reference the electrical schematic on


page 194 for location on connectors and
switches.

5. Disconnect connector J11 and switches S24 and


S25 inside the stem mount and all ring terminals
from the drive motor terminal block (see
Figure 5-2.)

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6. Remove the stem mount (see page 103) and stem


handle as an assembly from the transmission (see
Figure 5-3.) Remove the old harness from the
truck (see page 192.)
Upstop

Stem
Mount

Stem Handle

Transmission
Assembly

Figure 5-3: Stem Handle Mounting

7. Lay the new harness into the truck.


8. Connect the truck end of the harness. For the
proper harness connections, see Figure 5-3. For
schematics see page 194.
9. Install the harness down through the transmission
opening and connect cables and wires to the drive
motor terminal block (see Figure 5-2 on page
164.)
10. Check to make sure the power wires are vertically
stacked one on top of the other on the LEFT side of
the transmission opening above the power
terminals and the wire guard with ring terminals
match on see Figure 5-3.

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11. Position cables and wires as shown in see Figure


5-3 on page 165.
12. Correctly orient the wire guards and power wires
through the transmission as shown in Figure 5-4.
13. Make sure the short wire guard and wire tie are
running down through the transmission as shown
in Figure 5-4.

Stem Handle Wire Guard


Power Cables
Wire Tie

Field & Brake Wires


Figure 5-4: Transmission with Harness Wiring

14. Install the stem mount and stem handle assembly.

Wire 24
Wire 51 - S25

Wire 50 - S24
Figure 5-5: Stem Mount Switch Wiring

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15. Refer to see Figure 5-3 on page 165 when


installing ring terminals. Install ring terminal and
secure middle nut and torque to 79 in-lbs (8.9
Nm). Install ring terminal and secure outer nut,
making sure wire is out of the way, before torquing
outer nut to 79 in-lbs (8.9 Nm).
16. Install the upstop (see Figure 5-4 on page 166)
and truck covers.
17. Connect the battery connector to the truck.
18. Turn main ON/OFF switch to the ON position.
Enter key code and press the green ON button I
on the keypad.
19. Check all operating functions on the control
handle.

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3.3. Operator Display and Programming


The display is located on the top of the steering control
handle arm and displays the operator and machine-specific
register.
A

A - Numerical Field
B - Hour Meter Indicator
C - Parameter Control
D - Battery Indicator
E - Error Indicator

Operator Display
3.3.1. Special Modes
To enter a special truck mode proceed as follows:
1. Hold down horn switch.
2. Enter PIN code on keypad and push green ON
button (l) or turn key switch ON.
3. Release horn switch at desired display mode.
Options for the display mode are follows:

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(H)ourmeters; use thumb control to choose, see


parameter 20 on page 178 for Hourmeter options
(hours shown are rounded down, i.e., 3 hours 50
minutes will display as 3.)

(E)rror codes log; the most recent error code will


be displayed followed by the hour meter (activity
time) it occurred. Use thumb control to scroll
through the last 50 error codes (if no error code is
logged, dashes will be displayed.)

(P)arameters: use thumb control to choose and the


horn switch to access a parameter, the parameter
light blinks (a service key is required to change
some parameters (see page 174.) When the
service key is used to change driver
parameters and parameter 10, the driver
number appears to the right of the normal

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parameter number display. All driver parameters


and drivers are cycled through before Service
Parameters, 0 = 10th driver.)

(P)art (n)umbers: use thumb control to scroll


through the following:

(S)oftware (P)art (n)umber

(H)ardware (P)art (n)umber

(H)ardware (S)erial (n)umber

3.3.2. Service Display


Connect the service key (see page 174) in connection point
J41 (see page 194.) Push the green ON button I on the
keypad. The battery status is displayed and the armature
current symbol is lit continually. Use the horn button (S18) to
toggle between display modes.
No.

Flashing Symbol

Displayed Data

Speed reference value sent to transistor controller:


-127 (FL) to +127 (FT) x parameter 2 for Fast

Digital inputs/outputs from transistor controller


see page 170

Battery voltage (V) at ETAC

Armature current (A)

Field current (A)

Armature PWM (%)

Transistor Controller System Mode see page 171

Field resistance (Ohms), used for thermal cutback

NOTE!

BT Prime-Mover, Inc.

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The first drivers Driver Parameters are


used while in Service Display.

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3.3.3. Digital Inputs/Outputs from Transistor Controller


I

II

III IV

C
1A

6F

G
7

5
E
4
D

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2
B
3
C
DP
DP

Digit

Segment

I
I
I
I

1
2
3
4

DP

II
II
II
II
II
II
II
II

1
2
3
4
5
6
7
DP

III

III
III
III
III
III
III
III

2
3
4
5
6
7
DP

Function
Input (J5-14): Arm angle B see below
Input (J5-15): Lift limit
Input (J5-12): Arm angle A see below
Input (J5-2): Lower valve (lit if valve present &
not powered)
Input (J5-5): Brake (lit if brake is present & not
released)

Output (J5-2): Lower valve


Output (J5-4): Main contactor interlock
Output (J5-7): Horn
Output (J5-5): Brake
Output (J5-6): Pump contactor

ETAC input: lift forks


ETAC input: lower forks

ETAC input: horn

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3.3.4. Transistor Controller System Mode


The transistor controller system mode is used only in special
cases.
Status
1
4
6
10
11

16

Comment
Motor drive, plug or active neutral braking
Field reversal (transitional)
Disable (major fault, such as severe overvoltage)
Regen
Regen taper (transitional)
No activity: main contactor open because no output
requested for 30 seconds or an error occurred
Passive restraint

17
24
65
74
129
144

Active restraint while driving (overspeed)


Passive restraint (transitional)
Reverser (drive)
Reverser (regen)
Emergency shutdown while in drive
Emergency shutdown while in passive restraint

13

1. The system mode shows details of transistor controller activity,


including during normal operation. It is different than, and does
not correspond to, the code from the transistor controller
Status LED.
2. Throttle requests are not allowed for any status of 32 and
over.
3. Truck is in an emergency shutdown for any status of 128 and
over.

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3.4. Changing Driver Accessible


Parameters (P)
WARNING Modify specific truck parameters will
change the driving characteristics of the
truck.
1. Enter special truck mode until P is displayed. The
parameter control indicator is illuminated (see
page 168.)
2. Use the thumb control to scroll to the driver
parameters to locate the one to change or view the
following truck parameter table. Scrolling in tractorfirst position will show parameters 1-40. scrolling in
the tractor-first direction will show parameters 40-1.
Press and hold horn button (S18-1 or S18-2) until
P is displayed.
3. Press horn button once to access the parameter
shown on the display. The parameter symbol (D)
on the display starts flashing.
4. Change parameter value by pressing the thumb
control up or down.

NOTE!

Parameters 1-7 can only be modified, see


page 173. Parameters 10-40 can only be
viewed.

5. Press the horn button again to confirm the change.


The parameter symbol O on the display stops
flashing and remains illuminated (see page 168.)
6. End programming by pressing the red OFF O key
on the keypad.

NOTE!

172

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Moving the thumb control 1/4 - 3/8 inch


(6.35 - 9.25 mm) will show the parameter
display in digit I Releasing the thumb
control to neutral position will then display
the parameter value in digit III and IV,
depending on if it is a single or double digit
number.

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The parameter change is complete. The next time the truck is


started, the new parameter will be in effect.
All parameters can be viewed, however, not
all parameters can be changed. Truck
parameters may or may not be accessed,
depending on the value of parameter 39
(see page 179.)

NOTE!

Truck Parameters
Parameters 1-7 are Driver Parameters (7 parameters for each Drive PIN code entered

Parameter

Name

Unit

Range

Step

Default

Description

Max speed, slow mode

10 to 40

20

Maximum speed value sent to transistor


controller while in Slow, except during Turtle
Torque (gives torque boost if high load
encountered.)

Max speed, fast mode

70 to 98

94

Reduces speed value sent to transistor


controller while in Fast (all throttle positions.)

Acceleration

30 to 90

80

Defines trucks acceleration characteristic,


lower number gives less aggressive
acceleration.

Deceleration

40 to 90

65

Defines trucks automatic plug-braking


characteristic when throttle is reduced
(including to neutral); lower number gives
less aggressive acceleration

Truck off delay (keypad


only)

min

0 to 20

Sets truck off delay (energy saving feature);


if truck is not used for this amount of time,
the ETAC powers the truck off. When this
parameter is set to 0, the truck never
powers off. If parameter 39 is 1 or 2 (truck
has key switch option), the truck never
powers off.

BT Prime-Mover, Inc.

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3.5. Changing Service Parameters


NOTE!

A service key is required to change service


parameters.

1. Connect the service key at J41.

NOTE!

With service key connected, the truck does


not power ON using the keypad or key
switch.

2. Enter special truck mode (see page 168.)


3. Press and hold horn button until P is displayed.
The parameter control indicator is illuminated (see
page 169.)
View Parameters with Service Key
Service Key

When parameters 1-7 and 10 are viewed with the service


key, both the parameter (on the left side of the display, as
normal) and the driver number (on the right) are shown.
When the thumb control is rotated toward the forks, the
parameter
number
increases,
progresses
through
parameters 1 - 10, and then rolls over to the next driver (the
driver number increases.) There are ten drivers 1-9, (0 = 10th
driver.) If a parameter is changed, it is valid only for the driver
shown. Parameter 1 for the sixth driver is shown as an
example below:

01 6

Service Key

After scrolling through all drivers and driver parameters,


service parameters 11-40 will be displayed. Since these
parameters are valid for all drivers, no driver is shown.
Parameter 39 is shown as an example below:

39

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If display/access for a service parameter is required, it is


faster to initially rotate the thumb control away from the forks
(go backwards through parameters/drivers.) The parameter
number displays briefly, then if the thumb control is not
rotated further the parameter value is displayed.
Service Parameters
Parameters 1-7 (driver number) and Driver Parameters, 10-40 are Service Parameters

Parameter

Name

10

Range

Step

Default

Description

Pin code
(keypad only)

0 to 9999

Can set up to 10 PIN codes (need Service Key to


access this.)
Note: 0 disables a driver (the 2nd through 10th
drivers default PIN is 0), if all drivers are disabled
the truck cannot be driven without the service key,
and if two drivers have the same PIN, the higher
number drivers parameters will be used.

14

Creep speed

-10 to 10

-5

Defines speed at low throttle positions; a negative


number enhances low speed maneuverability, a
positive number makes the truck more responsive

20

Hourmeter
selection

1 to 5

1 (A.) = key time


2 (b.) = activity time (drive, lift or lower)
3 (c.) = drive
4 (d.) = lift
5 (s.) = time to service
(if parameter 25 = 0, the power-on 5 second hour
meter display is skipped and 5(s) is not shown
during Hourmeters special truck mode.) Time to
service counts backward from value of parameter
25 to zero and decrements the same as 2(b.)
increments.

21

Battery size
(The lower the
number, the
deeper the
discharge to
the battery.)

1 to 20

Defines battery capacity; higher number


represents larger capacity battery (the truck will
allow the battery to become more discharged given
the same displayed battery state-of-charge.) In
other words, if the battery state-of-charge reaches
0% too soon (the battery still contains adequate
charge to continue operation), this parameter
should be increased. The battery state-of-charge is
reset when the battery voltage is above 25.2V.

25

Service
interval

0 to 2000

50

Sets service timer. C29 will display when time is


up. To reset service timer, access this parameter
without changing the value. To disable the service
timer, set this parameter to 0. See parameter 20 on
page 178.

39

Access code

1 to 4

Defines whether truck has key switch or keypad


and what access level personnel will have to
parameters
1=key switch/driver parameters open
2=key switch and closed
3=keypad and open
4=keypad and closed (when closed, service key is
required to access driver parameters)

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3.5.1. Parameter Description


Parameter 1
Maximum speed value sent to transistor controller while in
Slow mode except during turtle torque (gives torque boost if
high load is encountered.)
Parameter 2
Reduces speed value sent from the Electronic Tiller Arm
Card (ETAC) to the transistor controller while in Fast mode
(all throttle positions.)
Parameter 3
Defines trucks acceleration characteristic when truck starts
from a stop. A high number gives maximum acceleration, a
lower number gives less aggressive acceleration.
Parameter 4
Defines trucks automatic plug-braking characteristic when
throttle is reduced (including to neutral.) A lower number
gives less aggressive acceleration.
Parameter 5
Time until the truck is switched OFF (energy saving feature)
when truck is idle and the brake is applied. Time is counted
from the latest power output is requested. If truck has the
key switch option, the truck never powers OFF.
Parameter 10
Defines the PIN code for the driver shown. The default
operator PIN-key code is 1. Programming new key codes
must be done using a service key (see page 174.) Each of
the 10 key codes may be programed individually for operating
parameters.
If two drivers have the same PIN, the higher number drivers
parameters will be used. (EXAMPLE: If both the first and
second drivers PIN codes are 1111 and the first drivers
maximum speed is 80 percent and the second drivers
maximum speed is 90 percent, when someone logs in with
1111 the maximum speed will be 90 percent.) Setting a
drivers PIN code to 0 will disable that driver. By default, the
first drivers PIN code is 1 and all other drivers PIN codes are
0. To enable additional drivers, change these PIN codes to
numbers other than 0. To program operating parameters
proceed as follows:
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With the battery connected to the truck, service key


connected, main ON/OFF switch turned to the ON
position, press and hold down the horn button.
Enter key code and press I or turn on key switch.
The display will now show: H - Hour meter, E - Error
Codes, P - Parameters, and Pn - Software number.
These symbols will cycle continuously until the horn
button is released.
Release the horn button when the display shows P
(if the horn button is released at the wrong time, turn
off the truck and start over.)
The parameter symbol below the display lights up;.
The value of parameter # 1 is shown on the display
(although parameter # 1 is not functional at this time.)
Use the thumb controls to scroll to the desired
parameter.
When the thumb control is rotated slightly, the display
changes to show the parameter number currently
active. Rotating the thumb control further increments
the parameter up or down according to which
direction the control is rotated.
Release the thumb control to neutral when the desired
parameter number is shown. (The current
programmed value of that parameter is now shown on
the display.)
Press the horn button once to make the parameter
value displayed start to flash.
Rotate the thumb control to increment the parameter
value up or down, depending upon the direction the
control is rotated.
Release the thumb control to neutral when the desired
parameter value is displayed.
Press the horn button once to lock in the new
parameter value and verify this parameter has quit
flashing.
Turn off truck when programming is completed.

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Parameter 14
Defines speed at low throttle positions. A negative number
enhances low speed maneuverability. A positive number
makes the truck more responsive.
Parameter 20
Choose the hourmeter to display.
1 = A. (key time)
2 = b. (activity time
3 = c. (drive motor time)
4 = d. (pump motor time)
5 = s. (time to service)
Parameter 21
Data must be provided on the battery installed on the truck.
To adjust the disconnection point of the battery discharge
indicator, measure the following:
WARNING The battery can be destroyed if the
parameter settings are not correct.
NOTE!

Acid concentration varies with different


battery brands.

The acid concentration of a fully-charged battery. To


check quality of battery (must be between 1.27 - 1.29
specific gravity (SG).
At lift cutout, acid
approximately 1.14 SG.

concentration

should

be

Reset voltage is 25.2V. Lift cutout occurs when the


display shows zero percent state-of-charge.
See Troubleshooting Chart Index on page 188.
Parameter 25
Used to set a time limit to the next service from 0 to 2000
hours in steps of 50 hours. When it is time for service, caution
29 will display, see page 182. To disable the service timer,
set this parameter to 0. To reset service timer, access this
parameter without changing the value.

