301460-003 1998 - January PDF

Service Manual
OE35
Electric Counterbalanced Order Selector
Effective Serial Number OE35027319000
WARNING Read and observe all warnings on this unit

before operating it.
WARNING DO NOT operate this equipment unless all
factory installed guards and shields are
properly secured in place.
Part no: 301460-003
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Date: January 29, 1998
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F-code
Section
C-code
BT Standard Codes
Version no
T-code
000
BT Standard Codes
B-Code
= Business area
F-Code
= Product family
T-Code
= Product type
C-Code
= Component function
Worksheet standard
W-Code = Working code
R-Code
= Reason code
SO-Code = Assortment
C-Code List
No Function Group
BT Products
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C-Code
Chassis
0000
Drive Motor
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
Service Manual
1997-07-15
F-code
Section
C-code
BT Standard Codes
Version no
T-code
000
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Service Manual
1997-07-15
Table of Contents
BT Standard Codes ....................................................................................... 1
Warning Symbols .......................................................................................... 9
Warning Levels .......................................................................................... 9
Prohibitory Symbols .................................................................................... 10
Ordinance Symbols .................................................................................. 10
Introduction, Service Manual ...................................................................... 11
Contents, Section M ..................................................................................... 13
Machine Information ................................................................................. 13
General Product Information ...................................................................... 15
Presentation of the OE35 ......................................................................... 15
Main Components ..................................................................................... 20
Inch (SAE) and Metric Fasteners ................................................................
Introduction ...............................................................................................
Nomenclature, Threads ............................................................................
Strength Identification ...............................................................................
Conversion of Metric and English Units ....................................................
23
23
24
25
31
Technical Service Data ................................................................................ 33

Ordering Spare Parts ................................................................................... 37
Service Schedule ......................................................................................... 39
Planned Maintenance Schedule ............................................................... 39
Planned Maintenance Procedures ..............................................................
Services to be performed daily or at each 8 hour operating shift .............
Services to be performed monthly or every 250 operating hours .............
Services to be performed annually or every 1200 operating hours ..........
43
43
45
48
Lubrication Chart ......................................................................................... 51

Oil and Grease Specifications .................................................................... 53
Approved Oils and Grease ....................................................................... 53
Contents, Section S ..................................................................................... 55
Service Instructions .................................................................................. 55
Inspection Covers ........................................................................................ 57
Removal Of Plastic Dash Panel ................................................................ 58
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Table of Contents
Drive Motor ...................................................................................................
General Information ..................................................................................
Operating Conditions ................................................................................
Troubleshooting ........................................................................................
61
61
61
61
Drive Motor 24 Volt ......................................................................................

Component Repair ....................................................................................
Inspection and Troubleshooting ................................................................
When changing brushes ...........................................................................
67
68
69
74
Drive Motor 36 Volt ......................................................................................

Component Repair ....................................................................................
Inspection and Troubleshooting ................................................................
When Changing Brushes ..........................................................................
75
76
77
82
Transmission ................................................................................................
System description ...................................................................................
Troubleshooting ........................................................................................
Removal ....................................................................................................
83
83
83
84
Transmission Disassembly / Assembly ..................................................... 87

Disassembly ............................................................................................. 88
Installation ................................................................................................. 95
Drive Wheel ................................................................................................... 97
Load Wheels ................................................................................................. 99
Stabilizing Caster Spring Loaded ..............................................................
Removal ...................................................................................................
Inspection ................................................................................................
Disassembly ............................................................................................
101
102
104
105
Torque Generator ........................................................................................ 107

Disassembly ............................................................................................ 109
Assembly ................................................................................................. 114
Steering System Pump ...............................................................................
General Information .................................................................................
Removal ...................................................................................................
Installation ................................................................................................
Disassembly ............................................................................................
Inspection ................................................................................................
Assembly .................................................................................................
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121
122
122
123
125
126
126
Table of Contents
Steering System .......................................................................................... 129
General Information ................................................................................. 129
Electrical System with TX and TT Card .....................................................
Electrical Schematic Part 1 ......................................................................
Basics Of Circuit Operation .....................................................................
Control Features ......................................................................................
General Maintenance Instructions ...........................................................
Trouble-shooting Instructions ..................................................................
131
131
132
133
135
143
144
Battery Controller / Hourmeter / Lift Interrupt ..........................................

Electrical ..................................................................................................
Battery Controller (BC) ............................................................................
Troubleshooting .......................................................................................
147
147
147
148
151
Dash Display ................................................................................................

Location ...................................................................................................
Operational Checks .................................................................................
Status Codes ...........................................................................................
155
155
156
156
157
EV100 LX Control Status Codes ................................................................ 159

SCR Component Checks ............................................................................
Main Logic Card .......................................................................................
Capacitor 1C ............................................................................................
Contactors Forward, Rearward, 1A, Power Steering, and Pump ............
Potentiometer in Accelerator ...................................................................
SCRs (1REC, 2REC, 5REC) ..................................................................
Rectifiers (3REC, 4REC, Diode Blocks) ..................................................
Thermal Protector (TP) ............................................................................
Filter Block (23FIL, etc.) ...........................................................................
Filter Block (23FIL, etc.) ...........................................................................
1X Choke and Reactor T3-T4 ..................................................................
Replacement of EV100 Components ......................................................
Instructions - EV100 Plugs ......................................................................
177
177
178
178
178
178
180
180
181
181
181
181
183
Direction Contactor ..................................................................................... 185

Remove / replace contact tips ................................................................. 186
1A Speed Contactor .................................................................................... 191
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Table of Contents
Disassembly ............................................................................................ 192
Assembly ................................................................................................. 194
Electrical System Troubleshooting ........................................................... 197
Control Circuits and Power Circuits ......................................................... 199
Electrical System Troubleshooting Charts ............................................... 201
Pump Contactor ..........................................................................................
Disassembly ............................................................................................
Assembly .................................................................................................
213
214
214
216
Steering Pump Contactor ...........................................................................

Disassembly ............................................................................................
Assembly .................................................................................................
219
220
220
222
EV100 Handset Operation ..........................................................................

Purpose ...................................................................................................
Operation .................................................................................................
Function Set-Up Procedures ...................................................................
Description and Location .........................................................................
Function Numbers for Controllers ............................................................
225
225
226
227
228
230
231
Hydraulic System ........................................................................................

Hydraulic Schematic ................................................................................
Maintenance ............................................................................................
Adjustments .............................................................................................
239
239
240
242
242
Hydraulic Troubleshooting ........................................................................ 243

Troubleshooting Chart ............................................................................. 243
Lift Pump Assembly ....................................................................................
Removal ...................................................................................................
Disassembly ............................................................................................
Inspection ................................................................................................
Assembly .................................................................................................
247
248
249
252
254
Mast, 2 Stage ............................................................................................... 257

Shimming Mast on Truck. ........................................................................ 258
Two Stage Mast ....................................................................................... 262
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Table of Contents
Mast, 3 Stage ............................................................................................... 267
Shimming Mast on Truck. ........................................................................ 268
Three Stage Mast .................................................................................... 273
Lift Cylinder, 2 Stage .................................................................................. 279
Cylinder Repair ........................................................................................ 280
Freelift Cylinder, 3 Stage ............................................................................ 283
Freelift Cylinder Repair ............................................................................ 284
Staging Cylinder, 3 Stage ........................................................................... 287
Micro 70 Wire Guidance Important Information ....................................... 291
Powering Up: ........................................................................................... 291
Powering Down: ....................................................................................... 291
Micro 70 Wire Guidance .............................................................................
Cautions and Warnings ...........................................................................
Operation Information ..............................................................................
Component Function and Relationship ....................................................
Truck Set Up On Site ...............................................................................
Troubleshooting Information ....................................................................
Troubleshooting Charts ...........................................................................
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293
293
294
296
298
300
302
306
308
311
314
Table of Contents
BT Products
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F-code
Section
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PS
Warning Symbols
Version no
T-code
000
Warning Symbols
Always follow the warnings given in this Instruction Manual
and on the truck to avoid accidents and incidents from
occurring.
1. Warning Levels
Always follow the warnings given in this Instruction
Manual and on the truck to avoid accidents from
occurring.
Warning levels
Warning texts are 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 you do not follow the
instructions.
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 crash/breakdown if the instructions are
not followed.
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Service Manual
1997-07-15
F-code
Section
C-code
PS
Prohibitory Symbols
Version no
T-code
000
Prohibitory Symbols
NO SMOKING
If smoking occurs in situations where a restriction agains
smoking is stated, a serious accident can occur.
OPEN FLAMES PROHIBITED

If open flames are used in situations where open flames are
prohibited, a serious accident can occur.
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.
10
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Service Manual
1997-07-15
F-code
Section
C-code
M
Introduction, Service Manual
Version no
T-code
000

The information in this Service Manual covers models OE35
order selector.
Federal and State laws require that operators be completely
trained in the safe operation of lift trucks.
An Operators Manual is attached to every BT lift 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
(319) 262-7700
This service manual is not a training manual. The information
contained in this service manual is intended as a guide to
help authorized technicians safely service this truck.
The Service Manual is divided into four separate sections
which cover different kinds of information needed for
servicing these truck types. The main subject for each of
these sections is described below.
SECTION
BT Products
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SUBJECT
MACHINE INFORMATION
PLANNED MAINTENANCE
SERVICE INSTRUCTIONS
OPTIONS
Service Manual
1997-07-15
11
F-code
Section
C-code
M
Version no
T-code
000
12
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Service Manual
1997-07-15
F-code
Section
C-code
M
Contents, Section M
Version no
T-code
001
Contents, Section M
1. Machine Information
BT Products
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M1.0
GENERAL PRODUCT INFORMATION
M2.0
TECHNICAL SERVICE DATA
M3.0
ORDERING SPARE PARTS
Service Manual
1997-07-15
13
F-code
Section
C-code
M
Contents, Section M
Version no
T-code
001
14
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Service Manual
1997-07-15
F-code
Section
C-code
PS
M1.0
General Product Information
Version no
T-code
000
OE35

1. Presentation of the OE35
OE-35 is a battery powered counterbalanced order selector
trucks.
These trucks are intended solely to be operated handling
pallets or similar load carriers indoors.
In their standard design, the trucks are equipped with a
steering wheel with all the controls for operating within easy
access.
The trucks have a maximum lifting capacities of 3000 lbs.
(review data plate on the truck to note the maximum lifting
capacity).
These trucks are equipped with a 24V or optional 36V
electrical system and the speed is regulated by means of a
SCR controller to provide gentle control of acceleration and
speed while operating.
The forks are raised by means of an electric powered
hydraulic pump unit. Both raising and lowering are done
electrically with separate push buttons on the control handle.
The trucks can be specially equipped to work in cold
conditions.
1.1. Intended Application of the Trucks

The trucks are solely designed and manufactured to handle
goods. The trucks should be fitted with the appropriate
accessories relevant to the application.
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Service Manual
1997-09-24
15
F-code
Section
C-code
PS
M1.0
Version no
T-code
000
OE35
1.2. Forbidden Application of the Truck

The trucks are designed for handling goods indoors. It is not
permitted to use the trucks for other purposes including the
following:
-
Do not use in areas that contain gases which can

cause fires or explosions
Do not use as a towing truck for trailers
Do not use to tow other trucks
Do not use to transport/lift passengers
Do not use to drive on gravel or grass
1.3. Truck Data

The following table provides information regarding some
technical data which is of value with daily use of the trucks.
Truck data
24 Volt
35 Volt
Lifting capacity rated load, lb
Up to 3000 lb.
Lift height, inches
Up to 300 in.
Operating speed without load, mph

Below 24 in.
24 in. to 150 in.
151 in. and 225 in.
Above 225 in.
Operating speed with load, mph
Below 24 in.
24 in. to 150 in.
151 in. and 225 in.
Above 255 in.
Service weight without battery, lb
2 stage mast (with 48 in. forks)
3 stage mast (with 48 in. forks)
Service weight including battery, lb
Minimum battery weight is 1100 lbs.
5.4 mph
2.5 mph
1.0 mph
0 mph
5.8 mph
2.5 mph
1.0 mph
0 mph
4.6 mph
2.2 mph
0.8-1.0 mph
0 mph
5.2 mph
2.2 mph
0.8-1.0 mph
0 mph
5200 lb
5500 lb
Above + battery
weight
Above + battery
weight
The trucks lifting capacity, and weight can be found on the

trucks data plate.
16
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Service Manual
1997-09-24
F-code
Section
C-code
PS
M1.0
Version no
T-code
000
OE35
1.4. OE35 Dimensions

The following diagram shows external dimensions for the
OE35 truck in its standard design.
42.0
4.0
24.0 Minimum
30.0 Maximum
70 Turning Radius
60.0
Picking
Height
76.0
or
80.0
OALH
36.0
41.0
33.0
27.0
2.0
7.5
2.5
58.2
Fork
Length
76.0 (2-Stage)
77.0 (3-Stage)
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Service Manual
1997-09-24
17
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Section
C-code
PS
M1.0
Version no
T-code
000
OE35
1.5. Data Plate

The following diagram shows the data plate used on the
truck.
Legend
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
18
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Truck model number

Truck serial number
Truck capacity
Mast serial number
Attachments
Truck type
Truck weight (less battery)
Back tilt degree (NOT USED ON THIS TRUCK)
Minimum battery weight
Maximum battery weight
Battery maximum AMP hours
Battery voltage
Battery type
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1997-09-24
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Section
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PS
M1.0
Version no
T-code
000
OE35
1.6. U.L. Construction Type

Know the U.L. construction type of this truck and make
certain that trucks of this type may be operated in restricted
areas before you enter. Never take an unauthorized truck in
restricted or hazardous areas.
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Service Manual
1997-09-24
19
F-code
Section
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PS
M1.0
Version no
T-code
000
OE35
2. Main Components
1. Steering wheel
The truck is to be controlled by the operator with 180
degree steering angle.
2. Parking brake pedal
The brake is applied in the up position.
3. Key Switch (toggle switch)
Shuts off electrical power to control system.
4. Emergency stop switch
The emergency stop switch will stop all control functions.
5. Pallet clamp
Applies clamping to retain pallets to lift platform.
6. Start switch
Pressed after key switch is turned on to start trucks
operation.
7. Steering direction indicator
Displays the direction the transmission is headed.
8. Fork lower switch
The forks will lower when switch is pressed or until lower
stops are reached.
9. Fork raise switch
The forks will raise when switch is pressed or until lift
stops are reached.
10. Horn switch
The horn sounds to warn others of your position.
11. Hydraulic pump unit
Pump motor and pump are an integrated unit.
12. Hydraulic electric solenoid valve
For controlling lifting and lowering function with electric
solenoid valve.
13. Battery
24V or optional 36V with different capacities and weights.
14. Drive unit with brake
Drive motor, gears, drive wheel and brake combined in
the drive unit.
20
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1997-09-24
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PS
M1.0
Version no
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000
OE35
15. Data plate