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Parameter 39
Determines whether the truck has a key switch or keypad and
what access level service personnel will have to the driver
parameters. This parameter is adjustable as follows:
1 = Key switch connected, driver parameters open
2 = Key switch connected, driver parameters must be
opened with service key
3 = Keypad connected, driver parameters open
4 = Keypad connected, driver parameters must be
opened with a service key.
3.5.2. Operating Parameter Programming
The following operating parameters may be programmed by
the operator:
Parameter 1 - Slow speed range 10 - 40
Parameter 2 - Fast speed range 70 - 98
Parameter 3 - Acceleration range 30 - 90
Parameter 4 - Deceleration range 40 - 90
Parameter 5 - Automatic time off interval (with keypad
only) - from 0 minute to 20 minutes (a setting of 0
disables automatic time off.)
Additional truck parameters may be viewed but cannot be
changed by the operator.
3.5.3. Display Part Numbers (Pn)
1. Enter special truck mode (see page 168.)
2. Press and hold horn button until Pn is displayed.
3. Use the thumb control to scroll and display the
following information:

HPn - Hardware part number

HSN - Hardware serial number

SPn - Software part number

4. End displaying the part number by pressing the red


OFF O key on the keypad.

BT Prime-Mover, Inc.

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3.6. Error Codes (E)


When an error occurs on the truck, a code is displayed (see
page 181.)
3.6.1. Error Code History
To access the error code history, proceed as follows:
1. Enter special truck mode (see page 168.)
2. Press and hold the horn button until E is
displayed. The error indicator (wrench icon) is
illuminated (see page 169.)
Use the thumb control to scroll through the last 50
error codes. The latest fault is shown first. The
display first shows the error code and then the hour
meter reading the fault occurred.
The error codes are divided into two groups; C Caution and E - Error.
The C error codes are not stored. It is only a
caution and is highlighted on the display as long as
the fault exists.
For example, if only one fault is registered in the
memory, the second empty place is shown as
follows: Fault E - - - and time: - - -.hour meter
reading.
3. End displaying the error code history by pressing
the red OFF O key on the keypad.

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3.6.2. Truck Fault Codes


Caution fault codes 0-49 are not logged. C codes 50-99 are
logged.
Code C14 - Arm Angle Reference Warning
Reason

Steering control handle was not in up position at power ON or after the truck has not been used for a time.

Performance Limits

Travel is not allowed until code is cleared.

How to Clear Code

Code is cleared as soon as steering control handle is put in the Top Brake position.

Possible Causes
with corrective
actions/checks

1.
2.

Control handle stuck in down position.


a. Check upstop.
Arm angle input may be stuck ON.
a. Check switch.
b. Check input to transistor controller.

Code C19 - Default Parameter Warning


Reason

Parameter(s) out-of-range (see page 175) or incompatible with software version.

Performance Limits

Truck functions are not allowed until after this code has been cleared.

How to Clear Code

Parameter area is automatically fixed and then code is cleared.

Possible Causes
with corrective
actions/checks

1.

ETAC parameter area is corrupt.


a. If code does not clear after 10 seconds, try restarting the truck.

Code C20 - Thumb Control Warning


Reason

Thumb control was not in neutral position at power ON, or a throttle position sensor failure was detected. Also
see code 160 on page 187.

Performance Limits

Truck functions are not allowed until code is cleared.

How to Clear Code

Code is cleared after problem is corrected.

Possible Causes
with corrective
actions/checks

1.
2.
3.

BT Prime-Mover, Inc.

Return

Thumb control stuck in drive position.


Bad ETAC.
Bad reverser button.

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Code C28 - Main ON/OFF Switch Warning


Reason

Transistor controller could not be reset via the CAN-bus at power ON or transistor controller reports main ON/
OFF switch is open.

Performance Limits

Truck functions are not allowed after code has been set.

How to Clear Code

This code can only be cleared after the problem is resolved and truck is turned OFF and back ON.

Possible Causes
with corrective
actions/checks

1.
2.

Main ON/OFF switch activated.


Low voltage to transistor controller (especially while lifting or driving) due to overcurrent or short circuit.

a. Try driving using a known-good battery.


3.

4.

5.

6.

PTC R1 missing, bad, or tripped (very high resistance, due to excessive current while main contactor is
open; should automatically recover.)
a. Carefully check to see if R1 is hot (tripped); if so unplug battery and allow it to cool. Locate low
impedance path that tripped R1 and correct.
Wire #24 at OV.
a. Check that J5 is connected, fuse and wiring.
b. Check for 24V at J5-16.
Short or open circuit in CAN wiring or electrical noise in CAN wiring due to bad connection or outside
interference, both at power ON.
a. Check CAN wiring.
b. Try operating truck in different environment.
Bad transistor controller.

Code C29 - Time to Service Warning


Reason

See service parameter 25 on page 178.

Performance Limits

None.

How to Clear Code

See service parameter 25 on page 178.

Possible Causes
with corrective
actions/checks

1.
2.

Time for service.


Service interval not reset after last service.

Code C41 - Battery Undervoltage Warning


Reason

Voltage at transistor controller B+ connection less than 17V (when main contactor is closed.) Low voltage can
also cause problems such as electrical components not powering up / staying activated and CAN errors.

Performance Limits

Truck functions are allowed unless the voltage was below 13V, in which case the truck must be restarted (Code
C28) may be displayed.)

How to Clear Code

Code is cleared when voltage recovers.

Possible Causes
with corrective
actions/checks

1.
2.
3.
4.
5.

182

Return

Low battery voltage.


a. Check for proper voltage; charge battery if necessary.
Battery parameter not adjusted correctly.
Circuit breaker has opened due to overloading or short circuit.
a. Check brake adjustment (see page 111.)
Open circuit to transistor controller B+ connection.
a. Check cabling.
Bad transistor controller.

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Code C42 - Battery Overvoltage Warning


Reason

Voltage at transistor controller B+ connection over 30V.

Performance Limits

Truck functions are allowed unless the voltage was above 34V, in which case the truck must be restarted (error
142, see page 186, may be displayed.)

How to Clear Code

Code is cleared when voltage recovers.

Possible Causes
with corrective
actions/checks

1.

High battery voltage.


a. Check for proper voltage; charge battery may be overcharged.
Extreme regenerative motor braking.
Battery charger plugged into truck.

2.
3.

Code C43 - Transistor Controller Thermal Cutback


Reason

High or low temperature (such as above 185 degrees F [85 degrees C] or below -13 degrees [25 degrees C] at
transistor controller heat sink.

Performance Limits

Truck functions may be allowed.

How to Clear Code

Code is cleared when transistor controller heat sink temperature recovers (see item 7 on page 191.)

Possible Causes
with corrective
actions/checks

1.
2.

3.
4.

Operating in extreme environment.


Excessive load on truck.
a. Check brake adjustment (see page 111.)
b. Reduce value of parameters 2, 3 and/or 4 to help decrease motor temperature.
Improper transistor controller mounting.
Bad transistor controller.

Code C44 - (Hot is displayed) - Traction (Drive) Motor Thermal Cutback


Reason

High traction motor temperature detected.

Performance Limits

Truck functions are allowed, but maximum speed value sent to transistor controller is reduced.

How to Clear Code

Code is cleared when temperature recovers.

Possible Causes
with corrective
actions/checks

1.
2.

3.
4.
5.

Operating in extreme environment.


Excessive load on truck.
a. Check brake adjustment (see page 111.)
b. Reduce value of parameters 2, 3 and/or 4 to help decrease motor temperature.
Air flow to motor restricted.
Problem with motor wiring.
Bad traction motor.

Code C46 - Severe Traction Motor Thermal Cutback


Reason

Very high traction motor temperature or extreme operation detected.

Performance Limits

Same as error code 44.

Corrective Action

Same as error code 44.

Possible Causes
with corrective
actions/checks

Same as error code 44.

BT Prime-Mover, Inc.

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NOTE!

Fault codes 100 and over are logged. The


log can contain multiple faults with the
same number code. Throttle is not allowed,
outputs are off (brake is mechanically
applied), and main contactor is dropped.
Code is cleared when problem is resolved
and truck is turned OFF and back ON
(unless otherwise noted.)

Code E101 - Transistor Controller Does Not Correspond with the Type of Truck
Reason

Transistor controller is not compatible with ETAC software.

Possible Causes
with corrective
actions/checks

1.

Incorrect transistor controller installed in truck.

Code E104 - Brake Power Error


Reason

Transistor controller could not detect presence of brake coil.

Possible Causes
with corrective
actions/checks

1.
2.
3.
4.
5.

Open circuit in brake circuit.


a. Check brake or brake coil wiring for a short or open wire.
Master control relay missing or stuck open.
Main contactor open circuit (especially after it has closed.)
Bad transistor controller.
Open in wire 57 or 26.

Code E106 - Digital Output or Field Overcurrent


Reason

Transistor controller attempted to deliver more current than allowed to main contactor coil; traction motor field
winding, or digital output.

Possible Causes
with corrective
actions/checks

1.

Short circuit in transistor controller output circuit.


a. Check main contactor coil, traction motor field winding, digital output and associated wiring.
b. Replace transistor controller.

Code E107 - Contactor Off


Reason

Contactor probably present but transistor controller could not close it successfully.

Possible Causes
with corrective
actions/checks

1.

2.
3.

184

Return

Problem with main contactor tips.


a. If contactor clicks prior to getting this code, try polishing contactor tips with a clean pencil eraser. If
this does not work or there is permanent contactor damage, replace contactor.
Low voltage.
a. Try closing contactor with a known-good battery.
Short in contactor coil.
a. Replace contactor.

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Code E108 - Contactor Welded or Missing


Reason

Main contactor tips welded or missing.

Possible Causes
with corrective
actions/checks

1.
2.
3.
4.
5.

Main contactor tips welded.


Open or short circuit in contactor circuit.
a. Check contactor, wiring (coil) and cabling.
Bad transistor controller.
Low voltage.
a. Try closing contactor with a known-good battery.
Blown drive fuse.

Code E110 - Braking System Fault


Reason

Transistor controller detected problem with braking functions.

Possible Causes
with corrective
actions/checks

1.
2.

Short circuit in brake circuit.


a. Check brake and wiring.
Bad transistor controller.

Code E112 - Arm Angle Sequence Fault


Reason

Improper sequence of arm angle inputs.

Possible Causes
with corrective
actions/checks

1.
2.
3.

Arm angle input stuck on or off.


Problem with arm angle input wiring.
Problem with arm.
a. Check for proper sequence of arm angle switches (see step 2 above.)

Code E114 - Traction (Drive) Motor Speed Fault


Reason

Transistor controller detected stalled traction motor.

Possible Causes
with corrective
actions/checks

1.
2.
3.

Traction motor stalled.


Excessive traction motor load at low speed.
a. Check brake adjustment (see page 111.)
Bad transistor controller.

Code E140 - Checksum Error


Reason

Electronic Tiller Arm Card (ETAC) software detected that checksum was invalid.

Possible Causes
with corrective
actions/checks

1.
2.

Bad software.
a. If applicable, try downloading new software.
Bad ETAC.

Code E141 - Software Problem


Reason

ETAC found problem with software.

Possible Causes
with corrective
actions/checks

1.

BT Prime-Mover, Inc.

Return

2.

Bad software.
a. If applicable, try downloading new software.
Bad ETAC.

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Code E142 - Transistor Controller Disable Error


Reason

Transistor controller detected a major fault.

Possible Causes
with corrective
actions/checks

1.
2.

3.

4.

Severe overvoltage (especially at main contactor close.)


a. Check for proper voltage.
High current at digital input.
a. Check transistor controller outputs and wiring.
b. Replace transistor controller.
Open circuit in traction motor field circuit.
a. Check transistor motor field wiring and field windings in motor.
b. Replace transistor controller.
Shorted brake coil.

Code E150 - Drive Communication Error


Reason

ETAC did not receive CAN data from transistor controller.

Possible Causes
with corrective
actions/checks

1.
2.

3.
4.

Short or open circuit in CAN wiring.


Electrical noise in CAN wiring due to bad connection, outside interference or low voltage.
a. Check CAN wiring.
b. Try driving using a known-good battery.
c. Try driving in a different environment.
Bad transistor controller.
Bad ETAC.

Code E151 - Drive Communication Tx Error


Reason

ETAC could not send CAN data to transistor controller.

Possible Causes
with corrective
actions/checks

1.
2.

3.

Short or open circuit in CAN wiring.


Electrical noise in CAN wiring due to bad connection, outside interference or low voltage (especially while
lifting or driving) possibly due to overcurrent or short circuit.
a. Check CAN wiring.
b. Try driving using a known-good battery.
c. Try driving in a different environment.
Bad ETAC.

Code E157 - CAN-bus Off Error


Reason

ETAC detected problem with CAN-bus.

Possible Causes
with corrective
actions/checks

1.
2.

3.
4.

Short or open circuit in CAN wiring.


Electrical noise in CAN wiring due to bad connection, outside interference or low voltage.
a. Check CAN wiring.
b. Try driving using a known-good battery.
c. Try driving in a different environment.
Bad transistor controller.
Bad ETAC.

Code E159 - Over Run Error


Reason

ETAC detected problem with the CAN-bus.

Possible Causes
with corrective
actions/checks

1.
2.

3.
4.

186

Return

Short or open circuit in CAN wiring.


Electrical noise in CAN wiring due to bad connection, outside interference or low voltage.
a. Check CAN wiring.
b. Try driving using a known-good battery.
c. Try driving in a different environment.
Bad transistor controller.
Bad ETAC.

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Code E160 - Error In Reversing Circuit


Reason

ETAC detected problem with the throttle position sensors, including the sensor used to initiate reversing. Also
see code 20 on page 181.

Possible Causes
with corrective
actions/checks

1.

Bad ETAC.

Code E161 - Lower Valve Error


Reason

Transistor controller could not detect presence of lower valve coil.

Possible Causes
with corrective
actions/checks

1.
2.
3.
4.
5.

Lower valve missing.


Open or short circuit in lower valve or wiring.
Master control relay missing or stuck open. Master control relay wired wrong.
Main contactor open circuit (especially after it has closed.)
Bad transistor controller.

Code E200 - Field Open


Reason

Transistor controller detected open field.

Possible Causes
with corrective
actions/checks

1.

Open circuit in traction motor field circuit.


a. Check traction motor field wiring and field windings in motor.
b. Replace transistor controller.

Code E201 - M-Error


Reason

Transistor controller detected an armature circuit fault.

Possible Causes
with corrective
actions/checks

1.
2.

Incorrect traction motor cabling.


Bad transistor controller.

Code E202 - Transistor Controller Sensor Error


Reason

Transistor controller reported an armature current sensor fault.

Possible Causes
with corrective
actions/checks

1.
2.
3.

Abnormal truck operation.


Low battery voltage or undersized battery.
Bad transistor controller.

Code E214 - Transistor Controller CAN Timeout


Reason

Transistor controller did not receive CAN data from ETAC or transistor controller self-test failed.

Possible Causes
with corrective
actions/checks

1.
2.

3.
4.

Short or open circuit in CAN wiring.


Electrical noise in CAN wiring due to bad connection, outside interference or low voltage.
a. Check CAN wiring.
b. Try driving using a known-good battery.
c. Try driving in a different environment.
Bad transistor controller.
Bad ETAC.

NOTE!

BT Prime-Mover, Inc.

Return

Only the first error of each type is


processed (errors of the same type that
happen after the first error are ignored.)

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3.7. Troubleshooting Chart Index


3.7.1. Travel (Forward / Rearward) System
1. No travel in either direction, lift/lower okay (Code
E106, Digital output or field overcurrent.)
2. No travel in either direction, lift/lower okay (Code
E201 M-error.)
3. No travel in either direction, lift/lower okay (Code
E214, transistor controller CAN timeout.)
4. Slow travel, lift/lower okay. No fault codes.
5. No travel (Code C42, Battery overvoltage warning.)
6. Slow or no travel (Code C41, Battery undervoltage
warning.)
7. Slow or no travel (Code C43, Transistor controller
thermal cutback.)
8. Truck does not accelerate correctly.
3.7.2. Wiring System
1. Truck Functions Partially, some functions do work
when commanded.
3.7.3. Other Possible Troubleshooting Issues
1. Green and red LEDs on keypad do not light when a
button on the keypad is pushed (keypad option
only.)
2. No fast travel mode.
3. No travel.
4. Horn does not sound when horn button is pushed.