Contains data designation, manufacturing number, year of
manufacture, service weight, battery weight, classified
lifting capacity, battery voltage, and manufacturer.
16. Cover
Hinged to provide good access for servicing.
17. Load wheel
Lubricate load wheels to prevent wheels from locking up.
18. Instrument (accessory)
Combined hourmeter/battery indicator, hourmeter/battery
indicator with lift interrupt, or hourmeter only.
19. Electronics
All the electronics
compartment.
are
collected
in
protected
20. Circuit circuit fuses

15A, BT Control fuse part number 201324
400A, 24 volt BT Pump fuse part number 25094-03
300A, 36 volt BT Pump fuse part number 25094-04
300A, BT Drive fuse part number 25094-04
21. Travel speed / direction selection
To select direction rotate in the direction you wish to
move. The further in that direction you rotate the faster
you move.
22. Mast
Covered by a finger protection which covers the
operators normal range of reach from the operating
position.
23. Dash display
The dash display is a four segment light emitting diode
(LED) display that displays the status codes, hourmeter
readings, and battery discharge indication from the
controller.
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1997-09-24
21
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Section
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PS
M1.0
Version no
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000
OE35
22
23
18
7
9
14
11
3
18
16
12
8
19
20
15
10
5
21
16
13
17
Main Components Chart
22
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Service Manual
1997-09-24
F-code
Section
C-code
M1.1
Inch (SAE) and Metric Fasteners
Version no
T-code
001
1. Introduction
Threaded fasteners such as bolts, nuts, cap screws, and
studs are made to specifications that describe the mechanical
strength and hardness of the 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. There are several standards used by these
countries in the manufacture of threaded fasteners. Many of
these fasteners are similar but cannot be used as direct
replacements.
Service persons 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 the 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.
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1997-09-24
23
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M1.1
Version no
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001
2. Nomenclature, Threads
The thread design is specified by a series of numbers and
letters for inch and metric fasteners (see figure below). The
diameter of the shank of the fastener is shown first in the
series, e.g. 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 the 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
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Service Manual
A = THREAD SIZE
B = PITCH
C = LENGTH
1997-09-24
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Section
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M1.1
Version no
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001
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 the marks that identify the grades and
property classes for different fasteners.
WARNING When fasteners must be replaced the new

fasteners must be of the same strength or
greater than the original fasteners. The
new fasteners must also be the correct
size.
NOTE! Identification marks are according to bolt
strength. The higher the number, or the
increase in the number of marks, indicates
increased bolt strength.
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Service Manual
1997-09-24
25
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Section
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M1.1
Version no
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001
Table 1. Bolt and Screw Designations
Types of
Fasteners
Metric Fasteners
Inch Fasteners
Strength Levels: SAE Grades
Strength Levels: Property Classes
* Markings Not Required

2
5.2
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
Hex Hea
Flange Screws
Same As Above
5
12 Point
Flange Screws
Hex Socket Head

Cap Screws
Markings Not Required
5.1
8.8
12.9
8.8
12.9
4.8*
9.8
4.8
9.8
SEMS
26
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1997-09-24
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Section
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M1.1
Version no
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001
Table 2. Stud and Nut Designations
Types of
Fasteners
Inch Fasteners
Metric Fasteners

4.6*
4.6
5.2*
5*
4.8
9.8
9.8
8*
4.8* 5.8*
8.8
8.8
5.8
10.9 12.9 Markings

for size
M5 and
Larger
12.9
10.9
8.1
or
Studs
Optional Geometric Symbols for

Size M5 through M11 ONLY.
Hex Nuts
Hex Slotted Nuts
Hex Flange Nuts
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10
12
10
12
10
12
8
or
or
10
12
10
12
10
12
10
12
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M1.1
Version no
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001
Table 3. Torque Nut Designations
Types of
Fasteners
Inch Fasteners
Metric Fasteners
10
10
or
All Metal Prevailing Torque
Nuts
G
9
10
or
All Metal Prevailing Torque
Flange Nuts
10
or
28
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M1.1
Version no
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001
Table 4. Torque Nut with Nylon Insert Designations
Types of
Fasteners
Metric Fasteners
Inch Fasteners
10
10
or
Nylon Insert Prevailing Torque
Nuts
Markings Not Require
or
or
10
10
or
Nylon Insert Prevailing Torque

Flange Nuts
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1997-09-24
29
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Section
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M1.1
Version no
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001
Table 5. Fastener Torque Values
Size and Pitch
Property, Class
8.8*
Property, Class
10.9**
Property, Class
12.9***
Nm
in.-lb
Nm
in.-lb
Nm
in.-lb
5-6
8-10
20-25
44-53
71-88
177-221
7-8
12-14
30-35
62-71
106-124
------------
8-10
14-16
------------
71-88
124-142
-----------
Nm
ft-lb
Nm
ft-lb
Nm
ft-lb
M8 x 1.25
M10 x 1.5
-----------40-45
-----------30-33
----------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
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

internally threaded fasteners made of property
class 10 material.
*** Property class 12.9, Protective Treatment CMHC
internally threaded fasteners of property class 12
material.
30
Return
Service Manual
1997-09-24
F-code
Section
C-code
M1.1
Version no
T-code
001
4. 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
0.039
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
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)
BT Products
Return
Service Manual
1997-09-24
31
F-code
Section
C-code
M1.1
Version no
T-code
001
TEMPERATURE
Multiply
By
To Get
Multiply
By
To Get
(Fahrenheit
-32)
0.56
Celsius (C)
(Celsius x 1.8)
+32
Fahrenheit (F)
By
To Get
TORQUE
Multiply
By
To Get
Multiply
inch pound
0.113
Newton meter (Nm) Newton meter
8.851
inch pounds
in.-lb
feet pound
1.356
Newton meter (Nm) Newton meter
0.738
foot pounds
ft-lb
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)
32
Return
Service Manual
1997-09-24
F-code
PS
Section
C-code
M2.0
Technical Service Data
Version no
T-code
000
OE35

MODEL
24 Volt
36 Volt
Series - DC
Series - DC
Duty factor
60 min.
60 min.
Minimum brush length
0.08 in.
0.625 in.
Minimum commutator diameter
2.625 in.
2.80 in.
Minimum brush spring tension
58-70 oz
40-65 oz
301984-000
29105-00
Double reduction
Double reduction
Gear ratio
14:1
14:1
Oil volume
About 1 quart
About 1 quart
Normal temperature
SAE 80W90
SAE 80W90
ATF
ATF
102 in. x 5 in. x 62 in.
102 in. x 5 in. x 62 in.
125 ft-lb
125 ft-lb
4 in. x 6 in.
4 in. x 6 in.
lb
lb
0.625 in.
0.625 in.
2.80 in.
2.80 in.
DRIVE MOTOR
Type
Power
Part no
TRANSMISSION/GEAR
Type
< +5oF-15C
WHEELS
Drive wheel
Drive wheel weight without load with
battery, lb
Drive wheel weight with rated load
and battery, lb
Torque axle Screw
Load wheel
Load wheel weight with rated load, lb
HYDRAULIC LIFT PUMP
Revolutions/min at work pressure
Duty factor
BT Products
Return
Service Manual
1997-10-21
33
F-code
Section
C-code
PS
M2.0
Version no
T-code
000
OE35
MODEL
24 Volt
36 Volt
40-65 oz
40-65 oz
300282-000
300281-000
0.625 in.
0.45 in.
2.155 in.
1.80 in.
26-28 oz
12-30 oz
Part number
200075
301492-000
Lifting pressure at rated load
2400 psi
2400 psi
Steering relief valve setting
850 psi
850 psi
Brake relief valve setting
180 psi
180 psi
7.3 gal.
7.3 gal.
Normal temperature
Sunoco TH
Sunoco TH
< -10F - 23C
Texaco 15
Texaco 15
Pump circuit fuse
400 Amp
400 Amp
Drive circuit fuse
300 Amp
300 Amp
Control fuse
15 Amp
15 Amp

Part number
HYDRAULIC STEERING PUMP
Revolutions/min at work pressure
Duty factor
HYDRAULIC SETTING
Pump flow
Tank volume
FUSES
BATTERIES
Dimension W x L x
Capacity (Min./Max. Amp-hrs.)
Weight (Minimum)
34
Return
13f in. x 363 in. x 313 in. 13f in. x 383 in. x 313 in.
750/1000
400/750
1100 lb
1100 lb
Service Manual
1997-10-21
F-code
PS
Section
C-code
M2.0
Version no
T-code
000
OE35
MODEL
24 Volt
36 Volt
Operating speed without load, mph

Below 24 in.
24 in. to 150 in.
151 in. and 225 in.
Above 225 in.
5.4 mph
2.5 mph
1.0 mph
0 mph
5.8 mph
2.5 mph
1.0 mph
0 mph
Operating speed with load, mph

Below 24 in.
24 in. to 150 in.
151 in. and 225 in.
Above 225 in.
4.6 mph
2.2 mph
0.8 mph
0 mph
5.2 mph
2.2 mph
0.8 mph
0 mph
Lift without load (2-Stage)

(slow speed)
(fast speed)
35-44 fpm
54-67 fpm
35-44 fpm
54-67 fpm
Lift without load (3-Stage)

(slow speed)
(fast speed)
34-42 fpm
50-62 fpm
34-42 fpm
50-62 fpm
Lift with rated load (2-Stage)

(slow speed)
(fast speed)
25-31 fpm
33-41 fpm
25-31 fpm
33-41 fpm
Lift with rated load (3-Stage)

(slow speed)
(fast speed)
24-30 fpm
32-40 fpm
24-30 fpm
32-40 fpm
Lower without load (2-Stage)

(slow speed)
(fast speed)
N/A
30 fpm
N/A
30 fpm
Lower without load (3-Stage)

(slow speed)
(fast speed)
32 fpm
57 fpm
32 fpm
57 fpm
Lower with load (2-Stage)

(slow speed)
(fast speed)
N/A
30 fpm
N/A
30 fpm
Lower with load (3-Stage)

(slow speed)
(fast speed)
30 fpm
53 fpm
30 fpm
53 fpm
DRIVING SPEEDS
LIFTING/LOWERING TIME
BT Products
Return
Service Manual
1997-10-21
35
F-code
Section
C-code
PS
M2.0
Version no
T-code
000
OE35
MODEL
24 Volt
36 Volt
Driving without load
120 Amp
120 Amp
Driving with rated load
140 Amp
140 Amp
Lifting without load (2-Stage)

(slow speed)
(fast speed)
168 Amp
250 Amp
168 Amp
250 Amp
Lifting without load (3-Stage)

(slow speed)
(fast speed)
180 Amp
260 Amp
180 Amp
260 Amp
Lifting with load (2-Stage)

(slow speed)
(fast speed)
285 Amp
480 Amp
285 Amp
480 Amp
Lifting with load (3-Stage)

(slow speed)
(fast speed)
290 Amp
520 Amp
290 Amp
520 Amp
Steering, motor (Not steering)

(Pump at relief)
20 Amp
60 Amp
20 Amp
60 Amp
CURRENT CONSUMPTION
NOTE! Performance may vary up to -10% due

to motor and system efficiency
tolerance. The performance shown
represents nominal values obtained
under typical operating conditions.
NOTE! These products and specifications are
subject to change without notice.
36
Return
Service Manual
1997-10-21
F-code
PS
Version no
Section
C-code
M3.0
Ordering Spare Parts
T-code
000

1. Locate the fault on the truck.
2. Find out the machine model and serial number.
3. Locate the page with the exploded diagram and find the
position number for the part you require.
4. Locate the position number in the table. Select the
column for the actual machine model and serial number.
5. Note the part number.
6. Call the local BT dealer and state the part number.
If you cannot find the machine model, serial number, or
the article number, call the local BT dealer and he will
help you.
BT Products
Return
Service Manual
1997-07-15
37
F-code
Section
C-code
PS
M3.0
Version no
T-code
000
38
Return
Service Manual
1997-07-15
F-code
PS
Section
C-code
P1.0
Introduction, Maintenance
Version no
T-code
000
The schedules of maintenance and lubrication given in this
section of the Service Manual cover up to one years
operation of a truck.
These schedules are based on hourly usage and can be
adapted to suit most normal one shift patterns. The following
hourly usage figures have been used when calculating the
schedule:
Single shift- 8 am-5 pm, 25 hours per week usage
Double shift- 6 am-2 pm, 2 pm-10 pm, 50 hours per
week usage
Triple shift- 6 am-2 pm, 2 pm-10 pm, 10 pm-6 am, 75
hours per week usage
The schedules are intended only as a guide, not as a rigid
structure. Operators of trucks may wish to adapt them 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 safety status of the equipment.
- Use only spare parts approved by BT.
- Always clean the equipment and carry out a full safety
check after service.
1. Safe Jacking Procedure

1. Disconnect battery.
2. Read and follow the correct operating procedures
for your jack or hoist.
BT Products
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Service Manual
1997-07-15
39
F-code
Section
C-code
PS
P1.0
Version no
T-code
000
40
Return
Service Manual
1997-07-15
F-code
Section
PS
P2.0
Service Schedule
Version no
T-code
000
OE35
C-code
Service Schedule
1. Planned Maintenance Schedule
ITEM
0000
0000.1
0000.2
0000.3
0640
0640.1
0640.2
0640.3
0840
0840.1
0840.2
0840.3
1700
1700.1
1700.2
1700.3
1700.4
1700.5
2550
2550.1
2550.2
2550.3
BT Products
Return
WORK REQUIRED
Interval in Hours
Interval in Days/Weeks/Months
Chassis
Check that the truck data plate is
legible
Check for damage and cracks
Check the cover screws
Operator Controls
Check that the travel direction/
speed selectors operational
Check that the horn button is
operational
Check that the hydraulic buttons
are operational
Drivers Protection
Check that the emergency stop
button is operational
Check that the start button is
operational
Check that all shields and guards
are secure and install correctly
Drive Motor
Check for arcing due to poor
connections
All connections tight
Clean motor of dirt and dust
Check torque of motor bolts
Check for abnormal noise in
motor bearings
Drive Gear
Check for oil leakage
Clean motor of dirt and dust
Check torque of motor bolts
Service Manual
5
1d
25
1w
100
1m
250
3m
600
6m
1200
12 m
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
1997-10-21
41
3600
36 m
F-code
Section
C-code
PS
P2.0
Service Schedule
Version no
T-code
000
OE35
ITEM
3100
3100.1
3100.2
3500
3500.1
3500.2
3500.3
3500.4
4100
4100.1
4100.2
5110
5110.1
5110.2
5110.3
5110.4
5200
5200.1
5300
5300.1
5300.2
5300.3
5400
5400.1
5400.2
5400.3
5400.4
5400.5
5710
5710.1
42
Return
WORK REQUIRED
Interval in Hours
Brake
Clean dust and debris
Check brake operation
Wheels
Remove all string, wrapping and
debris
Check all wheels for wear
Grease load wheel bearings
Grease caster and caster wheels
Steering Wheel
Check fasteners
Check ease of steering
Battery
Electrolyte level, 1/2 - 5/8 inch
above cell plates
All connections: battery, battery
and charger plugs
All cell and link covers intact
Check battery specific gravity
Instrument Panel
Check battery indicator and
hourmeter for correct operation
Electrical Control System
Check key switch
Check brake switch
Check power cables and control
wiring harness for proper routing
Electrical Panel
Cleaning and mounting to chassis
Tightening of connections
Check contactor tips
Check contactor tips for free
movements
Check all cable insulation for
damage
Electronic Card
Check for connections in harness
connectors
5
1d
25
1w
100
1m
250
3m
600
6m
1200
12 m
3600
36 m
X
X
X
X
X
X
X
X
X
X
X
X
X
Service Manual
X
X
X
X
X
X
X
1997-10-21
ITEM
6000
6000.1
6000.2
6000.3
6000.4
6000.5
7310
7310.1
7310.2
7310.3
7400
7400.1
7400.2
7400.3
7400.5
BT Products
Return
WORK REQUIRED
Interval in Hours
Hydraulic System
Check hose and connections for
leakage
Check hose for wear and damage
Check hydraulic tank for cracks,
leaks and mounting
Check correct oil level
Change the hydraulic oil
Lift Cylinder
Check for leakage
Check mounting
Lube all grease fittings
Lifting device
Check the clearance of the forks
Check the forks for damage and
cracks
Check the forks for wear and
cracks
Lube all grease fittings
Service Manual
5
1d
25
1w
F-code
Section
PS
P2.0
Service Schedule
Version no
T-code
000
OE35
100
1m
250
3m
600
6m
C-code
1200
12 m
X
X
X
X
X
X
X
X
X
X
X
X
1997-10-21
43
3600
36 m
F-code
Section
C-code
PS
P2.0
Service Schedule
Version no
T-code
000
OE35
3100
7310
5200
2550
1700
4100
6000
5300
5400
5710
0640
7400
5110
3500
44
Return
Service Manual
0000
1997-10-21
F-code
Section
C-code
PS
P2.0
Planned Maintenance Procedures
Version no
T-code
000
OE35