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3.8. Troubleshooting Charts


The following troubleshooting charts describe a course of
testing and repair for each problem listed. If the given test is
NOT successful, perform the repair listed with the test. If the
given test IS successful, go to the next test or follow the
special instructions given. For electrical legend see
page 196.
Travel (Forward / Rearward) System
1. No travel in either direction, lift/lower okay (Code E106,
Digital output or field overcurrent.)
Possible Cause

Remedy

Bad wiring between transistor controller


and main contactor

With main ON/OFF switch OFF and battery disconnected, check wiring between transistor
controller and main contactor (K10.)

Bad transistor controller

With main ON/OFF switch OFF and battery connector disconnected, measure resistance between
J5-16 and J5-4. If resistance is approximately 50 ohms, check wires for shorts to frame, B+, B-, or
other conductors. If none found replace transistor controller.

Bad main contactor coil

Disconnect and measure resistance of main contactor (K10) coil. If resistance is not approximately
50 ohms, replace coil.

2. No travel in either direction, lift/lower okay (Code E201


M-error.)
Possible Cause

Remedy

Bad wiring between transistor controller


and motor

With main ON/OFF switch OFF and battery disconnected, disconnect wires F1 and F2 from the
transistor controller. Check wiring between motor and transistor controller.

Bad transistor controller

With main ON/OFF switch OFF and battery connector disconnected, disconnect drive motor cable
at transistor controller terminal M-. Connect battery connector, turn key switch ON. If Code 1,3
(see page 246) is still displayed, replace transistor controller. If Code 1,3 is not displayed,
disconnect battery, remove wires F1 and F2 at transistor controller and measure resistance in
wiring harness between wires F1 and F2. If less than 1.0 ohm, replace transistor controller.

Bad motor

With main ON/OFF switch OFF and battery disconnected, remove wires F1 and F2 at motor. If
greater than 2.0 ohm, replace motor.

3. No travel in either direction, lift/lower okay (Code E214,


transistor controller CAN timeout.)
Possible Cause
Bad transistor controller

BT Prime-Mover, Inc.

Return

Remedy
Replace transistor controller.

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4. Slow travel, lift/lower okay. No fault codes.


Possible Cause

Remedy

Battery problems

Replace battery with fully-charged good battery.

Transistor
controller
programming changed
Binding
motor

drive

wheel

or

ETAC

assembly/drive

Verify programming. If changed, reset programming.


Jack and block truck (see page 58.) Disable brake (see page 111.) Check that drive wheel spins
freely. If not, repair or replace (see page 117.)

Binding brake disk

Check air gap adjustment (see page 111.)

Bad drive motor (may test ok with no


load, but fall under load) or worn brushes

Repair or replace motor brushes (see page 91.)

5. No travel (Code C42, see page 183), Battery overvoltage


warning.)
Possible Cause

Remedy

Battery problem

Verify the correct, fully-charged good battery is installed in truck.

Verify battery charger is not plugged into


truck

Disconnect the battery charger immediately.

Bad transistor controller

Verify correct battery is installed. Replace transistor controller.

6. Slow or no travel (Code C41, see page 182), Battery


undervoltage warning.)
Possible Cause

Remedy

Battery problems
Bad
battery
terminals
disconnect plug

Verify a correct, fully-charged good battery (24V) is installed in truck.


or

quick

Repair or replace battery terminals.

Bad transistor controller

Verify battery voltage at key switch input. Turn main ON/OFF switch OFF and disconnect battery
connector. Check for continuity and wiring shorts between B- battery to transistor controller B- and
key switch circuit wiring and fuses. Repair or replace. Measure voltage at transistor controller B+. If
24V, replace transistor controller.

Bad wiring or connector

Jack and block truck. With main ON/OFF switch OFF and battery connected, while attempting
travel, measure voltage between A2, transistor controller B+, B-, and F1, F2, M1, and M3. If not
24V, repair or replace wiring.

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7. Slow or no travel (Code C43 (see page 183), Transistor


controller thermal cutback.)
Possible Cause

Remedy

Battery problems

Verify a correct, fully-charged good battery (24V) is installed in truck.

Binding load wheel(s)

Make sure load wheels rotate freely, If not repair or replace (see page 122.)

Bad drive wheel assembly

Jack and block truck (see page 58.) Turn main ON/OFF switch ON. Pull steering control handle
down to release brake. Check drive wheel to see if it spins freely. If not, repair or replace (see
page 117.)

Binding brake disk

Jack and block truck (see page 58.) Turn main ON/OFF switch ON. Pull steering control handle
down to release brake. Check brake disk to see if it spins freely. If not, adjust, repair or replace
(see page 111 or page 112.)

Binding drive motor

Jack and block truck (see page 58.) Turn main ON/OFF switch ON. Pull steering control handle
down to release brake. Check the brake disk to see if it spins freely. Turn main ON/OFF switch
OFF. Remove brake disk and check armature shaft. Remove motor and repair or replace drive unit
or drive motor (see page 97.)

Worn brushes
Bad drive motor (may test ok with no
load, but fail under load)

Inspect brushes (see page 90.)


Repair or replace drive motor (see page 97.)

Truck overloaded
extreme conditions

Operate and load truck within specifications (see page 51.)

or

operating

in

Bad transistor controller

Check mounting of transistor controller. Check to make sure transistor controller is secure and in
contact with truck frame (acts as a heatsink.) If transistor controller is mounted correctly, replace
transistor controller.

Bad wire or connector

Jack and block truck (see page 58.) With main ON/OFF switch ON and battery connected, while
attempting travel, measure voltage between B- and transistor controller B+, B- and J5-16. If not
24V, repair or replace wiring.

8. Truck does not accelerate correctly.


Possible Cause

Remedy

Battery problems
Transistor
controller
programming not correct

Verify a correct, fully-charged good battery (24V) is installed in truck.


or

ETAC

Verify programming.

Bad motor brushes or motor

With main ON/OFF switch OFF and battery connector disconnect, check drive motor brushes (see
page 90) and motor (see page 97.)

Bad transistor controller

If all possible causes check out, replace transistor controller.

Wiring System
1. Truck functions partially, some functions do work when
commanded.
Possible Cause

Remedy

Bad wiring in steering control handle

With main ON/OFF switch OFF and battery connector disconnect, visually inspect wiring in the
handle where the wiring leaves the handle and over the brake. Repair or replace.

Bad wiring in hydraulic control area

With main ON/OFF switch OFF and battery connector disconnect, visually inspect wiring. Repair or
replace.

BT Prime-Mover, Inc.

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Other Possible Troubleshooting Issues


1. Green and red LEDs on keypad do not light when a button
on the keypad is pushed (keypad option only.)
Possible Cause

Remedy

Open circuit of wires that power ETAC

Check control wires, especially wires 1, 20, and 22 (red in steering control arm cable) and 40
(black in steering control arm cable.)

Bad connectors

Repair and replace bad connectors (check connector J11 at steering control arm base, connector
into ETAC and connector J5 to transistor controller.)

F50 Open

Ensure control fuse has not tripped.

Keyswitch jumper not connected

Connect keyswitch jumper.

2. No fast travel mode.


Possible Cause
Arm angle switch A always off

Remedy
Check for proper operation of arm angle switch A and correct if necessary. Check wiring,
transistor controller and switch adjustment.

3. No travel.
Possible Cause
Arm angle switch failure

Remedy
Check arm angle switch adjustment (see page 220), wiring and transistor controller.

4. Horn does not sound when horn button is pushed.


Possible Cause

Remedy

Bad horn switch/wiring in handle head

Repair/replace as necessary (see page 226.)

Bad transistor controller

Check and replace if necessary.

Bad horn

Replace horn.

5. No lift.
Possible Cause

Remedy

Lift cut out engaged. Battery dead or did


not reach reset voltage at 25.2 volts

Recharge battery or replace battery.

Lift limit switch bad or burnt open or


disconnected.

Adjust lift limit switch (see page 221) or replace lift limit switch (see page 225.)

Lift switch not functioning.

Replace lift switch (see page 225.)

Failed ETAC.

Replace ETAC (see page 251.)

192

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Main
Harness

3
2
1
4
7

5
8

Contactor
Panel
Assembly

9
I

Contactor
Power
Cable

Circuit
Breaker

Lift Limit
Switch

Steering Control
Handle Harness

Hydraulic
System

Relay

10 Amp
Fuse

Transmission
Assembly

Power
Cables

Power
Cables

BT Prime-Mover, Inc.

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194

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Sh. = Sheet or page of Diagram


First number = Previous page was found.
Second number = Second page wire is found.

Ledger

Electrical Schematic 1(2)

Master Service Manual

2006-12-12

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BT Prime-Mover, Inc.

Master Service Manual

2006-12-12
HORN SWITCH
S18-2

HORN SWITCH
S18-1

DISPLAY
A6

Sh. = Sheet or page of Diagram


First number = Previous page was found.
Second number = Next page wire is found.

Ledger

E.T.A.C.
A2

TRUCKS
WITH
KEYPAD

KEYPAD
A17

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Electrical Functions

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Electrical Schematic 2(2)

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Electrical Legend
Symbol
A1
A2
A2-S1 to A2-S9
A2-S10 to A2-S18
A2-S17
A2-S19
A2-S20
A6
A17
B+
BCB1
F50
F51
H1
J11
J41
K4
K10
K30
M1
M3
S17
S18-1
S18-2
S21
S24
S25
S36
Y1
Y10

196

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Description
Transistor controller
Transistor controller
Speed Ref Value
Speed Ref Value
Reverser
Lift
Lower
Transistor controller
Transistor controller
Battery
Battery
Circuit breaker
Fuse
Fuse
Horn
Wire Connection
Wire Connection
Contactor Relay
Contactor
Solenoid
Motor
Motor
Switch
Switch
Switch
Switch
Switch
Switch
Switch
Coil
Coil

Function
Drive motor
Electronic Tiller Arm Card
Electronic Tiller Arm Card
Electronic Tiller Arm Card
Electronic Tiller Arm Card
Electronic Tiller Arm Card
Electronic Tiller Arm Card
Operator Display
Keypad
Positive
Negative
Drive / Pump motor circuit
Keypad and tiller arm circuit
Main control

Remark
E.T.A.C.

24 volt
24 volt
110 amp
10 amp
10 amp

Handle stem base


Service key (CAN)
Main
Main
Pump motor
Drive
Pump
Key
Horn
Horn
Main ON/OFF
Arm angle (A)
Arm angle (B)
Lift limit
Brake
Lower valve

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Electrical Graphics
Graphic

BT Prime-Mover, Inc.

Return

Graphic

Description

Battery

Brake (coil)

Contactor

Diode

Main On/Off
Switch

Fuse

A1

Description

A2

Horn

Inductive sensor
(normally closed)

Inductive sensor
(normally open)

Key switch

Magnet switch
(normally closed)

Magnet switch
(normally open)

Motor

Potentiometer

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Electrical Graphics
Graphic

Description

Graphic

Push button switch


(normally closed)

Description
Push button switch
(normally open)

Resistor

Switch

Switch
(normally closed)

Switch
(normally open)

Valve

198

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5110
Battery

Battery
1. Theory of Operation
Check the trucks data plate for the weight of the battery
required for the truck. Contact your local battery supplier for
the purchase of a proper voltage battery. A 24 volt battery
may not be supplied with the truck.

2. Maintenance
Information in this section does not supercede or replace
information available by the battery and battery charger
supplier. Read, understand, and follow the procedures
available by the battery and battery charger supplier. Notify
your supervisor if there are any concerns or questions
regarding the battery or procedures.

2.1. Inspection and Care


WARNING Battery electrolyte is a solution of sulfuric
acid and water. Battery acid causes burns.
Should any electrolyte come in contact with
clothing or skin, flush the area immediately
with cold water. Should the solution get on
your face or in the eyes, flush the area with
cold water and receive medical attention
immediately.
CAUTION Before working on the battery, review
Battery Safety beginning on page 20.
Batteries may weigh more than 200 pounds
(91 kg). Use extreme care during
replacement. Use a suitable replacement
device or hoist for lifting.
NOTE!

Read, understand, and follow procedures,


recommendations
and
specifications
available by the battery and battery charger
supplier.

Batteries in industrial trucks pick up various kinds of dirt and


dust depending on their surroundings and the types of

BT Prime-Mover, Inc.

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material handled. If cells are overfilled and electrolyte collects


on the covers, the following occurs:
1. The top of the battery becomes wet and stays wet,
since the acid in the electrolyte does not
evaporate.
2. This moist surface, in combination with certain
kinds of dirt, becomes electrically conductive and
permits stray currents to flow externally over the
top of the battery. This degrades battery
performance and truck operation.
3. The acid also causes corrosion of cell posts, nuts,
connectors and the steel battery case.
When inspecting batteries, check the following:
1. Wet covers can indicate overfilling, leaky seals at
posts, or excessive gassing during charge. If
covers are wet, determine the cause and correct
the problem.
2. Make sure batteries cannot move more than 0.5
inch (13 mm) in any horizontal direction. Shim or
block the batteries to restrain them.

2.2. Exterior Cleaning


Refer to recommended battery suppliers guidelines for
details.

2.3. Charging
OSHA regulations require that battery charging installations
be located in areas designated for that specific purpose. Such
areas must provide for flushing and neutralizing spilled
electrolyte, fire protection, protecting charging equipment
from damage by trucks and adequate ventilation of fumes
from gassing batteries.
To charge a battery, direct current is passed through the
battery cells in the direction opposite that of discharge.
Charging time is 5 to 20 percent longer than discharge time.

200

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Battery

Read, understand, and follow procedures, recommendations


and specifications available by the battery and battery
charger supplier.

CAUTION NEVER plug the battery charger into the


truck. This will severely damage the trucks
electrical system. Plug the charger into the
connector from the battery.

2.4. Storage
Before storing the battery, make sure the electrolyte is at the
proper level in all the cells, the filler plugs are tight, and the
battery is fully charged. Store battery in a clean, cool, dry
location away from radiators and other sources of heat.
Check electrolyte level and specific gravity every 30 days
during storage. Whenever specific gravity is less than 1.230,
charge the battery.

BT Prime-Mover, Inc.

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2.5. History Record


A battery record system is essential because battery failure
can cause production slowdowns and increased battery
operating costs. A properly supervised record system can
detect and call attention to such operating irregularities as:
Overcharging
Undercharging
Over-discharging
Excessive water consumption
Excessive dirt and corrosion
Worn-out batteries
Excessive current consumption of trucks
Records should be kept for each battery. Your battery
supplier should be able to provide maintenance record
sheets. Each report should contain:
Battery number, type, serial number, and service
data
Specific gravity and voltage readings for each cell
Electrolyte
Amperes
Condition of connectors, covers, sealing
compound and tray
General cleanliness
Number of total cycles
Average specific gravity drop
Watering frequency

3. Troubleshooting
Many electrical problems are caused by a bad or dirty battery.
Make sure the battery is clean. Check the electrolyte level
and battery level. Look for simple causes of problems. A
trained, qualified, and authorized technician should perform
testing and troubleshooting on batteries.

202

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Battery

4. Repair and Rebuild


Contact your local battery supplier for replacements or
rebuilds.
Removal
1. Park truck on a level surface and make sure
parking brake is applied and load wheels are
blocked to prevent accidental movement.
2. Press red OFF button O on the keypad. Depress
main ON/OFF switch to the OFF position.
3. Disconnect the battery connector from the truck.
4. Position battery replacement device in accordance
with the suppliers recommendations.
5. If applicable, remove bolts securing the battery to
the truck. Remove battery from truck onto suitable
battery table or with battery lifting device.
Installation
1. With a fully charged and tested battery on the
battery handling device, position the handling
device at truck in accordance with the suppliers
recommendations.
2. Move the battery into the compartment. Be sure
the battery has no more than 0.50 inch (13 mm) of
free play movement in the battery compartment.
If applicable, secure battery bolts to the truck.
3. Move handling device from the area.
4. Connect the battery connector to the truck.
5. Remove blocks. Turn the main ON/OFF switch to
the ON position. Enter key code and press the
green ON button I on the keypad.
6. Test truck for proper operation before returning to
service.