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.
1. Services to be performed daily or at

each 8 hour operating shift
The daily inspection is to be made by the operator prior to
each operating shift. It is the operator's responsibility to report
any defects to the proper authorities, and the truck should not
be operated until it has been inspected and repaired by a
qualified technician. The operator is ultimately responsible for
the safe operation of the truck.
1.1. Battery Discharge Indicator with slow

down
The battery guard indicates the current charge status of the
trucks battery.
1
Full charge battery
1/2
Half charged battery
Discharged battery
The battery guard has an integrated cut-out function that cuts

out the trucks lift function when a predetermined charge level
has been reached. This prevents overloading the battery and
increases the operating economy of the truck. When the
battery has reached a charge level equivalent to 70%
discharge, a warning signal is given via flashing lights. A
further 10% of the batterys capacity can then be used before
the battery guard cuts out the lift function.
1.2. Dash Display

The dash display is a four segment light emitting diode (LED)
display that displays the status codes, hourmeter readings,
and battery discharge indication from the controller.
BT Products
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Service Manual
1997-10-21
45
F-code
Section
C-code
PS
P2.0
Version no
T-code
000
OE35
1.3. Hydraulic System

Inspect the entire truck for leaks, especially around the
hydraulic pump assembly and the lift cylinder. Any sign of oil
on the floor under the truck is an indication that the truck may
be leaking hydraulic oil or transmission fluid. Report any
problems to the proper authorities, and DO NOT operate the
truck until it has been inspected and repaired by a qualified
technician.
1.4. Frame/Sheet Metal

Inspect the truck for loose, damaged or missing parts. All
shields must be in place and functional. Report any problems
to the proper authorities. DO NOT operate the truck until it
has been inspected and repaired by a qualified technician.
1.5. Wheels/Tires
Inspect wheels and tires for wear and damage. 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.
1.6. Functions/Operations
Test the truck for the proper operation of all functions
including the travel controls, lift and lower functions, the
brakes and the emergency disconnect button. Safety 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 qualified technician.
46
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Service Manual
1997-10-21
F-code
Section
C-code
PS
P2.0
Version no
T-code
000
OE35
2. Services to be performed monthly

or every 250 operating hours
The monthly planned maintenance service should be
performed by a qualified technician.
2.1. Inspection
All of the services and inspections listed above for the daily
inspection should be performed at this time. The inspection
procedure should be more thorough, and minor deficiencies
should be corrected.
2.2. Transmission
Inspect for oil leakage.
2.3. Brakes
The brakes should stop a fully loaded truck at full speed in
approximately one truck length.
2.4. Battery
Contact your battery dealer for specific instructions on care
and maintenance of the battery.
An average battery will have a specific gravity of 1.170 at the
80% discharged level. However, there are many different
batteries on the market. Only the battery manufacturer can
accurately determine the fully charged and 80% charged
levels. Contact the battery manufacturer for this information.
BT Products
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Service Manual
1997-10-21
47
F-code
Section
C-code
PS
P2.0
Version no
T-code
000
OE35
2.5. Electrical Connections

All electrical connections should be checked that they are
clean and tight. Plug-in connectors should be unplugged and
plugged back in to clean the terminals. If the truck is equipped
with any of the cold-storage, freezer use, or corrosive
environment application packages, the di-electric compound
in the plug-in connectors should be renewed. This compound
is available through the parts department of your authorized
dealer.
2.6. Contactor Tips (NOT Sealed)

Inspect contactor tips for arcing, pitting, or burning. Minor
pitting of the tips is not a problem. However, if the tips are
pitted through the tip to the copper bar, the tips should be
replaced. DO NOT file tips. Replace tips only in complete
sets. Some contactors have concealed tips or are fully sealed
so that tips cannot be replaced.
2.7. Motor Brushe

Minimum brush lengths are given in the specifications section
of this manual. As a rule of thumb, the brushes should be
replaced if the brush spring is within 1/16 in. of touching the
brush holder.
2.8. Drive Motor

Blow out the drive motor fan and vents. Check for any signs
of oil on the drive motor fan and air vents. Check for any
damage to the fan or air vents.
WARNING Compressed air used for cleaning MUST
be reduced to less than 30 psi., and then
only with effective chip-guarding and
personal protective equipment worn.
48
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Service Manual
1997-10-21
F-code
Section
C-code
PS
P2.0
Version no
T-code
000
OE35
2.9. Hydraulic Reservoir

Check the fluid level in the hydraulic reservoir. The unit
should be fully lowered and filled to the bottom of the fill port.
2.10. Frame Lube

(Lubrication Chart on page55)
The pressure type grease fittings (zerk fittings) should be
lubricated with Texas Refineries #880 Crown and Chassis
lubricating grease. The total number of grease fittings
depends on the truck options when built. A truck with a coldstorage, freezer use, or corrosive environment application
package will have more grease fittings than a standard truck.
Look for flush-type grease fittings on the load wheel axles.
Regular fittings may be found on the transmission mounting
bearing and the mast chain sheave shafts.
2.11. Pivot Points

There are some pivot points and other items that need to be
lubricated but do not have grease fittings. Lubricate these
non-greasable wear points with a drip oil can using 10 wt.
machine oil.
BT Products
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Service Manual
1997-10-21
49
F-code
Section
C-code
PS
P2.0
Version no
T-code
000
OE35
3. Services to be performed annually

or every 1200 operating hours
The annual planned maintenance service will take a longer
period of time to complete than does the monthly service.
This would be a good time to arrange other repairs that have
been noted on the monthly service.
3.1. Inspection
All of the services and inspections listed in sections 1 and 2
for the daily and monthly inspection should be performed at
this time. The inspection procedure should be more thorough,
and minor deficiencies should be corrected.
3.2. Transmission
The transmission fluid should be drained once a year. The
drain port is located on the lower portion of the side cover
opposite the drive tire. Remove the plug to drain the
transmission fluid. Flush the transmission case with safety
solvent. Pour clean safety solvent into the fill port on top of
transmission case. With drive tire off the floor, allow solution
to run out of drain port while transmission is running. Stop
flushing when the solution runs clean. Allow the solvent to
drain well before replacing the drain plug. Replace the drain
plug. Refill the transmission with the proper clean oil before
operating truck.
3.3. Battery
At approximately 1500 hours, contact an authorized battery
dealer to determine the overall condition of the battery.
Determine if the battery needs to be washed down. This can
only be done by properly equipped and trained personnel.
50
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Service Manual
1997-10-21
F-code
Section
C-code
PS
P2.0
Version no
T-code
000
OE35
3.4. Hydraulic System

The hydraulic system should be drained, flushed and refilled,
and the pressure relief valve setting should be checked and
adjusted. This will maintain proper lubrication properties
within the system.
WARNING Before siphoning oil from reservoir, make
certain siphon is clean.
To drain reservoir, remove reservoir filter assembly.
Siphon oil from reservoir and purge oil out of hydraulic
system. Remove and clean screen in outlet ports on reservoir
and fill reservoir with proper clean oil. Operate raise and
lower function several times to purge air from system. Check
oil level, fill to line. Put rated truck capacity load on forks and
adjust pressure relief valve, if necessary, so that truck will lift
rated load.
3.5. Brakes
The brake release cylinder should have 3/8 in. to 1/2 in. of
travel. The cylinder travel itself in non-adjustable and the only
brake adjustment is the aggressiveness. Three allen head
screws on transmission cover case adjust brake
aggressiveness.
Loosen all three locknuts and turn set screws out
transmission cover until no force is felt pushing against any
set screw. Turn the set screws back in transmission cover
only until spring resistance is felt. Then turn each set screw
an additional 1/4 in. turn and secure in place with locknuts.
Test braking action.
BT Products
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Service Manual
1997-10-21
51
F-code
Section
C-code
PS
P2.0
Version no
T-code
000
OE35
52
Return
Service Manual
1997-10-21
F-code
Section
PS
P3.0
Lubrication Chart
Version no
T-code
000
OE35
C-code
Lubrication Chart
Pos. No
Service Point
Interval/Running Hours
250 h
1
2
3
4
5
6
7
Wheel bearings
Mast bearings
Lifting linkage
Hydraulic syste
Steering bearings
Drive gear
Drive gear drain
600 h
1200 h
Lubricant
(See Chart in
Section 6 for Code)
L
L
L
C
O
L
O
L= Lubrication
C = Check
O = Oil change
2
5
A
A
D
B
A
C
6, 7
4
1
BT Products
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Service Manual
1997-10-21
53
F-code
Section
C-code
PS
P3.0
Lubrication Chart
Version no
T-code
000
OE35
54
Return
Service Manual
1997-10-21
F-code
Section
C-code
PS
P4.0
Oil and Grease Specifications
Version no
T-code
000
OE35

1. Approved Oils and Grease
Lubricant
A
Grease
B
C
D
E
Hydraulic oil
Transmission oil
Motor oil
Grease
Grease
BT Products
Return
Specification
>14F(-10C) <14F(-10C)
Tex. Ref. C
Mobiltemp
and C #880
SHC 32
Sunoco TH
ATF
SAE 80w/90
SAE 75w
SAE 40
SAE5w-20
Molykote
Molykote
200025
200025
49670-00
49670-00
Service Manual
1997-10-21
Application area
<-13F(-25C)
Mobiltemp
SHC 32
Texaco 15
ATF
SAE5w-20
Molykote
200025
49670-00
Bearings and
bushings
Hydraulic system
Gears
Chains
Mast rails
Mast rails
55
F-code
Section
C-code
PS
P4.0
Version no
T-code
000
OE35
56
Return
Service Manual
1997-10-21
F-code
PS
Version no
Section
C-code
S
Contents, Section S
T-code
000
Contents, Section S
1. Service Instructions
NO FUNCTION GROUP
C-CODE
CHASSIS
0000
DRIVE MOTOR
1000
DRIVE GEAR / TRANSMISSION
2000
BRAKE / WHEEL SYSTEM
3000
STEERING SYSTEM
4000
ELECTRICAL / PNEUMATIC SYSTEM
5000
HYDRAULIC SYSTEM
6000
LIFTING MAST / CYLINDERS
7000
PERIPHERAL / INSTALLATION
8000
EQUIPMENT
9
BT Products
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OPTIONS / ATTACHMENTS
Service Manual
1997-04-15
9000
57
F-code
Section
C-code
PS
S
Contents, Section S
Version no
T-code
000
58
Return
Service Manual
1997-04-15
F-code
PS
Section
C-code
S0.1
0340
Inspection Covers
Version no
T-code
001
OE35
Inspection Covers
POS.
NO
POS.
NO
DESCRIPTION
POS.
NO
DESCRIPTION
Lockwasher
17
Panel, dash
24
Rivet, pop
Nut
18
Panel
25
Guard, right spring
10
Channel, Harness
19
Cable, manual
26
Guard, left spring
11
Shield, back cover
20
Rivet, pop
27
Shield, front top
12
Screw, socket head
21
Shield
28
Nut, clip
13
Washer, flat
22
Mat, floor
14
Nut
23
Pocket, manual
BT Products
Return
DESCRIPTION
Service Manual
1997-10-23
59
F-code
Section
PS
S0.1
Inspection Covers
Version no
T-code
001
OE35
C-code
0340
1. Removal Of Plastic Dash Panel

Before starting disassembly of any parts, thoroughly clean
out side of assembly with safety solvent or other noncorrosive cleaning fluid. Air dry all parts.
WARNING Be extremely careful when working with

solvent. Even a small explosion or fire
could cause injury or death.
1. Park the truck on a level surface and make sure
load wheels are blocked to prevent accidental
movement.
2. Fully lower the mast.
3. Disconnect and remove battery from unit to
prevent accidental operation.
4. Remove back shield (11) from rear of operator
platform.
5. Remove windshield bracket and windshield.
6. Remove steering wheel. Use puller (split bearing
type).
7. Remove retainer ring from steering shaft.
8. Loosen steering chain stop.
9. Remove chain from idler sprocket and steer
indicator sprocket.
10. Tap steering shaft 2 in. toward front of truck.
11. Loosen steer indicator idler sprocket bracket.
Remove beaded chain.
12. Remove key switch by rotating lock on back of
switch clockwise.
13. Disconnect emergency disconnect and start button
wires. Remove emergency disconnect and start
button.
14. Disconnect gauge wires. Remove gauges.
15. Remove three cap screws holding master switch
bracket.
60
Return
Service Manual
1997-10-23
F-code
PS
Section
C-code
S0.1
0340
Inspection Covers
Version no
T-code
001
OE35
16. Open wire harness plug. Push wires out of plug.

Use AMP tool #305183.
17. Remove other handle bracket.
18. Slide handle to right and remove.
19. Remove three screws in bottom of dash panel. Tip
dash from bottom and remove.
BT Products
Return
Service Manual
1997-10-23
61
F-code
Section
PS
S0.1
Inspection Covers
Version no
T-code
001
OE35
62
Return
C-code
0340
Service Manual
1997-10-23
F-code
Section
C-code
PS
S1.0
1700
Drive Motor
Version no
T-code
001
Drive Motor
1. General Information
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 troublefree operations -- is related to the time spent making
inspections and correcting minor problems as they occur.
The key to planned maintenance of the brush and
commutator is recognizing the undesirable brush and
commutator conditions. If this is done, corrective action can
be taken before a major component is damaged beyond
serviceability. The brushes and commutator should be
inspected for even wear and good commutation.
2. Operating Conditions
Operating environment of lift 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
Freezer operation
Processing plants (poultry, meat)
3. Troubleshooting
When a motor has trouble in operation a reasonable decision
has to be made as to the proper corrective course of action.
We have reviewed many troubleshooting guides and have
reduced them to a few which seem to be the most effective
Symptom/Cause relationships.
BT Products
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Service Manual
1997-07-15
63
F-code
Section
C-code
PS
S1.0
Drive Motor
1700
Version no
T-code
001
TABLE #1 Drive Motor Troubleshooting
Indications, Causes. and Correction of Unsatisfactory Brush Performance

Indications
Immediate Causes
Primary Faults
Sparking
Commutator surface condition

Overcommutation
Undercommutation
Too rapid reversal of current
Faulty machine adjustment
Mechanical fault in machine
Electrical fault in machine
Bad load condition
Poor equalized parallel
operation
Vibration
Chattering of brushes
1-2-3-43-44-45-46-49-59-60
7-12-31-33
7-12-30-32
7-12-30-32
8-9-11
6-14-15-16-17-18-19-20-21-2829
25-27-28-29-38-39-40-41-42
Wrong brush grade

Fluctuating contact drop
7-13-23-34
51-52
See Chattering or noisy
brushes
55-57-59
50
Etched or burned bands on

brush face
Overcommutation
Undercommutation
Too rapid reversal of current
7-12-31-33
7-12-30-32
7-12-30-32
Pitting of brush face
Glowing
Embedded copper
See Glowing at brush face

See Copper in brush face
Rapid brush wear
See specific surface fault in

evidence. Also see 50.
See Sparking
Severe sparking
Imperfect contact with
commutator
Wrong brush grade
11-14-15-16-51-52
54-58
Glowing at brush face
Embedded copper
Severe load condition
Bad service condition
Wrong brush grade

7-12
38-39-41-42
46-47
57-61-62
Copper in brush face

Wrong brush grade
2-3
43-46-47-48-49
59-61
Flashover at brushes
Machine condition
Bad load condition
Lack of attention
14-35
38-39-41-53
5-11
64
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Service Manual
1997-07-15
F-code
Section
C-code
PS
S1.0
1700
Drive Motor
Version no
T-code
001
Chattering or noisy

Looseness in machine
Faulty machine adjust
High friction
Wrong brush grade
See specific surface in evidence

15-16-17
10-11
6-43-45-49-52-58-59
55-58-59
Indications Appearing at Commutator Surface

Indications
Immediate Causes
Primary Faults
Brush chipping or breakage

evidence
15-16-17
52
See Chattering or noisy
brushes
14
Looseness in machine
Vibration
Chattering
Sluggish brush movement
Rough or uneven surface
1-2-3-4-17
Dull or dirty surface
5-44-60
Eccentric surface
1-19-22-52
High commutator bar
Sparking
17
Low commutator bar

streaking or threading of
surface
Sparking
Copper or foreign material in
brush face
Glowing
2-25
43-44-45-46-49-59
2-3-46-47-48-61
See Glowing at brush face
Bar etching or burning
Sparking
Flashover
2-3-7-12-30-31-32-33
5-11-14-35-38-39-41-53
Bar marking at pole

pitch spacing
Sparking
25-37
Bar marking at slot

pitch spacing
Sparking
7-12-30-57-60
Flat spot
Sparking
Flashover
Lack of attention
19-23-25-41-53
5-11-14-35-38-39-41-53
1-5-11
Discoloration of surface
High temperature
Atmospheric condition
Wrong brush grade
See Heating at commutator

44-46
60
Raw copper surface
Embedded copper
Wrong brush grade

43-45-47-49
59-61
Rapid commutator
wear with blackened
surface
Burning
Severe sparking
2-3-11-14
See Sparking
BT Products
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Service Manual
1997-07-15
65
F-code
Section
C-code
PS
S1.0
Drive Motor
1700
Version no
T-code
001
Rapid commutator
wear with bright surface
copper dragging
Foreign material in brush face

Wrong brush grade
Brush vibration
43-45-47-49
61
39-52-58-59
Indications Appearing as Heating

Indications
Immediate Causes
Primary Faults
Heating in windings

Unbalanced magnetic field
Unbalanced armature
currents
Poorly equalized parallel
operation lack of ventilation
38-41-42-53
18-19-20-21-27-28-29

Severe sparking
High friction
Poor commutator surface
Depreciation
High contact resistance
38-41-42
7-8-9-12-20-33-45-57
10-11-36-43-45-49-58-59
evidence
6-24
56

Severe sparking
Raw streaks on commutator
surface
Embedded copper
Wrong brush grade
38-41-42
7-10-11-12-26
See Sparking
See Streaking or threading of
surface
57-58-59-61-62
Heating at commutator
Heating at brushes
66
Return
Service Manual
8-19-22-25-27-28-29-37
7-13-23-24
1997-07-15
F-code
Section
C-code
PS
S1.0
1700
Drive Motor
Version no
T-code
001
TABLE # 2
Primary Sources of Unsatisfactory Brush

Performance
Preparation and Care of Machine
1.
2.
3.
4.
5.
6.
Poor preparation of commutator surface

High mica
Feather-edge mica
Bar edges not chamfered after undercutting
Need for periodic cleaning
Clogged ventilating ducts
Machine Adjustment
7.
8.
9.
10.
11.
12.
13.
Brushes in wrong position

Unequal brush spacing
Poor alignment of brush holders
Incorrect brush angle
Incorrect spring tension
Interpoles improperly adjusted
Series field improperly adjusted
Mechanical Fault in Machine

14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
Brushes tight in holders

Brushes too loose in holders
Brush holders loose at mounting
Commutator loose
Loose pole pieces or pole-face shoes
Loose or worn bearings
Unequal air gaps
Unequal pole spacing
Dynamic unbalance
Variable angular velocity
Commutator too small
Electrical Fault in Machine

25.
26.
27.
28.
29.
BT Products
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Open or high resistance connection at commutator

Poor connection at shunt terminal
Short circuit in field or armature winding
Ground in field or armature winding
Reversed polarity on main pole or interpole
Service Manual
1997-07-15
67
F-code
Section
C-code
PS
S1.0
Drive Motor
1700
Version no
T-code
001
Machine Design
30.
31.
32.
33.
34.
35.
36.
37.
Commutating zone too narrow

Commutating zone too wide
Brushes too thin
Brushes too thick
Magnetic saturation of interpoles
High bar-to-bar voltage
High ratio of brush contact to commutator surface area
Insufficient cross connection of armature coils
Load or Service Condition

38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
Overload
Rapid change of load
Reversing operation of non-interpole machine
Plugging
Dynamic braking
Low average current density in brushes
Contaminated atmosphere
Contact poisons
Oil on commutator or oil mist in air
Abrasive dust in air
Humidity too high
Humidity too low
Silicone contamination
Disturbing External Condition

51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
68
Return
Loose or unstable foundation

External source of vibration
External short circuit or very heavy load surge
Commutation factor too high
Commutation factor too low
Contact drop of brushes too high
Contact drop of brushes too low
Coefficient of friction too high
Lack of film forming properties in brush
Lack of polishing action in brush
Brushes too abrasive
Lack of carrying capacity
Service Manual
1997-07-15
F-code
Section
PS
C-code
S1.1
1700
Drive Motor 24 Volt
Version no
T-code
001
OE35
Drive Motor 24 Volt
POS. NO
DESCRIPTION
POS. NO
Screw, com. clamp
11
Lockwasher
21
Pole, main
Cover
12
Nut
22
Coil, field
Screw, retainer
13
Holder, brush
23
Bearing
Shield, com. end
14
Brush
24
Retainer
Terminal
15
Spring
25
Armature
Washer
16
Screw, brush
26
Shield, drive
Bushing
17
Screw, holder
27
Seal, shaft
Gasket
18
Bushing
28
Screw, clamp
Washer
19
Washer
29
Kit, EE
10
Washer
20
Screw, pole
BT Products
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Service Manual
DESCRIPTION
1997-10-21
POS. NO
DESCRIPTION
69
F-code
Section
PS
S1.1
Drive Motor 24 Volt
Version no
T-code
001
OE35
C-code
1700
1. Component Repair
Disassembly
1. Scribe or center punch locating marks in the
commutator end head and the frame. Although
locating marks are not always necessary because of
locating pins in some motors, they can save a lot of
time when the motor does not have locating pins.
2. Remove the commutator end head retaining screws.
Most motors have a slip fit bearing at the commutator
end, and the end head can be removed with very little
trouble.
3. Remove brush holding plate screws and remove plate
to replace brushes. Remove each brush from brush
holder and inspect brushes and commutator for worn
condition and uneven wear.
4. The brush springs may be checked at this time for
proper tension.
5. Separate the armature and drive end head as an
assembly from the frame and field coil/stator.
6. Separate the armature from the drive end head. This
operation is usually done by pressing the armature out
of the drive end bearing. Remove with puller.
When a puller is used, protect the end of the armature
shaft with a nut or a thick flat washer. If the shaft,
coupling, or spline is damaged when removing the end
head, the armature or the drive spline usually has to
be replaced. Use caution, and DO NOT damage the
armature.
7. Remove bearing from armature or end head.
70
Return
Service Manual
1997-10-21
F-code
PS
Section
C-code
S1.1
1700
Drive Motor 24 Volt
Version no
T-code
001
OE35
2. Inspection and Troubleshooting

After the motor components have been thoroughly cleaned
and dried, they should be inspected for the following:
2.1. Drive End Head

1. Check bearing recess for any signs of wear.
2. Check mounting holes for any stripped or crossed
threads or broken studs.
2.2. Commutator End Head

2. Check brush holder insulation for cracks or any signs
of burning.
3. Check brush holders and springs for wear.
2.3. Bearings
1. Check bearings by turning them with your fingers. Feel
for binding or gritty effects and excessive looseness or
wobble. A good bearing should also have a small
amount of drag or stiffness caused by the lubrication
but should turn smoothly. If the bearing turns very
freely, it should be replaced. Bearings should also be
changed, if worn out, damaged or removed from
armature shaft.
Ball bearings that have been pulled off of shafts,
pressed out of end heads, or side loaded in such a
way as to apply pressure on the balls and races must
be replaced. Although the bearing may appear or feel
good, the bearing races have been brinelled and will
fail within a relatively short period of service.
BT Products
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Service Manual
1997-10-21
71
F-code
Section
PS
S1.1
Drive Motor 24 Volt
Version no
T-code
001
OE35
C-code
1700
2.4. Brush and Commutator

The brushes and commutator should be inspected for even
wear and good commutation.
Good Commutation:A dark uniform coloring pattern at the
brush wearing surface.
Poor Commutation:The surface of the commutator
appearing rough, pitted, scored or signs of burning or heavy
arcing between bars. The color pattern will be:

Streaky film with commutator wear.

Bar edge burning.
Uneven film.
Carbon dust bridging between bars.
Brushes should be inspected for uneven wear and signs of

overheating, i.e.:

Discolored brush shunts.

Discolored brush springs.
Refer to the Brush Chart at the end of this section.
2.5. Armature
1. Check security of fan.
2. Check for loose commutator bars. Loose commutator
bars will usually be indicated by excessive wear or
burning on one bar. The commutator can be checked
for loose bars by lightly tapping all of the bars with the
handle of a plastic or wooden handled screwdriver. A
contrasting dull thud or vibration will indicate a loose
bar in which case, the armature must be replaced.
3. Check for grounded circuits using a test light. Most
commercial growlers incorporate a test light as shown
in illustration below.
Check the armature for grounded circuits by placing
one test lead of the test lamp on the commutator and
the other test lead on the armature shaft. If the test
light lights, the armature is grounded.
4. Standard Winding Armatures are tested on a growler
72
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Service Manual
1997-10-21
F-code
PS
Section
C-code
S1.1
1700
Drive Motor 24 Volt
Version no
T-code
001
OE35
(see illustration) using a steel strip or hacksaw blade to

locate any shorted windings.
Check for shorted windings by slowly rotating the
armature in the growler while holding the strip or blade
so that it passes over each armature core slot. If a
winding is shorted, the strip or blade will vibrate and
the blade will get hot.
NOTE: If the armature has been turned and

undercut prior to testing, check for and
remove any copper buildup or filings
between commutator bars and at the
commutator riser. This condition will
cause an armature to check shorted and
usually results from a dull undercutting
tool.
5. Check commutator bars for any signs of burning. If
deep burned sections are evident, either in the brush
track or on the riser ends of the commutator bars, an
open or short circuit in the armature windings is
indicated.
2.6. Frame and Field Assembly

Check the condition of all insulation. If the insulation on the
field coils appears blackened or charred, the serviceability of
the coils is questionable. Burned or charred insulation is a
result of coil overheating due to overloading conditions,
grounded or shorted coil windings. Check condition of all
other insulation such as brush rigging, under coil connections
and around terminal studs.
2.6.1. Testing
Frame and Field Assembly
After thorough inspection, the Frame and Field Assembly
should be checked for grounded, open or shorted circuits.
Grounded and open circuits can be checked using a test light.
Most commercial growlers incorporate a test light as shown in
opposite illustration.
Grounded Circuit
Touch one test lead to a clean bare metal spot on the
frame and check all terminals with the other lead. If a
BT Products
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Service Manual
1997-10-21
73
F-code
Section
PS
S1.1
Drive Motor 24 Volt
Version no
T-code
001
OE35
C-code
1700
grounded condition exists, the test light will light.

Open Circuit
Check between all connecting terminals with test
leads. If the bulb fails to light, an open circuit is
indicated.
Shorted Circuit
Shorted windings in series coils are very difficult to
detect. Generally, if the coil insulation is sound and
these are no signs of overheating, the coil can be
presumed good.
2.6.2. Frame and Field Service Notes

If the inside of the motor is exceptionally dirty and there is
evidence of a grounding condition caused by the dirt, the
inside of the motor can be given an additional coat of
insulating varnish. Red glyptol can be used if a better material
is not available, however, we recommend using a class H
Polyurethane air drying insulating varnish. This is readily
available under various brand names from electrical repair or
parts houses in aerosol type dispensers.
Before spraying field coils, make sure they are absolutely
clean and dry. Protect brush rigging, pole shoe faces and end
head seats to keep varnish off.
74
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Service Manual
1997-10-21
F-code
PS
Section
C-code
S1.1
1700
Drive Motor 24 Volt
Version no
T-code
001
OE35
2.7. Assembly
2.7.1. Field Coil Installation
Good solder connections are important due to the vibration
characteristics encountered by these motors which can cause
cold or poorly soldered connections to break.
Prior to installing the field coils, the connections

which require soldering should be buffed or wire
brushed clean to remove any oxidation. The
connections should then be tinned with a soldering
iron.
NOTE: We do not recommend using a soldering
gun or torch. Soldering gun cannot
provide the heat concentration required
and soldering torches can damage the
insulation.
After field coil installation, connect the solder joint

making sure the solder is flowing properly to avoid a
cold soldered joint.
Pole Shoe Screw Removal & Installation

(Field Coil Removal & Installation)
Continue assembly in the reverse of disassembly, paying
particular attention to the following points.
2.7.2. Bearing Installation
1. Whenever ball bearings are pressed into an end head
or onto a shaft, always press against the race that is
absorbing the pressure.
Press on the outer race when installing into end heads.
BT Products
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Service Manual
1997-10-21
75
F-code
Section
PS
S1.1
Drive Motor 24 Volt
Version no
T-code
001
OE35
C-code
1700
Press against the inner race when installing onto a shaft.