BT Prime-Mover, Inc.

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Swing Out Battery Pack

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Swing Out Battery Pack


1. Theory of Operation
The truck may be equipped with a multiple battery pack, or a
maintenance-free battery and charger.

2. Maintenance
WARNING Battery electrolyte is a solution of sulfuric
acid and water. Battery acid causes burns.
Should any electrolyte come in contact with
clothing or skin, flush the area immediately
with cold water. Should the solution get on
your face or in the eyes, flush the area with
cold water and receive medical attention
immediately.
CAUTION Before working on the battery, review
Battery Safety beginning on page 20.
Batteries may weigh more than 200 pounds
(91 kg). Use extreme care during
replacement. Use a suitable replacement
device or hoist for lifting.

2.1. Electrical Testing


2.1.1. Required Equipment
1. Common hand tools.
2. AC/DC volt/ohm meter.
3. Battery connector with + to - loop (use on charger
only.)
4. Battery hydrometer.
2.1.2. Instructions
1. Check condition of batteries (check each cell.)
a. Specific gravity, before and after charging.
Acceptable values:
Dead battery - 1.180
Fully charged battery - 1.280
BT Prime-Mover, Inc.

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Any cell that is different by more then 20 points


indicates a suspect battery.
b. Volts per cell, open circuit, before and after
charging.
Acceptable values:
Dead battery - 1.9 v/cell
Fully charged - 2.2 v/cell
c. Charging rate DC amps, at start and finish of
charge cycle.
Acceptable values

Start

Finish at 2.5 VPC

24 volt system

15 amps

0.5 amps or less

d. Charging rate at battery DC volts, at start and


finish.
Acceptable values

Start

Finish

24 volt system

25.6 volts

30.0 volts

2. Visually inspect
disconnected.

charger

with

all

power

a. Inspect AC power supply circuit breaker, wall,


outlet, plug, cord.
b. Inspect charger for physical damage.
c. Inspect internally for loose or discolored
connections and wires damaged due to
overheating.
d. Inspect
transformer
discrepancies.

coils

for

obvious

e. Inspect the chargers internal AC power fuse. It


should be 10 amp rated.
NOTE!

If the AC power fuse is blown, it could


indicate a shorted diode on the DC output
circuit.

3. Testing the DC output circuit.

206

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If the AC power fuse blows or the DC 1 x


circuit breaker trips, check for reverse
polarity of the battery connection.

a. Open circuit voltage test.


With batteries disconnected and the charger
turned on, the DC output voltage should be
1-1/2 times the rated DC voltage.
System voltage
24 volts
b. Short circuit amperage test.
With charger output battery connector short
circuited (positive to negative jumper connector
plugged into charger output connector), and the
charger turned on, the DC output amps should
be 80 percent of the normal DC amps.
System voltage
24 volts

Short circuit output voltage


approximate 12 amps

(1) With charger in the OFF position, connect


AC power cord to appropriate AC power
supply, connect with the + to - loop to the
charger.
(2) Turn battery charger on and note the amp
gauge reading. It should be as stated on the
chart above. Leave charger on for five
minutes while watching the amp gauge.
The amp gauge should remain steady. This
verifies the condition of the circuit breaker
and any loose connections.
(3) Turn charger off before disconnecting the
jumper connector.
4. Testing components

BT Prime-Mover, Inc.

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WARNING Before checking components disconnect


AC power supply, unplug batteries, and
discharge capacitor with an insulated
screwdriver. All tests should be made with
the charger disconnected unless otherwise
stated. Use extreme caution when a test
calls for the power to be on at the charger.
a. Diodes
(1) A quick test for shorted diodes may be
made by connecting the leads of the
ohmmeter to the charger battery connector
terminals and testing for continuity in each
direction. If the test shows open, the DC
circuit breaker, may be open. To bypass an
open DC circuit breaker, connect the test
leads to the positive and negative lugs
behind the circuit breaker and reverse the
ohmmeter probes. A shorted diode will
show continuity in both directions. Retest
the diodes individually to determine which
diode is bad.
(2) Disconnect diode flexible leads to isolate
the diodes from the circuit.
(3) Use an ohmmeter to test the continuity of
each diode in both directions. A shorted
diode will show continuity in both directions
and an open diode will show no continuity in
either direction. A good diode will show
continuity in only one direction.
(4) Connect diode leads in charger.
b. Capacitor
(1) Discharge capacitor.
(2) Disconnect the capacitor leads.
(3) Set ohmmeter R x 10,000 scale and
connect ohmmeter leads to terminals on
capacitor. When needle (or display) quits
moving, reverse leads.

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On a good capacitor, the needle will deflect


to the right (low resistance) and then deflect
back to the left (high resistance) each time
the meter leads are reversed. On a shorted
capacitor, the needle will deflect to the right
(low resistance) and remain there. On an
open capacitor, the needle will not deflect
(stationary display.)
(4) Connect the capacitor leads in the charger.
(5) Set AC voltmeter on a scale to read at least
500 volts AC. Connect the meter leads to
the capacitor terminals.
A shorted capacitor will indicate 0 volts AC.
An open capacitor will indicate about 300
volts +/-20 volts AC. This is the same as the
capacitor transformer winding voltage
without a capacitor connected in circuit.
(6) Turn on charger power.
WARNING Before checking components, disconnect
AC power supply, unplug batteries and
discharge
capacitor
with
insulated
screwdriver. All tests should be made with
the charger disconnected unless otherwise
stated. Use extreme caution when a test
calls for the power to be on at the charger.
5. Overcharging problems
Most complaints about charging problems can be
remedied by following the previous procedures.
Overcharging problems may not be the fault of the
charger. Often, overcharging is caused by bad
batteries or poor connections. The following items
should be checked to resolve problems of
overcharging or failure of charging amps to taper
down.
a. Charger and battery not properly matched.
Check specifications on both batteries and
charger. Battery pack (GNB) has been
designed for a specific size and type of battery.
If another battery has been installed, be certain
BT Prime-Mover, Inc.

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that it is comparable to the original batteries.


Automotive type batteries will not function
properly in this application.
b. Excessive battery temperatures
suppressed battery voltage.

causing

Allow batteries to cool.


c. Bad battery or poor DC connection.
Check battery voltage while charger rate is
controlled by the battery state of charge. This
will adjust the output to the proper level if the
battery is in good condition. If the voltage does
not come up to finish rate, this may indicate a
bad cell within a battery or a marginal DC
connection between the battery and the
charger. Carefully inspect connections for
excessive heat. Test battery cell voltages and
specific gravity.

3. Troubleshooting
The charger incorporates a very simple and reliable design
which makes troubleshooting relatively easy. The repair
procedure involves testing the output of the charger and then
testing individual components. The test procedures follow a
logical sequence of electrical flow through the circuit. Only
standard hand tools and an AC/DC volt/ohm meter are
required. A battery hydrometer is recommended.
WARNING Before checking charger, disconnect AC
power supply, unplug batteries, and
discharge capacitor with an insulated
screwdriver. All tests should be made with
extreme caution when a test calls for power
to be on at the charger.

4. Repair and Rebuild


Contact your local battery supplier for replacements or
rebuilds.

210

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19

4
3

7
8

18
15
12
11

16

20

17

10

13

14

Battery Specifications
Exide type GC-3 6 volt
75-91 AMPS
Trojan type T-90 or T-1900
6 volts 75-91 AMPS

BT Prime-Mover, Inc.

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Item No.
1
2
3
4
5
6
7
8
9
10

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Description
Battery pack complete
Decal
Charger, battery
Decal, warning
Screw
Cable assembly
Cover
Screw
Decal, warning
Tray, left

Master Service Manual

Item No.
11
12
13
14
15
16
17
18
19
20

Description
Screw
Grommet
Screw
Support, battery
Nut, clip
Screw
Nut, clip
Tray, right
Decal
Tray, cord

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Battery Cable Routing Diagram


2

3
11

11

1
6

2
11 10

11
1

11

11
1

2
11
1

2
11

Battery Specifications
Exide type GC-3 6 volt
75-91 AMPS

Item
No.
1
2
3
4
5
6
7
8
9
10
11

Description
Boot
Nut
Tie, cable
Cable
Cable
Battery connector
Cable
Cable
Battery
Cable
Washer, flat

Trojan type T-90 or T1900

BT Prime-Mover, Inc.

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Battery Pack (GNB Pallet Pro Start/Stop


Charger)
17
1

15

14

11
4
16

13

10
12
7
3
2

214

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Item No.

Description

Item No.

Description

1
2
3
4
5
6
7
8
9

Pallet pro battery pack, 24 Volt


Charger assembly
Battery, 6 Volt
Grommet
Decal, Champion
Decal, DANGER
Cable assembly
Bolt, 6x20
Lockwasher

10
11
12
13
14
15
16
17

Washer, flat
Decal, serial number
Bracket
Tray
Cable, SB175 plug
Battery connector
Cable, AC power
Screw, securing

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5190
Battery Connector

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SMX

Battery Connector
1. Theory of Operation
Battery Connector

The truck battery connector is located at the top of the truck


cover. The battery and charger have similar battery
connectors. It is necessary to connect the battery to the truck
before powering ON.

2. Maintenance
Visually inspect cables and connectors. Negative and positive
cables should be visually inspected for breaks and wear.
Check connectors for damage and to ensure proper
connections of cables.

2.1. Inspection
1. Press red OFF button O on the keypad. Depress
main ON/OFF switch to the OFF position.
2. Disconnect the battery connector from the truck.
3. Check the battery connectors for damaged cables.
4. Check to see if cables are pulling out of the
connectors.
5. Check cables at battery terminals. Connections
should be tight, with no corrosion.
6. Check inside connectors at internal contacts for
damage, dirt, or corrosion. DO NOT use a metal
object to clean connectors.
7. Connector housings must not be cracked or
broken.

3. Troubleshooting
Make sure cable wires are in good condition and connector
has proper connections to cables.

BT Prime-Mover, Inc.

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C-code

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4. Repair and Rebuild


To Battery

Item
No.

9
5

1
2
3
4
5
6
7
8
9

Description
Puller
Cable, negative
Cable, positive
Nut
Connector, SB-175
Cable, positive
Cable, negative
Screw, cap
Screw, cap

8
5

7
6

216

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5190
Battery Connector

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Do not attempt to repair or rebuild the battery connector or


power cables. Replace damaged parts with new.
Removal, Repair, and Installation
The cables to the battery connectors have a lip on the forward
end. This lip snaps over a spring-loaded retainer which is part
of the connector. To remove a cable from the connector, push
retainer down while pushing cable towards the rear and out of
the connector.

BT Prime-Mover, Inc.

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2004-03-08

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Battery Connector
Version no

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000

SMX

C-code

5190

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C-code

5310
Switches

Switches
1. Theory of Operation
The main ON/OFF switch (S21) is provided on the truck. In
the OFF position, battery power to all control functions is
interrupted. In the ON position, battery potential is provided to
all control functions via the transistor controller.
The arm angle switches are located at the base of the
steering control handle stem. The arm angles switches (S24)
and (S25) determine brake activation and truck travel speed.
Each switch is activated by the steering control handle
position. The steering control handle must be positioned
beyond 6 degrees of the upper rest position and above 8
degrees from the bottom in order for switches to close,
permitting travel. When steering control handle is within 6
degrees of the upper rest position, parking brake is activated.
When steering control handle is between 6 to 41 degrees of
the upper rest position, arm angle B switch (S25) closes and
enables slow speed operation. When steering control handle
is placed beyond 41 degrees from the upper rest position,
arm angle A switch (S24) also closes enabling fast speed
operation. When the steering control handle is placed in the
bottom 8 degrees of the operating range, arm angle switch B
(S25) opens, activating the parking brake.
Position

A Switch
(S24)

B Switch
(S25)

Function

Top 6

Open

Open

Top Brake

6 to 41

Open

Closed

Slow

41 plus

Closed

Closed

Fast

Bottom 8

Closed

Open

Bottom Brake

When forks are fully raised, lift-limit switch (S36) turns the
hydraulic pump motor off. This keeps the pump from trying to
extend the lift cylinder beyond its maximum travel. A twoposition (ON/OFF) optional key switch (S17) is located on the
main console, which energizes all truck control functions
when in the ON position, provided the main ON/OFF switch is
in the ON position.

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Switches

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2. Maintenance
General
Examine switch for signs of arcing, overheating,
discoloration, cracking, or other physical damage. Replace
switch if such damage is noticed.
Use an ohmmeter set to a low resistance scale to measure
resistance across the switch. In a closed position, the switch
should be less than 1 ohm. In an open position, the switch
should show a resistance greater than 10 megohms.
With the battery connected, use a voltmeter to check for
voltage on both the positive and negative side of the switch
while in the closed position. The voltage must be the same on
both sides of the switch. If not, the switch is worn or bad.

Main ON/OFF Switch Inspection

Main ON/OFF Switch

To inspect switch proceed as follows:


1. With the battery plugged in and main ON/OFF
switch (S21) in the ON position, battery voltage B+
must be present on the two terminals of the switch.
2. Test main ON/OFF switch with an ohmmeter after
disconnecting the battery and removing the wires
from the switch terminals.
3. In the OFF position, the ohmmeter must read
greater than 1 megohm. In the ON position, the
ohmmeter must read less than 1 ohm. If not,
replace switch.

Arm Angle Switches

Adjustment of Arm Angle Switches


To adjust switches, proceed as follows:
1. Press red OFF button O on the keypad. Depress
main ON/OFF switch to the OFF position.
2. Disconnect the battery connector from the truck.
3. Jack truck and block the frame (see page 58.)
4. Remove truck cover(s) [see page 84.]
Screws

220

Return

5. Loosen screws holding the switch on the bracket.


Slide the switch out as far as possible and
retighten screws.

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Switches

Make sure the cam arm makes solid


contact with switch lever. Switch S25 must
operate within 6 degrees of the upper rest
position or in the bottom 8 degrees of the
operating range. Make sure switch does not
bottom out when fully compressed.

6. Slide switch back in until the switch clicks. Move


the switch out (approximately 0.031 inch (0.7 mm)
until it clicks again. Retighten screws.
Steering Control Handle
Cover Installed

7. Install steering control handle cover.


8. Remove blocks. Connect the battery connector to
the truck.
9. Turn main ON/OFF switch to the ON position.
Enter key code and press the green ON button I
on the keypad.
10. Test truck for proper operation before returning to
service.

Lift Limit Switch Adjustment


Raise the forks until they reach their fully raised position. If
the lift-limit switch does not shut the pump down when the lift
cylinder reaches it upper limit, the relief valve on the hydraulic
pump will make a high-pitched squeal, indicating that the
relief valve is opening. To adjust lift limit switch, proceed as
follows:

Lift Limit
Switches

1. Press red OFF button O on the keypad. Depress


main ON/OFF switch to the OFF position.
2. Disconnect the battery connector from the truck.
3. Disconnect the wires on the switch.
4. Loosen bolt and slide switch bracket up or down to
activate (cut power off) when the lift is 0.5 to 1.0
inch (12.7 to 25.4 mm) before its fully raised
position. Tighten bolt.
5. Connect the wires to the switch.
6. Connect the battery connector to the truck.

BT Prime-Mover, Inc.

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7. Turn main ON/OFF switch to the ON position.


Enter key code and press the green ON button I
on the keypad.
8. Test truck for proper operation before returning to
service.