2. End heads having slip-fit bearings are normally
retained by a snap ring. Always install new snap
ring(s).
2.7.3. After Assembly
The motor should be connected as specified in

Troubleshooting, and tested to the specifications.
When testing motors, the voltmeter connections must

be made at the motor terminals.
3. When changing brushes

When changing brushes, the commutator must be serviced
as follows:
76
Return
Resurface the commutator by taking only light cuts

each time, 0.005 in. (0.12mm).
If reslotting/undercutting is necessary, the final

operation is to lightly sand the commutator with a fine
sandpaper to remove any burrs left from the
undercutting operation.
Service Manual
1997-10-21
F-code
Section
PS
C-code
S1.2
1700
Drive Motor 36 Volt
Version no
T-code
001
OE35
Drive Motor 36 Volt
POS. NO
BT Products
Return
DESCRIPTION
POS. NO
DESCRIPTION
coil, field
Head, commutstor end
Lead
Band, head
Brush
10
Armature assembly
Spring, brush
11
Fan
Plate, brush
12
Head, drive end
Ring, retainer
13
Seal
Bearing
Service Manual
1997-10-21
77
F-code
Section
PS
S1.2
Drive Motor 36 Volt
Version no
T-code
001
OE35
C-code
1700
1. Component Repair
1.1. Disassembly
1. Scribe or center punch locating marks in commutator
end head and the frame. Although locating marks are
not always necessary because of locating pins in
some motors, they can save a lot of time when the
motor does not have locating pins.
2. Remove the commutator end head retaining screws.
Most motors have a slip fit bearing at the commutator
end, and the end head can be removed with very little
trouble.
3. Remove brush holding plate screws and remove plate
to replace brushes. Remove each brush from brush
holder and inspect brushes and commutator for worn
condition and uneven wear.
4. The brush springs may be checked at this time for
proper tension.
5. Separate the armature and drive end head as an
assembly from the frame and field coil/stator.
6. Separate the armature from the drive end head. This
operation is usually done by pressing the armature out
of the drive end bearing. Remove with puller.
When a puller is used, protect the end of the armature
shaft with a nut or a thick flat washer.
NOTE! If the shaft, coupling, or spline is damaged
when removing the end head, the armature
or the drive spline usually has to be
DO NOT
replaced. Use caution, and
damage the armature.
7. Remove bearing from armature or end head.
78
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Service Manual
1997-10-21
F-code
PS
Section
C-code
S1.2
1700
Drive Motor 36 Volt
Version no
T-code
001
OE35
2. Inspection and Troubleshooting

After the motor components have been thoroughly cleaned
and dried, they should be inspected for the following:
2.1. Drive End Head

2. Check mounting holes for any stripped or crossed
threads or broken studs.
2.2. Commutator End Head

2. Check brush holder insulation for cracks or any signs
of burning.
3. Check brush holders and springs for wear.
2.3. Bearings
1. Check bearings by turning them with your fingers. Feel
for binding or gritty effects and excessive looseness or
wobble. A good bearing should also have a small
amount of drag or stiffness caused by the lubrication
but should turn smoothly.
2. If the bearing turns very freely, it should be replaced.
Bearings should also be changed, if worn out,
damaged or removed from armature shaft.
Ball bearings that have been pulled off shafts, pressed
out of end heads, or side-loaded in such a way as to
apply pressure on the balls and races, must be
replaced. Although the bearing may appear or feel
good, the bearing races have been brinelled and will
fail within a relatively short period of service.
BT Products
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Service Manual
1997-10-21
79
F-code
Section
PS
S1.2
Drive Motor 36 Volt
Version no
T-code
001
OE35
C-code
1700
2.4. Brush and Commutator

The brushes and commutator should be inspected for even
wear and good commutation.
Good Commutation: A dark uniform coloring pattern at the
brush wearing surface.
Poor Commutation: The surface of the commutator
appearing rough, pitted, scored, or showing signs of burning
or heavy arcing between bars. The color pattern will be:
Streaky film with commutator wear.
Bar edge burning.
Uneven film.
Carbon dust bridging between bars.
Brushes should be inspected for uneven wear and signs of

overheating, i.e.:
Discolored brush shunts.
Discolored brush springs.
2.5. Armature
1. Check security of fan.
2. Check for loose commutator bars. Loose commutator
bars will usually be indicated by excessive wear or
burning on one bar. The commutator can be checked
for loose bars by lightly tapping all of the bars with the
handle of a plastic or wooden handled screwdriver. A
contrasting dull thud or vibration will indicate a loose
bar. Replace the armature if any commutator bar is
loose.
3. Check for grounded circuits using a test light. Most
commercial growlers incorporate a test light as shown
in illustration below.
Check armature for grounded circuits by placing one
test lead of the test lamp on the commutator and the
other test lead on the armature shaft. If the test light
lights, the armature is grounded.
4. Standard Winding Armatures are tested on a growler
80
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Service Manual
1997-10-21
F-code
PS
Section
C-code
S1.2
1700
Drive Motor 36 Volt
Version no
T-code
001
OE35
(see illustration) using a steel strip or hacksaw blade to

locate any shorted windings.
Check for shorted windings by slowly rotating the
armature in the growler while holding the strip or blade
so that it passes over each armature core slot. If a
winding is shorted, the strip or blade will vibrate and
the blade will get hot.
NOTE! If the armature has been turned and undercut
prior to testing, check for and remove any
copper
buildup
or filings between
commutator bars and at the commutator
riser. This condition will cause an armature to
check shorted and usually results from a dull
undercutting tool.
5. Check commutator bars for any signs of burning. If
deep burned sections are evident, either in the brush
track or on the riser ends of the commutator bars, an
open or short circuit in the armature windings is
indicated.
2.6. Frame and Field Assembly

Check the condition of all insulation. If the insulation on the
field coils appears blackened or charred, the serviceability of
the coils is questionable. Burned or charred insulation is a
result of coil overheating due to overloading conditions, or
grounded or shorted coil windings. Check the condition of all
other insulation such as brush rigging, under coil connections
and around terminal studs.
2.6.1. Testing
After thorough inspection, the Frame and Field Assembly
should be checked for grounded, open or shorted circuits.
Grounded and open circuits can be checked using a test light.
Most commercial growlers incorporate a test light as shown in
opposite illustration.
Grounded Circuit
Touch one test lead to a clean bare metal spot on the
frame and check all terminals with the other lead. If a
grounded condition exists, the test light will light.
BT Products
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Service Manual
1997-10-21
81
F-code
Section
PS
S1.2
Drive Motor 36 Volt
Version no
T-code
001
OE35
C-code
1700
Open Circuit
Check between all connecting terminals with test
leads. If the bulb fails to light, an open circuit is
indicated.
Shorted Circuit
Check condition of coil insulation and look for signs of
overheating. Shorted windings in series coils are very
difficult to detect. Generally, if the coil insulation is
sound and there are no signs of overheating, the coil
can be presumed good.
2.6.2. Frame and Field Service Notes

1. If the inside of the motor is exceptionally dirty and
there is evidence of a grounding condition caused by
the dirt, the inside of the motor can be given an
additional coat of insulating varnish. Red glyptol can
be used if a better material is not available, however,
we recommend using a class H Polyurethane air
drying insulating varnish. This is readily available
under various brand names from electrical repair or
parts houses in aerosol type dispensers.
2. Before spraying field coils, make sure they are
absolutely clean and dry. Protect brush rigging, pole
shoe faces, and end head seats to keep varnish off.
82
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Service Manual
1997-10-21
F-code
PS
Section
C-code
S1.2
1700
Drive Motor 36 Volt
Version no
T-code
001
OE35
2.7. Assembly
2.7.1. Field Coil Installation
Good solder connections are important due to the vibration
characteristics encountered by these motors which can cause
cold or poorly soldered connections to break.
1. Prior to installing the field coils, the connections
which require soldering should be buffed or wire
brushed clean to remove any oxidation. The
connections should then be tinned with a soldering
iron.
NOTE! We do not recommend using a soldering gun
or torch. A soldering gun cannot provide the
heat concentration required, and a soldering
torch can damage the insulation.
2. After field coil installation, connect the solder joint,
making sure the solder is flowing properly to avoid a
cold soldered joint.
Pole Shoe Screw Removal / Installation

(Field Coil Removal / Installation)
Continue assembly in the reverse of disassembly, paying
particular attention to the following points.
2.7.2. Bearing Installation
1. Whenever ball bearings are pressed into an end head
or onto a shaft, always press against the race that is
absorbing the pressure.
BT Products
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Service Manual
1997-10-21
83
F-code
Section
PS
S1.2
Drive Motor 36 Volt
Version no
T-code
001
OE35
C-code
1700
Press on the outer race when installing into end heads.

Press against the inner race when installing onto a
shaft.
2. End heads having slip-fit bearings are normally
retained by a snap ring. Always install new snap
ring(s).
2.7.3. After Assembly
1. The motor should be connected as specified in
Troubleshooting, and tested to the specifications.
2. When testing motors, the voltmeter connections
must be made at the motor terminals.
3. When Changing Brushes

When changing brushes, the commutator must be serviced
as follows:
1. Resurface the commutator by taking only light cuts
each time, 0.005 in. (0.12 mm).
2. If reslotting/undercutting is necessary, the final
operation is to lightly sand the commutator with a fine
sandpaper to remove any burrs left from the
undercutting operation.
84
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Service Manual
1997-10-21
F-code
Section
PS
S2.0
2550
Transmission
Version no
T-code
000
OE35
C-code
Transmission
1. System description
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, and 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 brakes are on the drive motor.
Technical data
Gear Ratio
14:1
Oil Type
GL5 80w90
Oil Capacity
Approximately 1 quart
Drive Tire Size
10.5 in. x 5 in. x 6.5 in.
2. Troubleshooting
Because of the uncomplicated nature of this transmission,
troubleshooting is limited to identifying whether problems 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 speaking, 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.
BT Products
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Service Manual
1997-10-21
85
F-code
Section
C-code
PS
S2.0
Transmission
2550
Version noT-code
000
OE35
3. Removal
9
8
7
1
2
3
4
5
6
21
19
20
18
16
17
15
10
13
14
11
12
POS.
NO
86
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DESCRIPTION
POS.
NO
DESCRIPTION
POS.
NO
DESCRIPTION
Screw, cap
Lockwasher
15
Washer
Lockwasher
Screw, cap
16
Bearing
Clamp
10
Bearing, roller
17
Nut, twin
Spacer
11
Eccentric, adjuster
18
Switch
Ring, retainer
12
Screw, cap
19
Screw, machine
Bracket
13
Washer, flat
20
Nut, jam
Frame, main
14
Transmission
21
Fitting, grease
Service Manual
1997-10-21
F-code
Section
PS
S2.0
2550
Transmission
Version no
T-code
000
OE35
C-code

load wheels are blocked to prevent accidental
movement.
2. Fully lower the mast.
3. Label the motor power cables and remove cables
from drive motor.
4. Disconnect wire from the brake interlock switch.
5. Disconnect the wires from the steering travel
limiting switch.
6. Pull cables and wires up through the transmission
tube.
7. Disconnect the hydraulic return hose from the
control valve to the filter. Unbolt the control valve
bracket from the truck frame. Lay the control valve
off to the side.
8. Remove the brake cylinder from the transmission.
It is not necessary to disconnect the hydraulic
hose.
9. Raise and block the front of the truck for access
under truck.
10. Drain fluid from transmission.
11. Put transmission in straight ahead position and
mark the location of steering chain to transmission
for ease of reassembly.
12. Remove the steering chain
transmission and sprocket.
from
around
13. Loosen the cam adjustments on the steering guide

rollers.
14. Support the transmission from overhead. A chain
through the pivot tube is most convenient.
15. Remove the three cap screw that bolt the
transmission pivot mount to the truck frame.
16. The transmission can now be lifted up and away
from the truck.
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Service Manual
1997-10-21
87
F-code
Section
C-code
PS
S2.0
Transmission
2550
Version noT-code
000
OE35
17. Remove retaining ring from pivot tube and remove

pivot mounting bracket. The pivot bearing outer
race is pressed into the bracket.
88
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Service Manual
1997-10-21
F-code
Section
C-code
PS
S2.0
2550
Transmission Disassembly / Assembly
Version no
T-code
000
OE35
Transmission Disassembly /
Assembly
Torque nut to
250 ft./lbs. while
turning hub.
POS.
NO
BT Products
Return
DESCRIPTION
POS.
NO
DESCRIPTION
POS.
NO
DESCRIPTION
Screw, cap
13
Seat, spring
25
Pinion, motor
Cover
14
Cover, case
26
O ring
Shim, 0.10 in.
15
Screw, set
27
Shaft
Nut
16
Nut
28
O ring
Case, gear
17
Cover
29
Bearing
Pin, dowel
18
Shim, 0.010 in.
30
Gear
Plate, brake
19
Screw, cap
31K
Seal, oil
Disc, brake
20
Screw, cap
32K
Hub, axle
Rod, brake
21
Lockwasher
33K
Locknut
10
Lever, brake
22K
Gear, drive
11
Pin, roll
23K
Bearing
12
Spring
24
Bearing
Service Manual
1997-10-21
Kit, drive axle
89
F-code
Section
C-code
PS
S2.0
2550
Version noT-code
000
OE35
4. Disassembly
Before starting disassembly of any parts, thoroughly clean
out side of assembly with safety solvent or other noncorrosive cleaning fluid. Air dry all parts.
1. Remove drive tire and wheel.
2. Remove six cap screw that hold on the steering
guide ring. Remove the guide ring.
3. Remove four motor mounting hollow hex key cap
screws from the cover side of the transmission and
remove the drive motor.
4. Lay transmission on work surface with cover side
up.
5. Remove cover bolts and 1/2 in. locknut from side
cover.
6. Use four threaded holes in cover with cover bolts to
push cover off of dowels. Apply pressure equally
with all four pusher bolts.
Plug
Dowel
Pin
Breather
Locknut
Set
Screw
O rings
Nut
Drive Motor
Mounting Bolts
Fill Plug
Case Cover
Lockwasher
90
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Service Manual
Screw
Drain Plug
Screw
1997-10-21
F-code
Section
C-code
PS
S2.0
2550
Version no
T-code
000
OE35
7. Remove intermediate gear from case.