Key Switch (Optional) Inspection


To inspect optional key switch, proceed as follows:
1. Remove truck cover(s) [see page 84.]
2. With the battery plugged in and the key switch ON,
battery voltage B+ must be present on the two
terminals of the switch.
3. Turn key switch to OFF. Depress main ON/OFF
switch to the OFF position.
4. Disconnect the battery connector from the truck.
5. Remove wires from switch terminals.
6. Test key switch for continuity with an ohmmeter. In
the OFF position, the ohmmeter must read greater
than 1 ohm. If not, replace switch.

3. Troubleshooting
To troubleshoot the main ON/OFF switch see page 148, arm
angle switches see page 150 and/or page 152 and for the lift
limit switch see page 259.

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Switches

4. Repair and Rebuild

3
4

15
14
9
5 10

10

7
7

11
12
13

Item No.

Description

Item No.

Switch, main ON / OFF

Nut

11

Screw

Switch, key (option)

Switch, arm angle

12

Switch, lift limit

Screw

Bracket

13

Nut

Bracket

Screw

14

Switch, horn

Screw

10

Lockwasher

15

Button, horn

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Description

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Item No.

Description

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Switches

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The switches can not be repaired or rebuilt. Replace a bad


switch with new as necessary.

4.1. Main ON/OFF Switch


Removal
1. Press red OFF button O on the keypad. Depress
main ON/OFF switch to the OFF position.
2. Disconnect the battery connector from the truck.
3. Remove truck cover(s) [see page 84.]
4. Disconnect the wires from the switch.
5. Remove main ON/OFF switch.

Installation
1. Install new main ON/OFF switch and connect the
wires to the switch terminal.
2. Connect the battery connector to the truck.
3. Turn the main ON/OFF switch to the ON position.
Enter key code and press the green ON button I
on the keypad.
4. Test truck for proper operation before returning to
service.
5. Install truck cover(s).

4.2. Arm Angle Switches


Removal
1. Lower the forks completely.
2. Press red OFF button O on the keypad. Depress
main ON/OFF switch to the OFF position.
3. Disconnect the battery connector from the truck.
4. Remove truck cover(s) [see page 84.]
5. Disconnect the wires on the switch.
6. Remove the screws holding the switch on the
mounting bracket. Remove switch.

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Switches

Installation
1. Mount the switch to the mounting bracket.
2. Connect the wires to the switch.
3. Connect the battery connector to the truck.
4. Turn main ON/OFF switch to the ON position.
Enter key code and press the green ON button I
on the keypad. Test drive the truck.
5. Adjust switch if necessary (see page 220.)
6. Press red OFF button O on the keypad. Depress
main ON/OFF switch to the OFF position.
7. Install truck cover(s).

4.3. Lift Limit Switch


Removal
1. Press red OFF button O on the keypad. Depress
main ON/OFF switch to the OFF position.
2. Disconnect the battery connector from the truck.
3. Disconnect the wires on the switch.
4. Remove truck cover(s) [see page 84.]
5. Remove lift limit switch.

Installation
1. Connect the wires to the terminal.
2. Install new lift limit switch.
3. Connect the battery connector to the truck.
4. Turn main ON/OFF switch to the ON position.
Enter key code and press the green ON button I
on the keypad.
5. Test truck for proper operation before returning to
service.
6. Install truck cover(s).

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4.4. Key Switch (Optional)


Removal
1. Press red OFF button O on the keypad. Turn key
switch OFF.
2. Disconnect the battery connector from the truck.
3. Remove truck cover(s) [see page 84.]
4. Remove wires from switch terminals.
5. Remove key switch.

Installation
1. Install new key switch.
2. Connect the wires to the terminal.
3. Connect the battery connector to the truck.
4. Turn main ON/OFF switch to the ON position. Turn
key switch ON.
5. Test truck for proper operation before returning to
service.
6. Install truck cover(s).

4.5. Horn Switch


Removal
1. Press red OFF button O on the keypad. Depress
main ON/OFF switch to the OFF position.
2. Disconnect the battery connector from the truck.
3. Remove truck cover(s) [see page 84.]
4. Disconnect the wires on the switch.
5. Remove horn switch.

Installation
1. Connect the wires to the terminal.
2. Install new horn switch.
3. Connect the battery connector to the truck.

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Switches

4. Turn main ON/OFF switch to the ON position.


Enter key code and press the green ON button I
on the keypad.
5. Test truck for proper operation before returning to
service.
6. Install truck cover(s).

4.6. Converting Keypad to Key Switch


Removal
1. Lift forks to maximum height.
2. Remove truck cover(s) [see page 84.]
3. Using the service key (see page 174), change
parameter 39 to 1 or 2 (see page 174.)
4. Press red OFF button O on the keypad. Depress
main ON/OFF switch to the OFF position.

Main ON/OFF Switch

5. Disconnect the battery connector from the truck.


6. Disconnect the wires from the main ON/OFF
switch. Remove main ON/OFF switch.
7. Remove main ON/OFF switch mounting bracket
(see page 223.)

Installation
1. Install new main ON/OFF switch and key switch
mounting bracket.
Keypad
Cover

2. Install original main ON/OFF switch into new


mounting bracket. Connect the wires that were
removed earlier to the main ON/OFF switch.
3. Install key switch in mounting bracket.
4. Remove jumper wire between wire 20 and 22 (see
page 194.) Connect the wires 20 and 22 to new
key switch.

Keypad

5. Remove screw from keypad. Remove keypad.


6. Install new keypad cover.
7. Remove service key.
8. Connect the battery connector to the truck.

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9. Turn main ON/OFF switch to the ON position. Turn


key switch ON.
10. Test truck for proper operation before returning to
service.
11. Install truck cover(s).

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5390
Fuses/Circuit Breakers

Version no

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001

SMX

Fuses/Circuit Breakers

Fuse F50

Fuse F51

1. Theory of Operation
The keypad and electronic tiller arm card (ETAC) circuit FU50
fuse is 10 Amps. The main ON/OFF switch circuit fuse FU51
is 10 Amps. The fuses are located on the contactor panel.

10A, Fuse Keypad and ETAC, part number 2527512 (supplied with main harness)

10A, Fuse Main ON/OFF, part number 25275-12


(supplied with main harness)

110A, Power Circuit Breaker, part number 301890003

2. Maintenance
Examine the fuse for signs of overheating, discoloration,
cracking, or other physical damage. Check for blown fuse
through the fuse window. If fuse is damaged replace it. To
test a fuse, remove or isolate it from the electrical circuit. Do
this by removing the fuse from the truck or by removing all the
connections from one side of the fuse. Use an ohmmeter set
to Rx1 scale and measure the resistance across the fuse.
The resistance should be less than 1 ohm.

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Fuses/Circuit Breakers
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2.1. Wiring Harness

When working on the truck, use care around the wiring


harnesses.

Do not pull on wires.

Carefully mate and unmate all connectors.

Do not pry apart connectors with unspecified tools.

Examine and maintain any added materials used


to dress or protect wire. This includes spiral wrap,
brackets, cable ties, fasteners, flexible conduit, etc.

Check harness wires for abrasions, scrapes, nicks


in wire, damage from overheating or burns, or
other general insulation damage.

Replace terminations with exposed wire visible at


connectors. Damaged terminations, exposed
wires, or damaged connectors can cause
operational failure of truck.

There should be a wire marker at each termination. If marker


is missing or unreadable, remark wire to allow easier
identification.
NOTE!

230

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It is normal to find unused connectors for


uninstalled options that have had heat
shrink applied over them and have been
strapped to harness.

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Fuses/Circuit Breakers

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2.2. Power Cables

Power cables should be checked for damage including:

BT Prime-Mover

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Evidence of overheating

Burned spots in cable

Nicks in insulation

Damaged or overheated terminal lugs

Damaged mounting hardware or brackets

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Fuses/Circuit Breakers
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2.3. Circuit Breaker

Circuit Breaker CB1

Under extreme operating conditions, the current demand on


the battery may exceed the rating for the main circuit breaker
(CB1) and force it open. This causes the truck to become
inoperable until the circuit breaker automatically resets itself.
To test a circuit breaker, remove the circuit breaker from the
truck or isolate it from the electrical circuit by removing all the
connections from one side. Let it cool (or reset itself.) Use an
ohmmeter set to Rx1 scale and measure the resistance
across the circuit breaker. The resistance must be less than 1
ohm.

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Fuses/Circuit Breakers

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2.4. Master Control Relay

Wire #24

Wire #26

The master control relay should be tested regularly for proper


operation. To inspect/test master control relay proceed as
follows:
1. Remove truck cover(s) [see page 84.]
2. With the battery connector connected, press the
green ON (I) key on the keypad.
3. Use a voltmeter to check the voltage between wire
#26 (terminal 2) and wire #24 (terminal 4.) The
voltmeter should read approximately 24V.
4. Move steering control handle down into the
operate position. The voltmeter should now read
0V. If not, replace master control relay.

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Fuses/Circuit Breakers
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3. Troubleshooting
During troubleshooting and repairs, it is sometimes
necessary to unmate a connector, move a harness, cut a
cable tie, or remove wire from a bracket. Note carefully the
location of wire and all protective or securing attachments
before moving harness. When replacing fuses, make sure
fuses are installed in the proper position.

4. Repair and Rebuild


Repair or replace damaged cables or mounting hardware as
necessary. Power cables are marked on terminal lug with
location where they belong. If marking is missing or is not
readable, remark cable with correct information. The terminal
lugs should be crimped tightly and securely on the wire.
Replace cable if necessary. After repair, return or replace all
protective and/or securing hardware to its original condition.
Protective materials are necessary to provide reliable
performance of interconnect system. The fuses can not be
repaired or rebuilt. Replace fuses with new as necessary.

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S5.6
5436
Contactor Panel

Version no

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000

SMX

C-code

Contactor Panel
1. Theory of Operation
The main contactor (K10) controls the transmission of battery
power to the drive motor.

2. Maintenance
Visually inspect the contactors for any signs of burning or
physical damage.

3. Troubleshooting
3.1. Resistance Testing
1. Press red OFF button O on the keypad. Depress
main ON/OFF switch to the OFF position.
2. Remove truck cover(s) [see page 84.]
3. Disconnect the wires from the coil contactor.
4. Connect one coil lead of ohmmeter to the coil lead
from contactor. Connect the other lead to the lead
from the contactor.
5. The reading should be between 20 and 40 ohms. If
resistance is outside that range, replace contactor.

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Contactor Panel

5436

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4. Repair and Rebuild


5

4
1
3
2

17
16

18

15

14

10
9
11
12
13

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Item No.

Description

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S5.6
5436
Contactor Panel

Version no

T-code

000

SMX

Item No.

C-code

Description

Drive controller

10

Screw

Screw

11

Control cable / harness

Contactor

12

Horn

Panel

13

Screw

Battery connector

14

Relay

Nut

15

Screw

Decal, breaker

16

Breaker, circuit

Decal, fuse

17

Bar, bus

Lockwasher

18

Screw

Replace main contactor if coil resistance is outside a range


between 20 and 40 ohms.

Removal
1. Press red OFF button O on the keypad. Depress
main ON/OFF switch to the OFF position.
Disconnect the battery connector from the truck.
2. Remove truck cover(s) [see page 84.]
X and Y
Terminals

Bus Bar

Figure 5-6: Main Contactor

3. Disconnect the wires from the X and Y terminals on


the contactor (3) coils.

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Contactor Panel

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4. Remove screws (15) securing the bus bar (17) and


cables to the contactor (3), noting the location for
assembly later.
5. Remove screws (2) holding the contactor (3)
assembly to the electrical panel (4).

Installation
1. Secure contactor (3) to the electrical panel (4) with
screws (2).
2. Secure bus bar (17) and cable to the contactor (3)
with screws (15).
3. Connect the wires to the X and Y terminals.
4. Connect the battery connector to the truck.
5. Turn main ON/OFF switch to the ON position.
Enter key code and press the green ON button I
on the keypad.
6. Test truck for proper operation before returning to
service.
7. Install truck cover(s).

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Section

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S5.7
5460
Transistor Controller

Version no

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001

SMX

Transistor Controller
1. Theory of Operation
WARNING Interchanging the transistor controller
with another truck model could cause
internal failure to the transistor
controller. The warranty will be void if
the transistor controller is interchanged
from one truck to another!
The transistor controller is programmed specifically for this
truck. It is microprocessor based and programmable
designed for separately excited motors. The transistor
controller provides smooth control of the traction (drive) motor
utilizing four distinct operating modes. An LED is built into the
transistor controller that communicates controller status.

1.1. Basics Of Circuit Operation


The transistor controller provides both armature and field
outputs. Through these outputs, it regulates the voltage and
current applied to the motor according to its programmed
motor control algorithm. This programmable motor control
algorithm allows the user to optimize truck performance
based on their application. The polarity and magnitude of the
field is controlled to provide solid state, contactor-less
direction control and plug braking.
As the transistor controller is powered up, it performs an
internal self test.

A short between M- and Ground.


(Insures the M- output or power MOSFETs are not
shorted.)

Continuity in the field coil.


(Occurs each time forward or rearward travel is
selected.)

Selecting either tractor-first or forks-first travel selects the


direction of current flow in the field. The voltage and current in
the armature circuit raises when the throttle increases. The
field current will then follow a predetermined current map to
match the armature current. In this manner, the motor is kept
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Transistor Controller
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in its optimal commutation range and arcing on the


commutator is minimized. As the throttle is increased and the
motor speeds up, the armature voltage will approach the
battery. Top speed is limited by confining the minimum
allowable field current.
Plug braking involves reversing the travel control to the
opposite direction causing the truck to decelerate smoothly.
The operator may choose to continue holding the travel
controls in the opposite direction. This will start the truck
moving in that direction or the operator may release the
handle and allow the truck to come to a complete halt. The
parking brake is automatically applied when released.
When using plug braking the operator may regulate, within
the programmed capabilities, the degree of the plugging
force and distance travelled during plugging. For the lightest
plugging force, and the longest distance, the travel control
should be operated in the opposite direction. For the
strongest plugging power, and the shortest distance, the
travel control should be operated to full speed in the opposite
direction. Plug braking may be regulated with the steering
control handle at any point between full speed.

1.2. Interface
The direction control section controls the drive motor direction
by manipulating the drive motor field polarity according to the
directional signal inputs from the Electronic Tiller Arm Card
(ETAC).
The thumb control section controls the drive motor speed and
torque by monitoring the position change of the arm angle A
and arm angle B switches. Variable motor speed is
accomplished by separate control of field and armature
currents.
The reverser circuitry in the ETAC provides the directional
travel control commands to the transistor controller.
The control circuit section controls all truck inputs and outputs
(excluding steering control handle head inputs.)
The ETAC controls. The transistor controller is the slave.

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5460
Transistor Controller

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1.3. Control Features


Reversing without the use of direction contactors permitted
with full bridge control of motor field.
Controlled and limited truck speed at top end through
separate field and armature control.
Fully protected inputs and outputs.
Active power on self test and continuous diagnostics during
operation.
Internal watchdog circuits ensure proper software
operation.

1.4. Motor Circuit

Control
wire plug
16-pins
M-

B-

B+

F1
F2

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Transistor Controller
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The transistor controller has three terminals for the high


current circuits B-, M-, and B+. Two quick connect terminals
are provided for the field winding connections F1 and F2.
Terminal
BB+

MF1
F2

Connecting
Negative connection to battery
Overcurrent protected and K10 switched
positive connection to the battery and motor
armature
Motor armature
Motor field
Motor field

1.5. Control Circuit


The transistor controller has an integrated 16-pin connector
to provide the low power logic control connections. The
designation of the pins are according to the following table.

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5460
Transistor Controller

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Pin number 1 is located in the back row right side when


viewing the logic connector.
Pin No
P1
P2
P3
P4
P5
P6
P7
P8
P9
P10
P11
P12
P13
P14
P15
P16

Connecting
CAN High
IN/OUT Lower Valve
Not Used
Out Main Contactor
IN/OUT Brake
OUT Pump Contactor
OUT Horn
CAN Low
Not Used
Not Used
Not Used
IN Arm Angle A
Not Used
IN Arm Angle B
IN Lift Limit
IN +24 VDC

1.6. Definitions
Overtemperature. Overtemperature of the transistor
controller is from 185 degrees F (85 degrees C) and above.
Overheating is unusual, but can occur if the transistor
controller is installed incorrectly or overloaded. At
overtemperature the drive current limit is linearly decreased
from full set current down to zero. Plug current is not reduced
by any thermal conditions to allow full plugging strength at all
times.
Undertemperature. When the transistor controller is
operating at less than 13 degrees F (25 degrees C), the
current limit is cut back resulting in reduced travel speed and
acceleration.
Pulse Width Modulation. Pulse Width Modulation (PWM),
also called chopping, controls the speed of the motor by
switching the battery voltage to the motor on and off very
quickly.
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Transistor Controller
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001

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C-code

5460

Thermal Cutback. Thermal cutback of the transistor


controller is below -13 degrees F (-25 degrees C) or above
185 to 203 degrees F (85 to 95 degrees C), the PWM drive
current limit is linearly decreased from full set current down to
zero. At -13 to -40 degrees F (-25 to -40 degrees C), the
current limit is reduced to approximately half the set current,
resulting in reduced travel speed. Below -40 degrees F (-40
degrees C) or above 203 degrees F (95 degrees C), the
allowed PWM is zero percent.

2. Maintenance
There are no serviceable parts inside the transistor controller.
No attempt should be made to open the transistor controller.
OPENING THE TRANSISTOR CONTROLLER WILL VOID
THE WARRANTY!

2.1. Safety
WARNING Because there is a risk of short circuits,
remove all watches and jewelry; always use
insulated tools.
The transistor controller is essentially a high-power device.
When working around any battery powered vehicle, proper
safety precautions should be taken. These include, but are
not limited to the following: proper training, wearing eye
protection, avoiding loose clothing, removing watches and
jewelry, and using insulated tools.

2.2. Cleaning
It is recommended that the transistor controller exterior be
cleaned periodically with an approved and regulated air
supply (blower.) Although the transistor controller virtually
requires no maintenance if properly installed, the following is
recommended on a regular basis of 250 hours for cold
storage and 1500 hours for standard environment.
1. Remove power by disconnecting the battery at the
battery connector.
2. Discharge capacitors in the transistor controller by
connecting a load (such as a contactor coil or horn)
across the transistor controllers B+ and B-

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Section

C-code

S5.7
5460
Transistor Controller

Version no

T-code

001

SMX

terminals before doing any work on the transistor


controller.
3. Remove dirt or corrosion from the bus bar area.
The transistor controller should be wiped clean
with a moist rag. Allow to dry before reconnecting
the battery.
4. Make sure the connections to the bus bars are
tight. Use two well insulated wrenches for this task
in order to avoid stressing the bus bars.

3. Troubleshooting
3.1. Diagnostics and Troubleshooting
The transistor controller provides diagnostic information to
assist technicians in troubleshooting drive system problems.
The information can also be obtained by looking at the status
LED built in the transistor controller that is visible through the
window label.

3.2. Fault Codes

Transistor
Controller

J5 Connector

Figure 5-7: Transistor Controller

An internal microcontroller automatically checks the function


of the transistor controller. When this microcontroller detects
a fault, it signals the appropriate fault code through the
diagnostic LED on the bottom of the transistor controller.
These are not the codes that appear on the display. Under
normal operation, the LED flashes a single flash at
approximately one flash per second. A two-digit flash code
BT Prime-Mover, Inc.

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S5.7
Transistor Controller
Version no

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001

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C-code

5460

signals the transistor controller has detected a fault within


itself.
The following table list some transistor controller codes that
are okay (normal.)
Error
Code

Program
LCD Display

OFF

N/A

ON

N/A

0,1

No known faults

1, 1

Current shunt

1, 2

Hardware
failsafe

1, 3

M- shorted

1, 4
2, 1

SRO
Throttle Fault 1
EMR REV
Wiring
HPD
Throttle Fault 2

2, 2
2, 3
2, 4

3, 1

246

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CONT COIL/
FLD Short

Probable Cause

Explanation

Open circuit at transistor controller Transistor controller does not have


+24VDC logic input due to wire, fuse or voltage at +24VDC logic power supply
bad transistor controller.
input.
Transistor controller is not functioning
Bad transistor controller.
properly.
N/A
Normal hearbeat, everything is okay.
See truck error code 202 (see page 187.)
If ETAC does not display this code, there
may
be
a
problem
with
CAN See truck error code 202 (see page 187.)
communication, transistor controller or
ETAC.
If ETAC is not keyed on; the controller is
reporting it is not receiving CAN
messages from ETAC, which is normal.
If ETAC is keyed on and ETAC is
displaying an error code; see truck error
code (see page 181) for possible Transistor controller is reporting that it is
causes.
not receiving CAN messages from the
If ETAC is keyed on and ETAC is not ETAC or its self-test failed.
displaying any error code, there may be
a problem with CAN communications,
transistor controller or ETAC. This code
may take a few seconds to clear after
ETAC key-on.
See truck error code 201 (see page 187.)
If ETAC does not display this code, there
may
be
a
problem
with
CAN See truck error code 201 (see page 187.)
communication, the transistor controller or
ETAC.
Bad transistor controller or ETAC.
Bad transistor controller or ETAC.
Transistor controller is not setup or
Bad transistor controller or ETAC.
functioning properly.
Bad transistor controller or ETAC.
Bad transistor controller or ETAC.
See truck error code 106 (see page 184.)
If ETAC does not display this code, there
may be a problem with low battery See truck error code 106 (see page 184.)
voltage, CAN communication, transistor
controller or ETAC.

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2006-12-12

F-code

PT

Error
Code

Program
LCD Display

3, 2

Main CONT
Welded

3, 3

3, 4

4, 1

4, 2

4, 3

4,4

Section

Version no

T-code

001

SMX

Probable Cause

C-code

S5.7
5460
Transistor Controller

Explanation

Bad transistor controller or ETAC.

Transistor controller is not setup or


functioning properly.

See truck error code 200 (see page 187.)


If ETAC does not display this code, there
may
be
a
problem
with
CAN See truck error code 200 (see page 187.)
Field Open
communication, transistor controller or
ETAC.
Missing
Transistor controller is not setup or
Bad transistor controller or ETAC.
contactor
functioning properly.
See truck error code 41 (see page 182.) If
ETAC does not display this code after a
Low battery
few seconds, there may be a problem with See truck error code 41 (see page 182.)
voltage
CAN communication, transistor controller
or ETAC.
See truck error code 42 (see page 183.) If
ETAC does not display this code after a
few seconds, there may be a problem with See truck error code 42 (see page 183.)
Overvoltage
CAN communication, transistor controller
or ETAC.
See truck error code 43 (see page 183.) If
ETAC does not display this code after a
Thermal cutback few seconds, there may be a problem with See truck error code 43 (see page 183.)
CAN communication, transistor controller
or ETAC.
Transistor controller is not setup or
Anti-Tiedown
Bad transistor controller or ETAC.
functioning properly.

4. Repair and Rebuild


There are no serviceable parts inside the transistor controller.
No attempt should be made to open the transistor controller.
OPENING THE TRANSISTOR CONTROLLER WILL VOID
THE WARRANTY! Replace transistor controller with new as
necessary.

BT Prime-Mover, Inc.

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2006-12-12

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Transistor Controller
Version no

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C-code

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This page is intentionally left blank.

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F-code

Section

C-code

PT
S5.8
5700
Electronic Tiller Arm Card (ETAC)
Version no

T-code

000

SMX

Electronic Tiller Arm Card (ETAC)


1. Theory of Operation
The programmable motor control functions are performed by
the ETAC housed within the steering control handle. The
ETAC controls. The transistor controller is the slave. The
basic function of the ETAC include the following:

BT Prime-Mover, Inc.

Return

Monitor relative positioning of the thumb controls to 18


Hall effect sensors for speed and direction control.

Monitor position of reverser button for reversing of the


truck direction.

Monitor truck performance and provide input data and


commands to the service display.

Provide lift/lower input commands to the transistor


controller.

Monitor horn switches S18-1 and S18-2 for horn


operation.

Monitor and define truck performance parameters.

Fully compatible for programming, diagnostic and test


information.

Armature current controlled at all times, reducing


arcing and brush wear.

Automatic neutral braking: adjustable plugging force.

Truck acceleration and response controlled through


programmable parameters.

Linear temperature cutback on motor current limit. No


sudden loss of power under thermal conditions.

Interlock features ensure proper start-up sequence.

Integral fault LED provides a transistor controller


operating properly signal and flashes error code
information when a fault occurs.

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S5.8
5700
Electronic Tiller Arm Card (ETAC)
Version no

T-code

000

SMX

2. Maintenance
See Planned Maintenance Schedule on page 61.

3. Troubleshooting
See Error Codes (E) on page 180.

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PT
S5.8
5700
Electronic Tiller Arm Card (ETAC)
Version no

T-code

000

SMX

4. Repair and Rebuild


A bad ETAC must be replaced with a new card.

Reverser
Button

Push
Button

Electronic
Horn
Button Tiller Arm
Right Card (ETAC)

Lift/Lower
Button

Display
Horn
Button
Left

Housing

Horn Button/
Switch

Speed
Control

Steering
Control Handle

BT Prime-Mover, Inc.

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Keypad

2004-03-10

251

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PT
S5.8
5700
Electronic Tiller Arm Card (ETAC)
Version no

T-code

000

SMX

Removal
1. Press red OFF button O on the keypad. Depress
main ON/OFF switch to the OFF position.
2. Disconnect the battery connector from the truck.
3. Remove screw from keypad. Unplug and remove
keypad.
4. While holding the top cover firmly, remove screws
securing the top cover assembly to the handle.
5. Disconnect the ETAC cable.
CAUTION To avoid risk of static discharge that can
damage the electronics, make sure to take
the necessary precautions before working
with electronics (see page 25.)
NOTE!

Place fingers between the housing and


reverser button to hold the thumb control in
place.

6. Remove screws securing housing to gain access


to the ETAC board. Carefully lift off the housing.

Installation
CAUTION Do not use excessive force when prying on
the button or damage could result to the
locking tabs.
1. Install new ETAC board with screws.
2. Connect the cable to ETAC.
3. Install keypad and secure with screw. Connect the
keypad plug.
4. Connect the battery connector to the truck.
5. Turn the main ON/OFF switch to the ON position.
Enter key code and press the green ON button I
on the keypad.
6. Test truck for proper operation before returning to
service.

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S6.0
6000
Hydraulic System

Version no

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001

SMX

C-code

Hydraulic System
1. Theory of Operation
The hydraulic system consists of a compact hydraulic unit,
including a electric solenoid valve, pressure relief valve and a
cylinder for lifting the forks. The hydraulic solenoid activates
the hydraulic lowering valve that releases pressure on the lift
cylinder to lowing the forks. The hydraulic system is protected
by a relief valve installed in the adapter body.

Lift
Cylinder

Component Enclosure
Hydraulic Lines Joining
Motor (Electric)
Hydraulic Pump

Solenoid
Valve

Filter
Check
Valve

Reservoir (Vented)

1.3 GPM

Cylinder (Single Acting)


Cylinder (Double Acting)

3000
PSI

Check Valve
Hydraulic Lines Crossing

Orifice

M3

1.25
CC

Filter
Reservoir

BT Prime-Mover, Inc.

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S6.0
Hydraulic System
Version no

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001

SMX

C-code

6000

1.1. Lift
When the lift button is pushed, the lift pump solenoid is
energized starting the pump and motor. Fluid is drawn from
the reservoir, through a pick up screen to the inlet of the gear
pump. As the gear pump rotates, oil is forced out the pressure
port and is blocked from returning to the reservoir by a closed
relief valve and lowering valve. Oil continues to flow to the top
of the lift cylinder and pushes against the end of cylinder rod
to extend the rod from the cylinder tube. When the lift pump
motor is shut off and the gear pump is not turning, the
cylinder is held extended by a closed check valve and
normally closed lowering valve.

Pressure Oil
Return Oil
B+ Circuit
B- Circuit
Signal
Pre-Charge Voltage

1.3 GPM

3000
PSI

M3

254

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PT

S6.0
6000
Hydraulic System

Version no

T-code

001

SMX

C-code

1.2. Lower
Hydraulic fluid is retained in the hydraulic cylinder by a check
valve and electrical hydraulic lowering valve. When the
solenoid is energized, oil passage from the cylinder to
reservoir is opened. Due to the load on the lift cylinder, fluid is
forced out of the lift cylinder and back to the reservoir while
the lift cylinder is retracting. Lowering speed is regulated by a
flow regulator. This process allows the truck to lower.

Pressure Oil
Return Oil
B+ Circuit
B- Circuit

1.3 GPM

Signal
Pre-Charge Voltage

3000
PSI

M3

BT Prime-Mover, Inc.

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S6.0
Hydraulic System
Version no

T-code

001

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C-code

6000

1.3. Relief Pressure


The relief valve is set by the manufacturer to open at a
specified pressure of 3000 psi (20684 kPa).

Pressure Oil
Return Oil
B+ Circuit
B- Circuit
Signal
Pre-Charge Voltage

1.3 GPM

3000
PSI

M3

256

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CC

2006-08-08

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Section

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S6.0
6000
Hydraulic System

Version no

T-code

001

SMX

C-code

2. Maintenance
To prolong the life of the truck, keep all fittings and
connections tight to prevent leaks. To avoid damage or
distortion, do not over-tighten brass fittings. Before removing
any component from the hydraulic system, wash the
component and surrounding area with cleaning solution to
prevent foreign matter from entering the system. Cap and
plug all openings immediately. Whenever removing fitting
with a pipe thread, use a sealing compound on the
outside of threads before reinstalling. (Do not use
Teflon tape.) Make sure all parts are clean. When installing
a hose assembly, make sure that it is not twisted when fittings
are tightened. Always use two wrenches on a swivel-type
fitting, one to hold the fitting and the other to tighten the hose.

2.1. Changing Hydraulic System Fluid


Hydraulic fluid level must be checked periodically (see
Planned Maintenance Schedule on page 61.) If the
reservoir regularly requires additional oil to maintain proper
level, a leak is indicated and must be repaired. When
scheduled, the reservoir should be removed and drained for
cleaning and replaced with new oil. After refilling, check lift,
lower and other hydraulic functions for proper operation. If the
truck will not lift a full load, the pressure relief setting should
be checked and adjusted. During normal operation, pressure
relief setting will not change. As the lift pump wears with age,
some loss of performance will be experienced. When this loss
becomes severe, the lift pump should be replaced.
WARNING Fluid is under pressure and may spray or
splash. Point hose away from you body and
hold firmly in waste fluid container.
NOTE!

Be sure truck is in a clean area, away from


possible contaminating elements that could
enter the hydraulic system during the
changing process.

Contaminated hydraulic fluid is the major cause of


hydraulic system failures. Keep any service equipment,
such as containers, funnels, and hand pumps clean at all
times by covering when not in use.
BT Prime-Mover, Inc.

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Hydraulic System
Version no

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6000

1. Lower forks.
2. Press red OFF button O on the keypad. Depress
main ON/OFF switch to the OFF position.
3. Disconnect the battery connector from the truck.
4. Remove truck cover(s) [see page 84.]
Lift Cylinder Hose

5. Disconnect lift cylinder hose at the hydraulic


cylinder.
NOTE!

Wear protection eye and face gear when


draining oil.