8. Remove brake lever and adjusting rod from over
top of brake discs.
Adjusting
Rod
O ring Brake
Lever
Locknut
Screw
Shim
Cover
Roll
Pin
Spring
Spring
Seat
O
ring
Bearing
Retaining
Shaft
Intermediate
Gear
Bearing
9. Remove brake discs, plates and retaining shafts.
Drive Motor
O ring
Motor
Adapter
Brake
Separator
Pads
Bushing
Brake
Adjusting
Rod
Motor
Pinion
Brake Disc
10. Remove axle locknut and nub from axle. Remove

axle from case.
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1997-10-21
91
F-code
Section
C-code
PS
S2.0
2550
Version noT-code
000
OE35
11. Remove bearing races from case.
Locknut
Case
Seal
Drive Gear
Wheel
Hub
Bearing
Bearing
12. Remove motor pinion bearing and cover and
intermediate gear bearing and cover from side
cover.
13. Remove intermediate gear bearing and cover from
case.
14. Remove all old gasket material from cover, case
and drive motor.
15. Clean all parts in safety solvent and dry with
compressed air.
16. Inspect all gears for damage and wear.
17. Discard all o-rings and bearings. New parts should
be used during reassembly.
18. Install the drive axle bearing races into the gear
case. Races should be installed with the smallest
inside diameters back-to-back and tight against the
snap rings.
19. Press one bearing cone on the drive axle with the
large diameter against the gear.
20. Place the drive axle into the case.
21 Turn the gear case over with the gear side down.
Support the drive gear from underneath.
92
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1997-10-21
F-code
Section
C-code
PS
S2.0
2550
Version no
T-code
000
OE35
22. Install second bearing cone over drive axle.

23. Install lip seal in transmission case.
24. Install wheel hub on drive axle.
25. Put a solid bead of Loctite 515 "gasket eliminator"
around the seam between the axle and the hub.
26. Use Loctite thread lock on axle locknut and install

axle locknut on axle. Torque locknut to 250 ft-lb
while rotating the axle.
27. Press the intermediate gear bearing into the gear
case. Install the bearing cone and one 0.010 in.
shim. Use Loctite 515 as sealant and use Loctite
threadlock on the cover screws. Do not install the
intermediate gear at this time.
28. Install the motor adapter and motor pinion gears on
the drive motor armature shaft. If new adapter and
pinion gears are used they should be snapped
together by striking with a lead hammer.
29. Install a new gasket on the drive motor. Use a
small amount of Loctite 515 as sealant.
Drive Motor
Gasket
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1997-10-21
Motor
Adapter
Motor
Pinion
93
F-code
Section
C-code
PS
S2.0
2550
Version noT-code
000
OE35
30. Install the bushings and O ring for the brake

actuating rod into the gear case.
31. Install the drive motor in the gear case.
32. Install the brake actuating rod through the drive
motor into the gear case. This is done to help keep
the drive motor properly aligned in the gear case
during assembly.
33. Turn the transmission case so that the gear case is
facing up. The end of the motor will be on the work
surface. Support the drive axle end of the case with
a block.
34. Install a separator pad in the gear case over the
motor pinion. See illustration for proper orientation.
35. Place a brake disc onto the motor adapter gear
and on top of the separator plate. The hub of the
disc must be towards the motor (down).
36. Install a second separator plate over the brake
disc.
37. Place the second brake disc over the second
separator plate. Position this brake disc with the
hub away from the drive motor. Orient the disc so
that the rivets are spaced between the rivets of the
first disc at a 45 degree angle.
38. Place the third separator plate over the second
brake disc.
39. Install new o-rings on the retaining shafts and
install the retaining shafts through the separate
plates and into the gear case, small end first. Make
sure the shafts are fully seated and do not pinch
the lower separator plate.
40. Install the intermediate gear into the bearing in the
gear case.
41. Install the brake lever and adjusting rod into the
gear case. The brake lever must be free to pivot on
the adjusting rod and roll pin. A locknut adjusting
nut secures the adjusting rod into place on the
motor side of the gear case.
94
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Service Manual
1997-10-21
F-code
Section
C-code
PS
S2.0
2550
Version no
T-code
000
OE35
Adjusting
Rod
O ring Brake
Lever
Locknut
Screw
Cover
Roll
Pin
Spring
Spring
Seat
O
ring
Bearing
Retaining
Shaft
Shim
Intermediate
Gear
Bearing
42. Adjusting the brake lever:
a. The brake lever has a slight V shape on the
side closest to the brakes. The section of the
brake lever directly under the three countersunk
spring anchor holes should contact the last
brake separate plate.
b. Lift up on the adjusting rod to hold adjusting
locknut tight against motor side of gear case.
c. Use a feeler gauge between brake lever and
separator plate to determine contact area.
d. Tightening the nut will move the adjusting rod
towards the drive motor and will move the
contact area towards the brake lever pivot.
Incorrect adjustment will cause the brakes to
drag or loss of braking force.
43. Place three springs with spring seats into the three
countersunk spring seat holes in the brake lever.
44. Install the baffle in the bottom of the gear case. (if
used)
45. Use a solid bead of Loctite 515 gasket eliminator
around the gear case cover flange. Circle all bolt
holes and dowel pin holes.
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1997-10-21
95
F-code
Section
C-code
PS
S2.0
2550
Version noT-code
000
OE35
46. Install dowel pins in gear case.

47. Carefully install the gear case cover. Take care to
line up the three brake springs and the brake
separator plate retaining shaft with the appropriate
holes in the cover. The motor pinion and
intermediate gear bearings have not yet been
installed.
48. Tighten down all the cover screw equally. Torque
to 30 ft-lb.
49. Put new O rings on and install four motor mounting
bolts. Tighten bolts in an X pattern and torque to
35 ft-lb.
50. Install the locknut on the brake adjusting rod end
that comes through the side cover.
51. Install three spring adjusting hollow hex key
screws. Tighten the screw until they just touch the
spring seats then 1/4 additional turn. Install
locknuts on screws.
52. Install the bearing for the intermediate gear into the
gear case cover.
The outer race must NOT be below the cover. It
may be flush with or above the cover.
53. Place shims around bearings so that shims are
flush with outer race.
54. Install bearing cover. Use Loctite 515 as a sealant
and put Loctite threadlock on the cover mounting
bolts.
55. Install the drive motor pinion bearing in the cover.
A. Make sure the motor shaft and gear are
concentric with the bearing mounting hole in
gear case cover.
WARNING Do not force the bearing in the mounting
hole by bending drive motor shaft. This will
result in armature breakage.
B. To check for concentricity, use a telescoping
gauge and a micrometer to measure four
96
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Service Manual
1997-10-21
F-code
Section
C-code
PS
S2.0
2550
Version no
T-code
000
OE35
opposing locations.
Subtract the smallest number from the largest
number.
The specification for total indicated runout (TIR)
is 0.055 in.
C. If drive motor shaft and gear are not concentric,
first remove the drive motor and check for any
burrs, pieces of old gasket material, etcs., that
might cause these parts to be misaligned. If
okay, install drive motor taking special care
tightening drive motor mounting bolts.
56. Install the bearing cover over the bearing with
shims and Loctite 515.
The bearing cover must be shimmed so that it is
0.010 in. above the outer bearing race. Put shims
around bearing so they are 0.010 in. higher than
the bearing.
57. Fill transmission with about one quart of ATF
Dextron II.
58. Install the steering guide ring with six bolts and
lockwashers. Torque bolts to 50 ft-lb.
59. Install the drive wheel assembly to the hub with five
bolts. Torque to 100 ft-lb.
5. Installation
1. Install new pivot bearing on pivot tube with washer
under bearing.
2. Install new bearing cup in pivot tube mounting
bracket.
3. Put mounting bracket over pivot tube and install
retaining ring around top of pivot tube.
4. Attach hoist to transmission with a chain through
the pivot tube.
5. Raise and block the front of the truck about 12 in.
off the ground.
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1997-10-21
97
F-code
Section
C-code
PS
S2.0
2550
Version noT-code
000
OE35
6. Set transmission into truck from the top.

7. Bolt the pivot mount to the truck frame with three
bolts. Torque to 75 ft-lb.
8. Adjust transmission steering ring guide rollers
snug, but not tight, against the guide ring (+0.0156
in. ; -0.0 in.).
9. Turn the transmission to the straight ahead
position.
Line up the marks made during removal on the
steering chain and transmission and install the
steering chain around the transmission and chain
sprocket.
If no match marks are visible then keep the
steering wheel centered between the steering
stops and keep the transmission in a straight
ahead position during chain installation.
Adjust the chain tension for a maximum of 1/8 in.
side-to-side motion at the mid-point of the chain
between the transmission and the sprocket.
10. Verify that the transmission will turn an equal
amount in each direction.
11. Lower truck to ground.
12. Reinstall the brake cylinder onto transmission
case. Be sure that brake rod is lined up properly for
switch operation.
13. Pull drive motor cables and brake interlock wires
through transmission tube.
14. Attach cables to proper drive motor terminals.
15. Connect wires to brake interlock switch.
16. Connect proper wires to steering travel limiting
switch.
17. Remount the control valve to the truck frame and
connect return hose to filter.
18. Recheck transmission fluid level.
19. Connect battery and test drive truck.
Check for proper steering and braking action.
98
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Service Manual
1997-10-21
F-code
Section
PS
S3.1
Version no
T-code
001
OE35
C-code
3500
Drive Wheel
Drive Wheel
5.1. Removal
The drive wheel can be removed without removing the
transmission by following these steps.
1. Park truck on level surface, and block truck from
moving.
2. Disconnect the battery.
3. Hoist machine and securely block truck with drive
tire about 1 in. off floor.
4. Remove lug bolts and remove tire and wheel
assembly.
Lug Bolts
5. Press drive tire (2) from wheel hub (3).
1
3
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1997-10-21
99
F-code
Section
C-code
PS
S3.1
Drive Wheel
3500
Version noT-code
001
OE35
5.2. Installation
1. Press drive tire (2) onto wheel hub (2). This is
usually done while pressing off old tire. Press hub
to center of tire.
1
3
2. Install drive tire and hub on axle. The drive tire lug
bolts should be torqued to 125 ft-lb.
Lug Bolts
100
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Service Manual
1997-10-21
F-code
Section
PS
S3.2
Version no
T-code
001
OE35
C-code
3550
Load Wheels
Load Wheels
POS.
NO
DESCRIPTION
POS.
NO
DESCRIPTION
Pin, roll
Seal, oil
Nut
10
Bearing
Axle
11
Wheel, load
Fitting, grease
1. Park truck on level surface, and apply the brake.
2. Hoist machine so load wheels are approximately two
inches off of the floor, and securely block.
3. Drive roll pin (5) further in support arm to allow nut
(6) to be removed.
4. Remove nut (6), axle (7), and load wheel assembly
from support arm.
5. Drive roll pin (5) from support arm.
6. Inspect bearings (10).
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1997-09-15
101
F-code
Section
C-code
PS
S3.2
Load Wheels
3550
Version no
T-code
001
OE35
7. Install new load wheel (11) and bearing (10) as

needed.
7. Install load wheel assembly in support arm. Slide
axle (7) in support arm from outside and install nut
(6).
8. Tighten nut (6) only until all end play is removed
from load wheel assembly. Then turn nut (6) to
closest slot that lines up with roll pin (5) hole and
install roll pin (5) to lock nut (6) in place.
102
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Service Manual
1997-09-15
F-code
Section
C-code
PS
S3.2
3560
Stabilizing Caster Spring Loaded
Version no
T-code
001
OE35
POS.
NO
BT Products
Return
DESCRIPTION
POS.
NO
DESCRIPTION
POS.
NO
DESCRIPTION
Base, plate
10
Lockwasher
19
Washer, spacer
Bearing, thrust
11
Screw
20
Bearing, ball
Seal
12
Spring, inner
21
Wheel
Frame
13
Spring, outer
22
Frame, wheel
Pin
14
Plate, spring
23
Washer, spacer
Washer
15
Bushing
24
Screw
Nut, slotted
16
Washer, shim
25
Bearing, roller
Pin
17
Fitting, grease
Cap, hub
18
Axle, caster
Service Manual
1997-07-15
103
F-code
Section
C-code
PS
S3.2
3560
Version no
T-code
001
OE35
1. Removal
NOTE! CLEANLINESS! Perform procedures in a clean
environment. Make sure all parts are cleaned
before disassembly and kept clean during
assembly.
parking brake is applied.
solvent. Even a small explosion or fire could
cause injury or death.
WARNING Compressed air used for cleaning MUST be
reduced to less than 30 p.s.i., and then only
with effective chip-guarding and personal
protective equipment.
2. Release pressure in hydraulic system by pressing
the lowering button on steering control handle.
4. Raise and block drive end of truck so casters
wheels are 2 in. to 3 in. off the floor.
5. Open access door fully and disconnect negative
wire from hydraulic pump solenoid to prevent pump
from operating.
6. Remove four cap screws and nuts securing caster
assembly to frame.
7. Remove caster assembly from truck.
8. Before disassembly, thoroughly clean exterior of
the caster assembly in a cleaning solvent to
remove all contamination.
104
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1997-07-15
F-code
Section
C-code
PS
S3.2
3560
Version no
T-code
001
OE35

BT Products
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Service Manual
1997-07-15
105
F-code
Section
C-code
PS
S3.2
3560
Version no
T-code
001
OE35
2. Inspection
assembly.
1. Thoroughly clean all parts and remove all nicks
and burrs with emery cloth.
2. Inspect all bolts (4) and replace if needed.
106
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1997-07-15
F-code
Section
C-code
PS
S3.2
3560
Version no
T-code
001
OE35
3. Disassembly
assembly.
1. Before disassembly, thoroughly clean exterior of
the caster assembly in a cleaning solvent to
1. Remove axle (5) from yoke (4) and remove the
wheel assembly.
2. Remove cap (6) from the yoke (4).
3. Remove roll pin (9) and nut (8) from the base plate
spindle.
4. Clean and inspect all bearing and replace as
needed.
5. Assemble caster in reverse order.
3.1. Installation
1. Install caster assembly under truck, and secure
with cap screws and nuts.
2. Lift truck and remove all blocking.
3. Reconnect the negative wire to pump solenoid.
4. Connect battery to truck.
5. Close access door.
BT Products
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Service Manual
1997-07-15
107
F-code
Section
C-code
PS
S3.2
3560
Version no
T-code
001
OE35
108
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Service Manual
1997-07-15
F-code
Section
PS
S4.0
4130
Torque Generator
Version no
T-code
001
OE35
C-code
Torque Generator
BT Products
Return
Service Manual
1997-10-27
109
F-code
Section
PS
S4.0
Torque Generator
Version no
T-code
001
OE35
POS.
NO
110
Return
C-code
4130
DESCRIPTION
POS.
NO
DESCRIPTION
POS.
NO
DESCRIPTION
Hosing, valve
Pin
17
Seal, quad
Seal, shaft
10
Plate, spacer
18
Key, woodruff
Washer
11
Spacer
19
Shaft, power end
Ring, retainer
12
Geroler
20
Washer
O ring
13
Plate, spacer
21
Washer
Spool
14
Drive, control end
22
Retainer
Spring
15
Screw, cap
23
Shaft, power end
Sleeve
16
Housing, power end
Service Manual
1997-10-27
F-code
Section
PS
S4.0
4130
Torque Generator
Version no
T-code
001
OE35
C-code
1. Disassembly
Before starting disassembly, thoroughly clean out side of
assembly (making sure all ports are sealed) with safety
solvent or other non-corrosive cleaning fluid. Air dry all parts.
NOTE! Although not all drawings show the torque
generator in a vise or on a bench, we
recommend that you follow instructions in
the steps as to the placement of parts
whether it be in a vice or on the bench.
Vise Jaws
(top View)
Output Shaft
(power end) Up
1. To disassemble the torque generator, first support the

unit in a vertical position with the seven cap screws up
and control end shaft down.
CAUTION
When a bench vise is used to support the

torque generator, do not to use excessive
clamping pressure on the control housing.
Excessive pressure can distort the
housing. When using a vise, CLAMP
ACROSS PORT FACE SIDES ONLY.
2. With the torque generator firmly supported, use a 6

point drive (E10) socket wrench and remove seven
cap screws (early production units used 12 point drive
screws).
BT Products
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Service Manual
1997-10-27
111
F-code
Section
PS
S4.0
Torque Generator
Version no
T-code
001
OE35
C-code
4130
Cap Screw
Key
Housing and Shaft Assembly

3. Remove the housing (power end) and shaft assembly.
4. Turn the housing and shaft assembly over and remove
the shaft with retaining ring in place.
NOTE! In most cases it is not necessary to remove
the retaining ring from the shaft.
Washer
Washer
Quad Seal
Housing (Standard)
Shaft and Retaining Ring

(power end)
Housing (bearings -- Needle type)
5. Remove both washers from the housing (power end),
and re-position the housing with seal end up. Use
small screwdriver or similar tool to remove quad seal
from the housing. Housing with two bearing sets
(needle type) use the same output shaft, quad seal,
washers, and retaining ring as the standard housing,
however if bearings are to be replaced they are not
sold separately as replacement parts.
112
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Service Manual
1997-10-27
F-code
Section
PS
S4.0
4130
Torque Generator
Version no
T-code
001
OE35
C-code
Spacer Plate
Gerotor or Geroler
Drive
(power end)
O ring
6. Use a small screwdriver or similar tool to remove O
ring from the spacer plate.
7. Remove spacer plate from the gerotor or Geroler.
8. Remove drive (power end) from the gerotor or Geroler.
9. Remove O ring from the gerotor or Geroler.
Spacer
Plate
Spacer
Drive
Geroler
O ring
NOTE! Remove the gerotor or Geroler, try to keep
all parts together, Geroler has 7 rolls to
retain along with the star (step 10).
10. Remove the gerotor or Geroler.
11. Remove the spacer.
12. Using a small screwdriver or similar tool, remove the O
ring from the spacer plate.
13. Remove spacer plate from the valve housing.
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1997-10-27
113
F-code
Section
PS
S4.0
Torque Generator
Version no
T-code
001
OE35
C-code
4130
14. Again using a small screwdriver or similar tool, remove

O ring from the valve housing.
15. Remove the control end drive from the spool/sleeve
assembly in the valve housing.
Valve Housing
Washer
Shaft Seal
(can be
Quad Seal
or Lip Seal)
Sleeve Spool
Centering Springs
Retaining Ring
and Cross Pin
16. Re-position valve housing, shaft horizontal and

remove the spool/sleeve assembly.
17. Re-position valve housing shaft end up. Use a small
screwdriver or similar tool to remove shaft seal.
18. Remove the washer from spool/sleeve assembly.
Sleeve
6 Springs
(Standard)
Pin
Spool and Retaining Ring
6 Springs and 4 Spacers

for Increased Input Torque
Spool (Special for Increased Input Torque)
19. To separate spool from the sleeve, the cross pin must
be removed. To remove the cross pin, use a small
screwdriver or similar tool and push pin from the spool/
sleeve.
114
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1997-10-27
F-code
Section
PS
S4.0
4130
Torque Generator
Version no
T-code
001
OE35
C-code
20. With cross pin removed, push spool forward to

disengage the control spool and centering springs
from the sleeve.
NOTE! To prevent possible loss of the (six)
centering springs, cover the control spool
and springs with a clean shop towel when
pushing springs from the spool. This will help
contain springs in one location (step 21).
21. Remove centering springs from the control spool (and
if applicable, four spring spacers). Retaining ring on
spool need not be removed if no damage is apparent.
Relief Valve
Valve Housing
(for Relief Valve Option)
O ring
Plug
NOTE! Valve housing with inlet relief valve has one

O ring on the plug. After O ring replacement,
install relief valve and plug into valve
housing and torque plug to 30-34 ft-lb (41-46
N$m).
BT Products
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Service Manual
1997-10-27
115
F-code
Section
PS
S4.0
Torque Generator
Version no
T-code
001
OE35
C-code
4130
2. Assembly
Replace all worn and damaged parts, also a good service
policy is to replace all seals. Lubricate all seals with
petroleum jelly, and also lubricate all mating surfaces with
good clean hydraulic fluid for ease of reassembly and to
provide instant lubrication between rotating parts at start-up.
1. Lubricate the spool and install it into the sleeve, align
the centering spring opening of the spool with the
spring notches in the sleeve.
Sleeve
6 Springs
(Standard)
Pin
Spool and Retaining Ring
6 Springs and 4 Spacers

for Increased Input Torque
Spool (Special for Increased Input Torque)
Spring Installation Tool

Springs
Alternate Method
Add One Spring
At a Time
2. In preparation of installing the control spool and sleeve

centering spring set, stand all springs on a clean flat
surface with the notched side of the centering spring
pointed down. Next place centering springs with
arched side of each set of three pointing toward each
other as shown above.
3. To install centering springs, first insert spring
installation tool through spring openings in the spool
116
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1997-10-27
F-code
Section
PS
S4.0
4130
Torque Generator
Version no
T-code
001
OE35
C-code
sleeve. Insert one end of the entire centering spring

set (with notched side toward the spool/sleeve) into
the spring installation tool. Compress extended ends
of the centering spring set and push springs into the
spool/sleeve (do not pull on the spring tool),
installation tool will guide the springs through the spool
and sleeve. Increased Input torque spring package
has 4 spring spacers 2 on each of the out sides of the
six springs.
NOTE! When spring installation tool is not available,
the centering springs may be installed by
hand. First install two (2) outside springs and
add the others one at a time in between
previously installed outside springs.
4. With spring set installed, center spring sets within the
sleeve and push down on the spool until top of the
centering springs are flush with upper surface of the
sleeve.
Valve Housing
Washer
Shaft Seal
(can be
Quad Seal
or Lip Seal)
Sleeve Spool
Centering Springs
Retaining Ring
and Cross Pin
5. Install the cross pin into the spool/sleeve.

6. Lubricate and install the washer into the valve housing.
NOTE! The input shaft seal has had two different
configurations and both seal types (Quad or
Lip), have been addressed in the steps
below.
7. Quad Seal In preparation of installing the quad seal,
first install the spool/sleeve assembly into the valve
housing backwards, shaft end up. Carefully retain the
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Service Manual
1997-10-27
117
F-code
Section
PS
S4.0
Torque Generator
Version no
T-code
001
OE35
C-code
4130
spool/sleeve and washer assembly in the valve

housing, and turn the assembly over, support it on a
clean flat surface. Temporarily installing these shaft
parts in the valve housing in the opposite direction
from which was originally intended will create a groove
or pocket into which the quad seal can be easily
installed from the input end of the valve housing.
8. Quad Seal Lubricate and install the quad seal in its
seat.
9. Quad Seal After seal installation, make sure the seal
is not twisted. Turn the valve housing over and remove
the spool/sleeve assembly.
10. Lip seal Insert this seal into valve housing (without
shaft installed) from the inside and guide it with your
finger all the way into the seal groove. the seal lip must
be positioned so it is towards the inside of the valve
housing.
Spacer
Plate
Spacer
Drive
Geroler
O ring
NOTE! Careful insertion of input shaft upon

reassembly will prevent shaft seal damage.
11. With the washer still resting firmly in the valve housing.
lubricate the spool/sleeve assembly and carefully
install it in the valve housing shaft end down.
12. Lubricate the valve housing O ring and install it into the
valve housing.
118
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1997-10-27
F-code
Section
PS
S4.0
4130
Torque Generator
Version no
T-code
001
OE35
C-code
13. Install the control end spacer plate, aligning the cap
screw holes and porting passages with the matching
holes in the control valve housing.
14. Lubricate and install the O ring in the groove located in
the spacer plate.
Gerotor
Star
Valley
Geroler
Drive
(Marked)
Pin
15. The preferred method of drive installation is to mark
the drive with a felt tip pen, as shown here. Mark the
splined end of the drive, from tooth-to-tooth, with a line
that parallels the slotted end of the drive. This method
helps assures proper alignment of the drive and
gerotor or Geroler star (meter section).
16. Install the drive, make sure you fully engage the slot
on the end of the drive with the cross pin in the spool
and sleeve assembly.
17. This illustration (above) shows the correct relationship
of the spool/sleeve assembly cross pin and the gerotor
or Geroler star for proper torque generator timing.
18. With the O ring groove side of the outer ring facing
upward. install the gerotor or Geroler by aligning any
two star valleys with the previously marked drive. After
engaging the gerotor or Geroler star with the marked
drive, rotate the outer ring of the gerotor or Geroler to
align with the threaded holes in the valve housing.
BT Products
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Service Manual
1997-10-27
119
F-code
Section
PS
S4.0
Torque Generator
Version no
T-code
001
OE35
C-code
4130
Spacer Plate
Gerotor or Geroler
Drive
(power end)
O ring
19. Lubricate and install the O ring into the gerotor or
Geroler.
20. Install the spacer in the Geroler star.
21. Lubricate and install the drive into the gerotor or
Geroler star.
NOTE! The spline on one end of the drive is not as
thick as the other and this thinner spline end
must be installed into the gerotor or Geroler
star.
22. Lubricate and install the spacer plate, with the seal
groove side facing upward. Install by aligning the cap
screw holes with the matching holes in the gerotor or
Geroler.
23. Lubricate and install the O ring in the groove located in
the spacer plate.
Washer
Washer
Quad Seal
Housing (Standard)
Shaft and Retaining Ring

(power end)
Housing (bearings -- Needle type)
120
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Service Manual
1997-10-27
F-code
Section
PS
S4.0
4130
Torque Generator
Version no
T-code
001
OE35
C-code
24. Lubricate and install the quad seal in the groove

located in the power end housing.
25. After installing, make sure the quad seal is not twisted
and is firmly seated in its groove.
26. With the quad seal installed, turn the power end
housing over and support it in an upright position
(surface with seven mounting holes up). Lubricate and
install the first washer by aligning the bump on the
washer with the matching recess in the power end
housing.
27. Lubricate and install the second washer in the power
end housing.
NOTE! Careful reassemble will prevent shaft seal
damage when pushing the power end shaft
into place.
28. Lubricate and install the power end shaft in the
housing.
29. Before engaging the power end housing assembly,
align the input and output shaft keyways and cross
holes. Spline on the drive and the spline in the power
end shaft should line up. With the power end assembly
installed, rotate housing to align cap screw holes.
30. Install the cap screws and torque in a criss-cross
sequence to 200 in-lb (23 N$m).
31. The torque generator is now ready for test and
installation.
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Service Manual
1997-10-27
121
F-code
Section
PS
S4.0
Torque Generator
Version no
T-code
001
OE35
122
Return
C-code
4130
Service Manual
1997-10-27
F-code
PS
Section
C-code
S4.0
4150
Steering System Pump
Version no
T-code
001
OE35
24 VOLT
36 VOLT
BT Products
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Service Manual
1997-10-29
123
F-code
Section
C-code
PS
S4.0
4150
Version no
T-code
001
OE35
POS.
NO
DESCRIPTION
POS.
NO
DESCRIPTION
POS.
NO
DESCRIPTION
Pump and motor
Gasket
13
Pump assembly
Motor
Pump, steering
14
Kit, coupler
Lockwasher
Pump and motor
15
Gasket
Screw, cap
10
Motor
16
Pump assembly
Pump assembly
11
Lockwasher
17
Coil
Kit, coupler
12
Screw, cap
A duplex pump powered by a single motor is used for the
power steering and the brake release. The upper pump is for
the power steering and the lower pump is for the brake
release. Each pump has a pressure relief valve. In addition,
the lower pump has a normally open hydraulic solenoid valve
to allow brake release pressure to bleed off so the brakes will
apply.
2. Removal
1. Drain hydraulic fluid from reservoir. The truck
hydraulics may be used to pump the fluid out of the
reservoir.
3. Remove electrical wires from solenoid mounted on
pump body.
4. Remove hoses from pump.
5. Remove four bolts that mount the pump onto the
motor and lower the pump to separate it from
motor. Be careful to not lose the spider coupling.
124
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1997-10-29
F-code
PS
Section
C-code
S4.0
4150
Version no
T-code
001
OE35
NOTE! Access to the rear most pump mounting bolt

is difficult. This can be made easier by
disconnecting the motor electrical cables,
removing four motor-to-frame mounting bolts
and removing the pump and motor from the
truck as an assembly. The pump can now be
removed from the motor by removing four
mounting bolts.
3. Installation
1. Put spider coupling onto pump input shaft.
2. Put pump onto motor so that spider coupling
engages motor coupling.
3. Install four bolts to hold pump onto motor.
If the motor was loosened or removed from truck,
reinstall and tighten motor mounting bolts.
4. Connect hoses to pump.
5. Connect wires to solenoid coil.
6. Fill hydraulic reservoir with proper oil.
7. Attach pressure gauges to steering and brake
hoses.
8. Energize pump motor and set pressure relief
valves.
The brake pressure relief setting is made by
disconnecting the hose from the brake cylinder and
deadheading it directly into a gauge.
The steering pressure relief may be measured at
the quick disconnect tap between the pump and
the torque generator, it is necessary to block
transmission from turning before the steering stops
hit at the steering wheel shaft.
9. Install the caps over the relief valve adjusting
screws.
BT Products
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Service Manual
1997-10-29
125
F-code
Section
C-code
PS
S4.0
4150
Version no
T-code
001
OE35
POS.
NO
126
Return
DESCRIPTION
POS.
NO
DESCRIPTION
POS.
NO
DESCRIPTION
Shaft, drive
11
Gear
21
O ring
Key
12
Gasket
22
O ring
Pin
13
Housing, gear
23
Ring, backup
Ring, retainer
14
Plug
24
Plug
Gear
15
Housing, end gear
25
Pin
Cap, hex
16
Screw, cap
26
Shaft, idler
Gasket, copper
17
Valve, solenoid
27
Stator
Screw, adjustment
18
Coil
28
Seal, oil
Spring
19
Valve
10
Spring, ball
20
Kit, seal
Service Manual
1997-10-29
F-code
PS
Section
C-code
S4.0
4150
Version no
T-code
001
OE35
4. Disassembly
assembly.
1. Remove solenoid valve coil from solenoid valve.
2. Remove solenoid valve from pump body.
3. Remove coupling half from input shaft.
4. Remove relief valve caps, adjusting screws,
springs, and balls from upper and lower pump
bodies.
5. Scribe match marks on side of pump bodies to
assure proper alignment during reassembly.
6. Remove eight bolts that hold pump housings
together.
7. Separate end body from intermediate body.
8. Remove lower pump gears and pins (keys) from
shafts.
9. Remove intermediate body from front housing.
The driven shaft and gear may come out with
intermediate body.
10. Remove retaining ring, drive gear, woodruff key,
and second retaining ring from drive shaft.
11. Remove drive shaft from front housing by pulling it
out the front side of the housing.
12. Remove seal from front housing.
13. Clean all pump parts in safety solvent and dry with
compressed air.
BT Products
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1997-10-29
127
F-code
Section
C-code
PS
S4.0
4150
Version no
T-code
001
OE35