6. Insert hose in a waste fluid container.


7. Connect the battery connector to the truck.
8. Turn the main ON/OFF switch to the ON position.
Enter key code and press the green ON button I
on the keypad.
9. Run hydraulic pump by pressing the lift button until
all hydraulic fluid is pumped from the system.
10. Press red OFF button O on the keypad. Depress
main ON/OFF switch to the OFF position.
11. Disconnect the battery connector from the truck.
12. Connect the lift cylinder hose.
13. Remove vent plug and fill reservoir to within 1
inch (25.4 mm) below the filler port elbow with
recommended fluid (see page 72.) The usable
reservoir capacity is 0.8 quart (0.75 liter). Replace
vent plug.
14. Install truck cover(s).
15. Connect the battery connector to the truck.
16. Turn the main ON/OFF switch to the ON position.
Enter key code and press the green ON button I
on the keypad.
17. Raise and lower forks several times to purge air
from the system.
18. Properly dispose of waste fluid.

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S6.0
6000
Hydraulic System

Version no

T-code

001

SMX

C-code

2.2. Hydraulic Pump Pressure Relief Valve


The hydraulic system is protected by a relief valve installed in
the adapter body. The relief valve is set by the manufacturer
to open at specific pressure (3000 psi [20684 kPa]). There is
no need to ever adjust the relief valve on this truck.

3. Troubleshooting
NOTE!

Proper care and cleanliness should be


observed in servicing to insure oil does not
become contaminated with dirt or other
foreign material. Contaminants can be
drawn into pump so as to stick or score
pump which will cause failure of pump
assembly.

If the hydraulic pump assembly does not operate properly,


the following preliminary checks should be made:
1. Proper oil level
2. All electrical connections tight
3. Battery fully charged
When checking voltage at contactors, make sure hydraulic
lines and components are fully installed.
When possible, keep the main ON/OFF switch OFF and
battery connector disconnected.
After the preliminary check is accomplished, install a 0-5000
psi (0-34473 kPa) pressure gauge in the 0.375 inch (9.525
mm) NPTF outlet port near the relief valve in the adaptor. The
installation of a pressure gauge is required to insure proper
observation of what is occurring in the unit during trouble
shooting. Start pump and raise lift cylinder to its upper limit
stops to develop maximum pressure of the unit, which will
normally be passing all flow over a relief valve. Pressure
gauge should be reading the set pressure of the relief valve.
Remove pressure on hydraulic system by actuating the
solenoid operated lowering valve.
Normal trouble that may occur with pump assembly have
been grouped under three headings: Failure to (A) Raise (B)
Hold (C) Lower load. One or more of the listed trouble

BT Prime-Mover, Inc.

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Hydraulic System
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001

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C-code

6000

sources may be causing improper operation. Refer to the


proper heading (relief valve) for detailed instructions for
disassembly and check parts to remedy the trouble.
1. If pump operates but will only develop low pressure
or slow lift:
a. Relief valve seat scored, foreign particles
under ball.
b. Dirt in hydraulic lowering valve.
c.

Pump worn, replace pump.

2. If pump develops pressure but will not hold:


a. Dirt in hydraulic lowering valve.
b. Relief valve seat scored, foreign particles
under ball.
3. If pump develops pressure but will not release load:
a. No electrical contact to hydraulic lowering
valve.
b. Solenoid in hydraulic lowering valve coil
burned out.
c.

Relief valve bottomed causing pressure to


go beyond the unloading limit of the
hydraulic lowering valve.

3.1. Troubleshooting Chart Index


1. No lift, lift motor does not run, travel is okay.
2. No lift or slow lift, lift motor does run.
3. No lower, lift and travel okay.
4. Unable to pick up a load.
5. Slow lower.
6. Load drifting/settling.

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6000
Hydraulic System

Version no

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001

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C-code

3.2. Troubleshooting Charts


The following troubleshooting charts describe a course of
testing and repair for each problem listed. If the given test is
NOT successful, perform the repair listed with the test. If the
given test IS successful, go to the next test or follow the
special instructions given. For electrical legend see
page 196.
1. No lift, lift motor does not run, travel is okay.
Possible Cause

Remedy

Bad ETAC (A2)

With main ON/OFF switch in the ON position, the pin key code entered
in the keypad, the green ON button I pressed on the keypad, and the
lift switch depressed, does main contactor (K10) and pump contactor
(K30) energize (click)? If not, check Service Display on page 169. If
no signal is detected, check mechanical problems in the steering
control head. Replace electronic tiller arm card ETAC (A2) as a last
alternative in resolving problem.

Bad lift pump contactor

With main ON/OFF switch in the ON position, the pin key code entered
in the keypad, the green ON button I pressed on the keypad, and the
lift switch depressed, does main contactor (K10) and pump contactor
(K30) energize (click)? If not, measure voltage between pump contactor
coil terminals. If B+ voltage is present, replace the pump contactor.

Bad wiring continuity or wiring


shorts

With main ON/OFF switch OFF and battery connector disconnected,


check for continuity and wiring shorts in wiring harness or cables.

Bad lift-limit switch

With main ON/OFF switch OFF, battery connector disconnected, and


forks lowered, check continuity through the lift-limit switch. Replace if
necessary.

Bad lift pump motor brushes

With main ON/OFF switch in the ON position, the pin key code entered
in the keypad, the green ON button I pressed on the keypad, and the
lift switch depressed, does pump contactor (K30) energize (click)? If
yes, measure voltage between B- and lift pump motor terminal. If okay,
check lift motor brushes (see page 91.)

Bad lift pump motor

If lift motor brushes are okay, test pump motor.

Bad pump

If motor is okay, remove motor from the pump and rotate pump shaft by
hand. Replace pump if not okay.

2. No lift or slow lift, lift motor does run.


Possible Cause

Remedy

Battery problems

Replace battery with fully-charged battery.

Mechanical binding in lift


mechanism

Repair lift mechanism.

BT Prime-Mover, Inc.

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S6.0
Hydraulic System
Version no

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6000

Possible Cause

Remedy

Low hydraulic pressure

Check hydraulic pressure setting and adjust if necessary (see


page 259.)

Relief valve contaminated or


bad. (Unable to get the
correct hydraulic pressure)

When main ON/OFF switch OFF, and battery connector disconnected,


remove pressure relief valve and check for damage or contamination.
Replace valve or flush system and replace the hydraulic fluid (see
page 257.)

Bad lift
brushes

Check lift motor brushes (see page 91.) If brushes are okay, replace lift
pump.

pump

motor

or

Contamination found in pump

Flush system and replace hydraulic fluid (see page 257.)

Bad pump

If motor is okay, remove motor from the pump and rotate pump shaft by
hand. Replace pump if necessary.

3. No lower, lift and travel okay.


Possible Cause

Remedy

Bad lower solenoid valve

With main ON/OFF switch in the ON position, cycle the lower switch.
Does the lower solenoid valve energize (click)? If yes, disconnect the
battery connector, then slowly loosen, but DO NOT REMOVE the
hydraulic line at the hydraulic pump assembly. Have drain pan and rags
ready and allow the forks to slowly lower.

If forks do not lower, check for


mechanical binding in lift
cylinder or fork mechanism

Replace lift cylinder or repair lift mechanism.

If forks lower, remove and


inspect hydraulic lowering
valve

Inspect for free movement and signs of contamination. Clean solenoid


valve or flush system, clean filter and replace hydraulic fluid. If not
contamination is found, repair or replace hydraulic lowering valve or
pump assembly.

Check for bad ETAC (A2)

With main ON/OFF switch in the ON position, the pin key code entered
in the keypad, the green ON button I pressed on the keypad, and the
lower button depressed, check Service Display on page 169. If no
signal is detected, check mechanical problems in the steering control
handle head. Replace ETAC (A2) as a last alternative in resolving
problem.

4. Unable to pick up load.


Possible Cause

Remedy

Load too large for lift truck


capacity

Check load weight. Check lift pressure setting.

Battery problems

Replace battery with fully-charged battery.

Incorrect lift pressure


adjustment

Check and adjust lift pressure setting.

262

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Possible Cause

F-code

Section

PT

S6.0
6000
Hydraulic System

Version no

T-code

001

SMX

C-code

Remedy

Contaminated or bad
pressure relief valve

Check for contamination in hydraulic fluid. If contamination is present,


flush, fill and bleed the hydraulic system and clean relief valve. If no
contamination is found, replace relief valve.

Bad lift pump

Replace lift pump (see page 270.)

Bad lift motor

Replace lift motor (see page 92.)

5. Slow Lower.
Possible Cause

Remedy

Bad lift/lower solenoid valve


or wiring

Repair or replace valve or wiring.

Plugged or malfunctioning
flow hydraulic lowering valve

Check for contamination in hydraulic fluid. If contamination is present,


flush, fill and bleed hydraulic system and clean valve. If no
contamination is found, replace flow control valve.

Contamination
solenoid valve

Inspect solenoid for contamination or binding.

in

Mechanical binding
mechanism

lowering
in

lift

Bad or mid adjusted lift-limit


switch

Adjust or replace mechanism.


Adjust lift limit switch (see page 221) or replace lift limit switch (see
page 225.) Pump should not hit relief if lift limit switch is operating
properly.

NOTE: If pump hits relief and lower is attempted, lowering will be slow. Release lower button
momentarily, then continue to lower. Normal lower speed should resume.

6. Load Drifting/Settling.
Possible Cause

Remedy

Incorrect lift pressure adjust

Check and adjust lift pressure setting (see page 259.)

Contamination or bad check


valve

Check for contamination in hydraulic fluid. If contamination is present,


flush, fill and bleed hydraulic system and clean check valve. If no
contamination is found, replace check valve.

Leaking or contaminated
hydraulic lowering valve

Check for contamination in hydraulic fluid. If contamination is present,


flush, fill and bleed hydraulic system and clean hydraulic lowering valve.
If no contamination is found, replace hydraulic lowering valve.

Load too large for lift truck


capacity

Check load weight. Check lift pressure setting.

BT Prime-Mover, Inc.

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S6.0
Hydraulic System
Version no

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001

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C-code

6000

4. Repair and Rebuild


The lift motor solenoid, hydraulic reservoir, lowering valve,
adapter body and lift pump can be repaired or rebuilt.
Replace items as necessary.

39
38

37

40
7

5
6

36
35 34 33
32

8
9
10

12

31
30

14
15
16
17

13

11

18
19

41

20
21
29

22
23
24
25

28

27

264

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Master Service Manual

26

2006-08-08

Item No.

BT Prime-Mover, Inc.

Return

Description

F-code

Section

PT

S6.0
6000
Hydraulic System

Version no

T-code

001

SMX

Item No.

Description

Pump and motor assembly

22

Tube

Pump motor

23

Magnet

Solenoid

24

Strainer

Washer, flat

25

Clamp, hose

Lockwasher

26

Reservoir

Screw

27

Elbow, 90 degrees

Fitting, male tap 45 degrees

28

Breather

Plug

29

Tube

Plug

30

O Ring

10

Spool, flow control

31

O Ring

11

Hydraulic lowering valve


assembly

32

Adapter

12

Valve, relief

33

Seat, relief

13

Coil, 24 Volt

34

Plunger

14

Spring

35

Spring

15

Coupler

36

O Ring

16

O Ring

37

Cap

17

Pump assembly

38

Gasket

18

Washer

39

Cable

19

Screw

40

Nut, adjustment

20

Seal, washer

41

Insert, tube

21

Fitting

Master Service Manual

2006-08-08

C-code

265

F-code

Section

PT
S6.0
Hydraulic System
Version no

T-code

001

SMX

C-code

6000

WARNING DO NOT use your hands to check for


hydraulic leakage. Use a piece of
cardboard or paper to search for leaks.
Escaping fluid under pressure can
penetrate the skin causing injury. Relieve
pressure before disconnecting hydraulic or
other lines. Tighten all connections before
applying pressure. Keep hands and body
away from pinholes and nozzles which
eject fluids under high pressure.

4.1. Hydraulic Unit


Removal
1. Lower forks to the floor.
2. Press red OFF button O on the keypad. Depress
main ON/OFF switch to the OFF position.

Pump Motor

3. Disconnect the battery connector from the truck.

Lift Motor
Solenoid

4. Remove truck cover(s) [see page 84.]


5. Remove and tag all wires and cables connected to
the pump motor (2).
6. Remove and cap hydraulic line from the hydraulic
unit. Disconnect contactor control wires.

Lowering
Valve
Adapter Body
(Pump)

Fill/Vent
Plug

7. Remove bolts attaching hydraulic unit mounting


bracket to truck.
8. Remove hydraulic unit from truck.

Hydraulic
Reservoir

266

Return

Master Service Manual

2006-08-08

F-code

Section

PT

S6.0
6000
Hydraulic System

Version no

T-code

001

SMX

C-code

Installation
1. Install hydraulic unit on the truck and bolt bracket.
2. Install hydraulic line on hydraulic unit.
3. Fill reservoir with specified fluid (see page 72.) Use
a funnel with a flexible neck. Fill reservoir to within
1 inch (25.4 mm) below filler plug elbow. Use up to
0.8 quart (0.75 liter).
4. Install vent plug.
5. Connect the wires and cables to the pump motor.
6. Connect the battery connector to the truck. Turn the
main ON/OFF switch to the ON position. Enter key
code and press the green ON button I on the
keypad.
7. Raise and lower forks. Check hoses and fittings for
leaks.
8. Check hydraulic fluid level in the reservoir (see
page 257.)
9. Install truck cover(s).

4.2. Hydraulic Solenoid


Removal
1. Lower forks to the floor.
2. Press red OFF button O on the keypad. Depress
main ON/OFF switch to the OFF position.
3. Disconnect the battery connector from the truck.
4. Remove truck cover(s) [see page 84.]
5. Remove wires from terminals on the solenoid (3).
6. Remove nut holding solenoid coil (13) to the
hydraulic lowering valve (11).
7. Lift solenoid coil (13) off the relief valve (12) stem.
8. Remove relief valve (12) from the adapter (32)
body.

BT Prime-Mover, Inc.

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Master Service Manual

2006-08-08

267

F-code

Section

PT
S6.0
Hydraulic System
Version no

T-code

001

SMX

C-code

6000

Inspection
1. Inspect seat where hydraulic lowering valve stem
seals against the adapter body. The sealing
surface must be completely clean and free from
any nicks or damage.
Installation
1. Thread adapter body into the adapter (32) and
torque to 204 - 240 in-lbs (23 - 27 Nm).
2. Install solenoid coil (13) and torque nut to 48 to 60
in-lbs (5 to 7 Nm).
3. Connect the wires to the terminals.
4. Install truck cover(s).
5. Connect the battery connector to the truck.
6. Turn the main ON/OFF switch to the ON position.
Enter key code and press the green ON button I
on the keypad.

4.3. Reservoir
Removal
1. Remove hydraulic unit from truck (see page 266.)
2. Remove hose clamp securing hydraulic reservoir to
the adapter (32) housing.
3. Tap reservoir (26) lightly to loosen. Wiggle reservoir
sideways while pulling up on the pump and motor at
the same time to remove.
4. Remove reservoir (26) and properly dispose of old
hydraulic fluid.
5. After fluid has drained, flush the inside of the
reservoir with a suitable cleaning solution.
6. Dry the inside of the reservoir with clean, dry
compressed air.
Inspection
1. Inspect the reservoir O ring and inside leading
edge for defects. Replace if necessary.
268

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Master Service Manual

2006-08-08

F-code

Section

PT

S6.0
6000
Hydraulic System

Version no

T-code

001

SMX

C-code

Installation
1. Lubricate O ring with hydraulic fluid. Install O ring.
2. Carefully install reservoir on adapter (32) housing
and attach with hose clamp. Torque clamp to 48 60 in-lbs (5.5 - 7 Nm).
3. Install hydraulic unit on truck (see page 267.)

4.4. Filter Screen and Inlet Tube


Removal
1. Remove reservoir (see page 268.)
2. With pump assembly inverted, unthread and
remove inlet tube fitting and sealing washer from
pump housing.

Filter Screen

3. Clean filter screen at the bottom of the inlet tube


with a suitable cleaning solution.
Inlet Tube

Inspection
1. Inspect filter screen and inlet tube for defects.
Replace if necessary.
Installation
1. Install inlet tube sealing washer and fitting in the
pump housing. Torque to 245 - 275 in-lbs (27 - 31
Nm).
2. Install hydraulic reservoir to gain access to the
pump.
3. Install hydraulic unit on truck (see page 267.)

BT Prime-Mover, Inc.

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Master Service Manual

2006-08-08

269

F-code

Section

PT
S6.0
Hydraulic System
Version no

T-code

001

SMX

C-code

6000

4.5. Lift Pump


Removal
1. Remove hydraulic unit from truck (see page 266)
and put on a clean bench for disassembly.
2. Remove reservoir to gain access to pump (see
page 268.)
3. Remove inlet tube with filter screen from pump
housing (see page 269.)
4. Remove pump mounting bolts. Remove pump from
adapter (32) body.
Installation
1. Stand motor assembly on end, with adapter (32)
body facing up.
2. Lubricate O ring and install on adapter (32) body
facing up.
3. Insert pump drive coupling on the end of the motor
armature shaft and fill the cavity with lubricant.
4. Align splines on the motor drive and pump shaft.
Gently push pump pilot on the adapter (32).
5. Secure pump with mounting bolts and torque to 40
to 45 in-lbs (4.5 to 5 Nm).
6. Install hydraulic reservoir (see page 269.)
7. Install hydraulic unit on truck (see page 267.)

270

Return

Master Service Manual

2006-08-08

F-code

Section

PT

S6.1

Version no

T-code

000

SMX

C-code

6420
Lift Cylinder

Lift Cylinder
1. Theory of Operation
The lift cylinders are the positive displacement type, meaning
there are NO seals on the inner end of the cylinder rod.

2. Maintenance
Inspect cylinder for leakage. Inspect cylinder rod for gouges
or pits. Fluid leakage indicates that the seal is worn. Replace
seal, wiper and lock ring when fluid leakage becomes
excessive.

2.1. Inspection
WARNING When using compressed air, wear effective
chip-guarding and personal protective
equipment. Compressed air used for
cleaning MUST be reduced to less than 30
psi (207 kPa).
NOTE!

CLEANLINESS! Perform procedures in a


clean environment. Make sure all parts are
cleaned before disassembly and kept clean
during assembly.

NOTE!

Call-outs in the following procedure refer to


illustration on page 272.

1. Press red OFF button O on the keypad. Depress


main ON/OFF switch to the OFF position.
2. Inspect cylinder rod (2) for nicks, scratches, or
scoring. If heavy scoring is found replace cylinder
rod (2).
3. Inspect hydraulic hose and replace if worn.

3. Troubleshooting
Check cylinder for leakage.

BT Prime-Mover, Inc.

Return

Master Service Manual

2006-12-12

271

F-code

Section

C-code

PT
S6.1
Lift Cylinder

6420

Version no

T-code

000

SMX

4. Repair and Rebuild


1
6
5
4

3
2

Item No.

Description

Item No.

1
2
3

Cylinder assembly
Rod, cylinder
Ring, retaining

4
5
6

Description
Wiper, rod
Seal, rod
Tube

If the cylinder contains gouges or pits it can not be repaired.


The rod wiper, rod seal, and retainer ring are replaced as new
in the seal kit available for this cylinder.
DANGER HOT OIL under pressure may be present.
Be certain truck is safely blocked and
pressure is released. Some spillage of
hydraulic oil may occur.
WARNING When using compressed air, wear effective
chip-guarding and personal protective
equipment. Compressed air used for
cleaning MUST be reduced to less than 30
psi (207 kPa).

272

Return

Master Service Manual

2006-12-12

NOTE!

F-code

Section

PT

S6.1

Version no

T-code

000

SMX

C-code

6420
Lift Cylinder

CLEANLINESS! Perform procedures in a


clean environment. Make sure all parts are
cleaned before disassembly and kept clean
during assembly.

Removal
1. Raise and block lift frame. Release pressure in
cylinder by activating lowering valve.

Lift
Frame

2. Press red OFF button O on the keypad. Depress


main ON/OFF switch to the OFF position.
3. Disconnect the battery connector from the truck.
4. Remove truck cover(s) [see page 84.]
5. Thoroughly clean outside of cylinder before
removing hydraulic hose.
Lift
Cylinder

6. Remove hydraulic line and pivot cylinder out of


pocket.
7. Remove cylinder and place on a clean bench for
disassembly.
8. Clean exterior of lift cylinder.
9. Push cylinder rod (2) in until the end of rod and
retaining ring (3) can be seen through inlet port.
10. Insert screwdriver in inlet port and slide retaining
ring (3) in deep groove in cylinder rod (2).
11. Remove cylinder rod (2) from cylinder tube (6).
12. Remove wiper (4) and seal (5) from the inside
diameter of cylinder tube (6).

Inspection
1. Clean and dry all parts thoroughly. Remove all
nicks and burrs with an emery cloth.
2. Inspect inside surface of cylinder tube (6) for
excessive wear or scoring.
3. Inspect outside surface of cylinder rod (2) for nicks,
scratches or scoring.

BT Prime-Mover, Inc.

Return

Master Service Manual

2006-12-12

273

F-code

Section

C-code

PT
S6.1
Lift Cylinder

6420

Version no

T-code

000

SMX

Assembly
1. Using seal tool, install new seal (5) on the inside
diameter of cylinder tube (6). Install new wiper (4)
with lips facing inward to bottom on cylinder tube
(6).

Seal Tool

NOTE!

Refer to the Parts Book for the correct tool


part number based on seal size.

2. Install new retaining ring (3) in deep groove of


cylinder rod end.
3. Oil outside of cylinder rod (2) and carefully insert in
tube assembly (6).
4. Push cylinder rod (2) in cylinder tube (6) until
retaining ring (3) areas of cylinder rod can be seen
through port.
5. Using a screwdriver through port, move retaining
ring (3) to lock position.
6. Extend cylinder rod (2) to the fully out position to
make sure retaining ring (3) is locked in place.

Installation
1. In order to prevent air from filling the cylinder
assembly, it is recommended that the cylinder rod
(2) is fully retracted.
2. Install upper mount first and hold in place with
shoulder bolt.
3. Connect the hydraulic hose and use the pump to
extend the cylinder.
4. Place bottom of cylinder in line with lower pocket.
5. Raise and unblock lifting frame of unit.
6. Install truck cover(s) [see page 84.]
7. Connect the battery connector to the truck.

274

Return

Master Service Manual

2006-12-12

NOTE!

F-code

Section

PT

S6.1

Version no

T-code

000

SMX

C-code

6420
Lift Cylinder

DO NOT use your hands to check for


hydraulic leakage. Use a piece of
cardboard or paper to search for leaks.
Escaping fluid under pressure can
penetrate the skin causing an injury.
Relieve pressure before disconnecting
hydraulic or other lines. Tighten all
connections before applying pressure.
Keep hands and body away from pinholes
and nozzles when eject fluids under high
pressure.

8. Turn the main ON/OFF switch to the ON position.


Enter key code and press the green ON button I
on the keypad.
9. Test operation of cylinder and look for leakage
around fitting and cylinder rod.

BT Prime-Mover, Inc.

Return

Master Service Manual

2006-12-12

275

F-code

Section

C-code

PT
S6.1
Lift Cylinder

6420

Version no

T-code

000

SMX

This page is intentionally left blank.

276

Return

Master Service Manual

2006-12-12

Index
Index

A
Application
Intended Truck Application
Prohibited Truck . . . . . . .

. . . . . . . . . . . .33
. . . . . . . . . . . .34

B
Battery . . . . . . . . . . . . . . . . . . . . . . . . . .199

Interface . . . . . . .
Legend . . . . . . . .
Normal Operation .
Service Display . .
Service Parameters
Special Modes . . .
Truck Fault Codes
Wiring . . . . . . . .

. . . . . . . . . . . . . . . . 240
. . . . . . . . . . . . . . . . 196
. . . . . . . . . . . . . . . . 145
. . . . . . . . . . . . . . . . 169
. . . . . . . . . . . . . . . 175
. . . . . . . . . . . . . . . . 168
. . . . . . . . . . . . . . . . 181
. . . . . . . . . . . . . . . . 156

Electrical Functions

. . . . . . . . . . . . . . . . . . . . .111
. . . . . . . . . . . . . . . . . . . . .111
Brake Disk . . . . . . . . . . . . . . . . . . . . . . .112

. . . . . 147
. . . . . 146
. . . . . 154
. . . . . 155
. . . . . 148
. . . . . 153
. . . . . 150
Electrical Schematic . . . . . . . . . . . . . . . . 194
Error Codes . . . . . . . . . . . . . . . . . . . . . . 180
ETAC . . . . . . . . . . . . . . . . . . . . . . . . . . 249

. . . . . . . . . . . . . . . . . . . . . . . . . .20
Battery Connector . . . . . . . . . . . . . . . . . .215
Safety

Battery Pack
Swing Out

. . . . . . . . . . . . . . . . . . . . . .205

Cable Routing Diagram . . . . . . . . . . .213


Brake
Adjustment
Release . .

Fasteners

Caster

. . . . . . . . . . . . . . . . . . . . . . . . .125
Contactor Panel . . . . . . . . . . . . . . . . . . .236
Conversion Formulas . . . . . . . . . . . . . . . .48
Wheel

Cylinder

Lift . . . . . . .
Retention Kit

. . . . . . . . . . . . . . . . . . . .271
. . . . . . . . . . . . . . . . . . . . .82

D
Decals . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Definitions
Electrical . . . . . . . .
Transistor Controller

. . . . . . . . . . . . . . .156
. . . . . . . . . . . . . . .243
Drive Motor Brush Replacement . . . . . . . . .89
Drive Wheel
Specifications

. . . . . . . . . . . . . . . . . . . .115

Drive Wheel Nut Inspection . . . . . . . . . . .115

E
Electric Motors . . . . . . . . . . . . . . . . . . . . .87
Electrical
Di-electric Compound
Error Code History .
Error Codes . . . . . .
Functions . . . . . . .
Graphics . . . . . . . .

BT Prime-Mover, Inc.

Return

Battery Plugged In With Key Switch


Battery Plugged In With Keypad . .
Lift . . . . . . . . . . . . . . . . . . . . . .
Lower . . . . . . . . . . . . . . . . . . . .
Main ON/OFF Switch/Keypad ON .
Reverser . . . . . . . . . . . . . . . . . .
Travel, Low Speed . . . . . . . . . . .

. . . . . . . . . . . . . .156
. . . . . . . . . . . . . . .180
. . . . . . . . . . . . . . .180
. . . . . . . . . . . . . . .145
. . . . . . . . . . . . . . .197

Master Service Manual

Designations . . . . . .
Strength Identification
Torque Values . . . . .

. . . . . . . . . . . . . . . 42
. . . . . . . . . . . . . . . 41
. . . . . . . . . . . . . . . 46

Fault Codes

. . . . . . . . . . . . . . . 245
. . . . . . . . . . . . . . . 181
Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Fuses/Circuit Breakers . . . . . . . . . . . . . . 229
Transistor Controller
Truck . . . . . . . . . .

G
Grease Location Points . . . . . . . . . . . . . . . 72

H
Hydraulic

. . . . . . . . . . 269
. . . . . . . . . . 254
. . . . . . . . . . 255
. . . . . . . . . . 256
. . . . . . . . . . 268
Hydraulic Schematic . . . . . . . . . . . . . . . . 253
Filter Screen and Inlet Tube
Lift Schematic . . . . . . . . .
Lower Schematic . . . . . . .
Relief Pressure Schematic .
Reservoir . . . . . . . . . . . .

Hydraulic System

Changing Fluid . . . . . . . . .
Pump Pressure Relief Valve
Troubleshooting Charts . . .

2004-03-19

. . . . . . . . . . 257
. . . . . . . . . . 259
. . . . . . . . . . 261

277

Index

I
Interface
ETAC and Transistor Controller

. . . . . . . . . . 25
. . . . . . . . . . 27
Service Key . . . . . . . . . . . . . . . . . . . . . . 174
Spare Parts, Ordering . . . . . . . . . . . . . . . . . 1
Steering Bearing . . . . . . . . . . . . . . . . . . 141
Steering Control Handle . . . . . . . . . . . . . 129
Static Discharge Precautions
Welding . . . . . . . . . . . . . .

. . . . . . . .240

Switch

Jacking Truck off the Floor . . . . . . . . . . . . .58

L
Lift Pump . . . . . . . . . . . . . . . . . . . . . . . .270
Load Wheel

. . . . . . . . . . . . . . . . . . . .121
Lubricants . . . . . . . . . . . . . . . . . . . . .59, 72
Cold Storage . . . . . . . . . . . . . . . . . . . . .59
Standard . . . . . . . . . . . . . . . . . . . . . . . .59
Lubrication Chart . . . . . . . . . . . . . . . . . . .71
Specifications

Arm Angle . . . . . . . . . . . . . . . .
Converting Keypad to Key Switch
Horn . . . . . . . . . . . . . . . . . . .
Key . . . . . . . . . . . . . . . . . . . .
Lift Limit . . . . . . . . . . . . . . . . .
Master Control ON/OFF . . . . . . .

Symbols

Caution . .
Danger . . .
Ordinance .
Prohibitory
Warning . .

. . . . . . . . . . . . . . . . . . . . . . 13
. . . . . . . . . . . . . . . . . . . . . . 13
. . . . . . . . . . . . . . . . . . . . . . 14
. . . . . . . . . . . . . . . . . . . . . . 14
. . . . . . . . . . . . . . . . . . . . . . 13

M
Motor

. . . . . . . . . . . . . . . . . . . . . . . . . .96
. . . . . . . . . . . . . . . . . . . . . . . . . .92
Motor Brush Inspection and Replacement . .89
Drive
Pump

Technical Service Data . . . . . . . . . . . . . . . 51


Transistor Controller . . . . . . . . . . . . . . . . 239
Control Circuit
Interface . . . .
Motor Circuit .

Transmission

Fluid Changing

. . . . . . . . . . . . . . . . . . . 242
. . . . . . . . . . . . . . . . . . . 240
. . . . . . . . . . . . . . . . . . . 241

. . . . . . . . . . . . . . . . . . . . 99

Troubleshooting

Oil and Grease . . . . . . . . . . . . . . . . . . . . .72


Operator Display and Programming . . . . .168

. . . . . . . . . . . . . . . . . 161
. . . . . . . . . . . . . . . . . 261
Truck Torque Specifications . . . . . . . . . . . 47
Electrical System
Hydraulic System

Parameters

. . . . . . . . . . . . . . . . .174
. . . . . . . . . . . . . . . . .172
Planned Maintenance Schedule . . . . . . . . .61
Pump Motor Brush Replacement . . . . . . . .90
Changing Service
Changing Truck .

S
Safety
Battery

278

Return

. . . . . . 224
. . . . . . 227
. . . . . . 226
. . . . . . 226
. . . . . . 225
. . . . . . 224

. . . . . . . . . . . . . . . . . . . . . . . . .20

Wheels
Caster (Optional)
Drive . . . . . . . .
Load . . . . . . . .

Wiring

. . . . . . . . . . . . . . . . . 125
. . . . . . . . . . . . . . . . . 115
. . . . . . . . . . . . . . . . . 121

Circuit Breaker . . . .
Harness . . . . . . . .
Master Control Relay
Power Cables . . . .

Master Service Manual

. . . . . . . . . . . . . . . 232
. . . . . . . . . . . . . . . 230
. . . . . . . . . . . . . . . 233
. . . . . . . . . . . . . . . 231

2004-03-19

Return

Back Cover

BT Prime-Mover, Inc., 3305 N. Highway 38, Muscatine, Iowa 52761-8800 U.S.A.


Tel (563) 262-7700 Fax (563) 262-7600 www.primemover.biz

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