be reduced to less than 30 p.s.i., and then
personal protective equipment.
5. Inspection
1. Parts must be kept clean and dry for inspection.
2. Inspect gears, pump bodies, and shafts for
excessive wear.
There should be no wear, scratches, or grooves
greater than 0.005 in.
Clearance between shafts and bushings should not
exceed 0.0005 in.
3. If excessive wear is indicated, pump replacement
is in order.
6. Assembly
CAUTION
Assemble pump only in a clean work

area. Any amount of dirt or contamination
will cause excessive wear and premature
failure in the hydraulic system.
1. Install drive shaft through front side of front

housing.
2. On drive shaft, install one retaining ring, woodruff
key, drive gear, and second retaining ring.
3. Install driven shaft with gear into front housing so
that gears mesh.
4. Place gasket on mating surface of front housing,
install intermediate body onto front housing. Insure
that dowel pins are in place and match marks line
up.
5. Install keys and gears for lower pump onto shafts.
128
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PS
Section
C-code
S4.0
4150
Version no
T-code
001
OE35
6. Place gasket between mating surfaces and install

end body to intermediate body.
7. Tighten eight bolts holding pump together to 10 ftlb +/- 0.5 ft-lb.
8. Install relief valve balls, springs, and screws. Do
not tighten down caps until relief pressures have
been checked and adjusted.
9. Install shaft seal in front housing. Outer face of seal
should be recessed 0.5 in. from front edge of bore.
10. Install coupling half on front of input shaft.
11. Install solenoid valve and coil in end body.
BT Products
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1997-10-29
129
F-code
Section
C-code
PS
S4.0
4150
Version no
T-code
001
OE35
130
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Service Manual
1997-10-29
F-code
Section
PS
S4.0
4170
Steering System
Version no
T-code
001
OE35
C-code
Steering System
The steering is cable and chain operated and power assisted
through the use of a hydraulic torque generator. Because of
the complexity of the steering linkage, if any adjustments are
required, the entire adjusting procedure must be followed.
1. Adjust transmission steering ring guide rollers
snug, but not tight, against the guide ring (+0.0156
in. ; -0.0 in.).
Guide rollers are mounted on eccentric pins.
Loosen bolts and turn cam on eccentric. Be sure to
tighten nuts and bolts.
2. Adjust steering chain around transmission and
bottom sprocket of torque generator.
Loosen two 3/8 in. NC bolts that lock chain ends to
transmission case. Turn adjusting turnbuckle to
tighten chain so that it has 1/8 in. to 1/4 in. of slack
on one side. Tighten locking bolts.
3. Adjust upper chain around torque generator and
jackshaft.
Jackshaft mounting bracket is on a pivot. Loosen
locknuts on stud and pivot mounting bracket to
adjust chain for 1/8 in. to 1/4 in. of slack on one
side. Tighten lock nuts.
4. Adjust steering cable in mast.
Raise platform and block securely so that cable
tension springs and turn buckles are visible. Both
turn buckles must be adjusted an equal amount so
that the steering remains centered.
Adjust turn buckles so that tension springs are
collapsed all but one full coil.
BT Products
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Service Manual
1997-10-29
131
F-code
Section
C-code
PS
S4.0
Steering System
4170
Version no
T-code
001
OE35
132
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Service Manual
1997-10-29
F-code
Section
C-code
PS
S5.0
5000
Electrical System with TX and TT Card
Version no
T-code
001
OE35
Electrical System with TX and TT

Card
1. Electrical Schematic Part 1
NOTE! Items represented with dashed lines are
options that may not be present on all
models.
See Electrical Schematic Part 2 for further information.
BT Products
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Service Manual
1997-10-23
133
F-code
Section
C-code
PS
S5.0
5000
Version noT-code
001
OE35

134
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1997-10-23
F-code
Section
C-code
PS
S5.0
5000
Version no
T-code
001
OE35
3. Basics Of Circuit Operation

The control circuit is energized by closing the key switch,
pushing start button, closing foot pedal switch (which closes
brake interlock switch), and rotating direction control to either
forward or rearward direction. Rotating the direction controls
closes forward and rearward direction switches and positions
the accelerator potentiometer which controls the speed of the
truck. This applies electrical power to the control card turning
on the card internal PMT driver, which will close the selected
directional contactor and complete the circuits to the drive
motor.
The control card then supplies a gate pulse to 2REC turning it
on to a conducting state, allowing current to flow from the
battery through 1C, 1X, 2REC, motor field, motor armature,
sensor, and back to the battery. After 1C charges, 2REC
shuts off due to lack of holding current. The control card
checks that 1C is charged and unlocks the gate to 1REC and
5REC.
The control card then supplies a gate pulse to 1REC turning it
on to a conducting state, allowing current to flow from the
battery through 1REC, motor field, motor armature, sensor,
and back to the battery. 5 REC turns on and allows current to
flow T4-T3, 1C, 1REC, 5 REC to T4-T3. This current charges
the bottom of 1C positive with respect to the battery positive
bus. This charging cycle occurs in less than 1 millisecond
(.001 sec.) and 5 REC shuts off. This charge is now stored on
the capacitor until it is time to turn off 1REC.
Current continues to flow in 1REC until the control card fires
2REC. When 2REC conducts, capacitor 1C discharges
around the circuit composed of 1C, 1X, 2REC, and 1REC.
This discharge current opposes the battery current through
1REC so that the resultant current is zero. With reverse
voltage across 1REC, 1REC is turned off. Current continues
to flow in the 2REC, 1C, motor and battery loop until the
capacitor (card terminal 14) is fully charged negative. This
charge exceeds battery voltage by an amount which is a
function of peak motor current, and 2REC turns off. The
illustrates below shows the pulsing of current from the
battery.
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Dash Line Shows Average Motor Current
During the off time, the energy stored in the motor, by virtue
of the motors inductance, will cause current to circulate
through the motor around the loop formed by 3REC. Thus,
providing what is called flyback current. The illustrate above
shows the nature of the motor current which is composed of
both battery current and the inductive flyback current. It
should be noted that the average motor current measured will
be greater than the average battery current. The SCR control,
in effect, converts battery current at battery volts into a higher
motor current and a lower motor volts.
The time for the next ON and OFF cycle to start is determined
by the time that the control card takes to oscillate. This
frequency of oscillation is controlled by the potentiometer in
the accelerator and automatic circuitry in the card. Slow
speed is obtained by having maximum ohms in the
potentiometer. As the resistance in the potentiometer
decreases, the speed of the motor increases. The SCR circuit
is capable of delivering approximately 95% speed. For full
speed operation, the 1A contactor is closed to apply full
battery voltage across the motor.
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4. Control Features
4.1. Oscillator
The oscillator section of the card has two adjustable features

and one fixed feature. With the accelerator potentiometer at
maximum ohms, the creep speed can be adjusted by the
handset unit. Top speed is fixed by card and is obtained with
the accelerator potentiometer at minimum ohms. The % ON
time has a range of approximately 5 to 95 percent. The center
operating condition of the oscillator is at 50 percent ON time
with a nominal 1.8 milliseconds ON time and 1.8 millisecond
OFF time. This corresponds to a maximum operating
frequency of about 300 hertz. At creep the ON time will
decrease to approximately 0.8 milliseconds while OFF time
will become in the order of 20 milliseconds. At full SCR
operation, this condition will be reversed (short OFF time,
long ON time). This variation of ON and OFF time of the
oscillator produces the optimum frequencies through the SCR
range. The frequency curve of the oscillator is shown above.
The rate at which the oscillator may increase its percent ON
time is limited by Controlled Acceleration. The minimum
time required to go from creep speed to 80-85% on time point
may be varied by function 3, adjustable from approximately
0.1 seconds to 22.0 seconds.
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4.2. Current Limit

This circuit monitors motor current by utilizing a sensor in
series with the armature. The information detected across the
sensor is fed back to the card so current may be limited to a
pre-set value. If heavy load currents are detected, this circuit
overrides the oscillator and limits the average current to a
value set by function 4 of the handset. The C/L setting is
based on the maximum thermal rating of 1REC and the peak
voltage on the capacitor. Because of the flyback current
through 3REC, the motor current usually runs 2 to 3 times
battery current. See current limit curves for available current
and adjustment range.
4.3. Plugging
Slow down is accomplished when reversing by providing a
small amount of retarding torque for deceleration. If the
vehicle is moving and the directional lever is moved from one
direction to the other, the motor field is reversed. The plug
signal is initiated by the fact that the directional switch has
moved from one direction to the other. The motor armature,
driven by the inertia of the vehicle, acts as generator. This
generated current passes through 4REC and the sensor. The
oscillator circuit regulates at a plug current limit level as set by
the handset. This controls the pulse rate of 1REC to regulate
the generated motor current and bring the truck to a smooth
stop and reversal. With the accelerator potentiometer is at
minimum resistance, function 5 will enable adjustment of
plugging current from max to min current level for plug current
limit.
4.4. Pedal Position Plug

This feature will allow for plugging distance based on pedal
position. Pedal position will reduce the plugging current to the
current value set by this function as the accelerator is
returned to the creep speed position. Maximum plug current
is obtained with the accelerator in the top speed position. This
feature is adjustable by using function 16 on the handset.
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4.5. Ramp Start

This feature provides full SCR torque to restart a vehicle on
an incline. The memory for this function is the directional
switch. When stopping on an incline, the directional switch
must be left in its original or neutral position to allow the
control to assure full power when restarted.
4.6. Full Power Transition

This built-in feature provides smooth transition from SCR to
1A bypass. This is accomplished by the SCR continuing to
pulse until the 1A contactor power tips close.
4.7. Control Acceleration and 1A Time

This feature allows for adjustment of the rate of time it takes
for the control to accelerate to 96% applied battery voltage to
the motor on hard acceleration. The 1A contactor will
automatically close. Two seconds after the controlled
acceleration stops and the accelerator input is less than .5
volts or less than 50 ohms. C/A is adjusted by function 3 from
.1 to 22 seconds.
4.8. 1A Current Drop Out

This adjustable feature can be set to open the 1A contactor if
the traction motor is subject to excessive currents. The
dropout is adjustable with function 6 of the handset. Once the
control has dropped out the 1A contactor due to excess
current, the directional or accelerator switch must be returned
to neutral to unlock the dropout circuit to allow the control to
pick up the 1A contactor again. Using this feature will reduce
the 1A contactor tip life, thus it should be used only where
needed to protect the motor.
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4.9. Static Return to OFF

This built-in feature of the control is set up to make the driver
return the directional lever to neutral anytime he leaves the
vehicle and returns. If the foot pedal switch or key switch is
opened, the control will shut off and cannot be restarted until
directional lever is returned to neutral. A time delay of
approximately 1.5 seconds is built into the foot pedal switch
input to allow momentary opening of the foot pedal switch if a
bump is encountered.
4.10. Accelerator Volts Hold-OFF

This feature checks the voltage level at the accelerator input
whenever the key switch or foot pedal switch is activated. If
the voltage is less than 2.5 volts the control will not start. This
is to assure that the control is calling for low speed operation
at start-up.
4.11. Coil Driver Module

These drivers are internal to the logic card. They are the
power devices that operate forward, rearward, 1A, and power
steering contactor coils. These drivers open or close these
coils on command from the logic card. All modules are
equipped with reverse battery protection in that if the battery
is connected incorrectly, none of the contactors controlled
can be closed electrically.
4.12. 1A Thermal Hold-OFF

This feature prevents the 1A contactor from closing when the
truck is in severe thermal cutback to avoid torque jumps.
When the control goes into severe cutback, the must pulse to
time will inhibit the 1A timer.
4.13. Must Pulse to Time

This feature prevents the 1A timer from timing if the
oscillation pulse rate has not reached a particular level of
operation.
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4.14. Pulse Monitor Trip (PMT)

This feature contains three features which shuts down or
locks out control operation if fault conditions exist that would
allow uncontrolled (run away) speed of the vehicle:
Look ahead
Look again
Automatic look again and reset
The PMT circuit will not allow the control to start under the
following conditions:
1. If 1REC is shorted or if 1A contactor is welded, the
control will not allow the forward or rearward
contactor to close.
2. Will not allow the control to operate if forward and
rearward internal coil drivers are shorted or if 3
REC diode is shorted.
The PMT circuit will shut down operation of the control
(opening of the forward or rearward contactor) under the
following conditions:
If 1REC fails to commutate (shut off), or if 1A power tips
remain closed when they should be open. After opening the
forward or rearward contactor the PMT circuit will check for a
fault and if none is found will reclose the directional contactor.
If the fault still exists, the directional contactor will open and
remain open.
If 1A closes before a second commutation failure, the look
again counter will automatically reset. This eliminates the
inconvenience of resetting the PMT with the key switch if the
trip is due to random noise.
When the PMT circuit prevents forward or contactors from
closing, the PMT circuit can be reset only by opening the key
switch.
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4.15. Thermal Protector - (TP)

This temperature sensitive device is mounted on the 1REC
heat sink. If the 1REC temperature begins to exceed the
design limits, the thermal protector will lower the maximum
current limit and not allow 1REC to exceed its temperature
limits. Even at a reduced current limit, the vehicle will
normally be able to reach sufficient speed for full 1A
operation, thereby allowing the panel to cool. As the panel
cools, the thermal protector will automatically return the
control to full power.
4.16. Low Voltage

Batteries under load, particularly if undersized or more than
80 percent discharged, will produce low voltages at the SCR
control terminals. The EV-100 control is designed for use
down to 50 percent of a nominal battery volts of 36-84 V, and
75 percent of a nominal battery volts of 24 V. Lower battery
volts may cause the control to not operate correctly; however,
the PMT should open the forward or rearward contactor in the
event of a commutation failure.
4.17. Top Speed (Motor volts) Limit

This feature provides a means to limit motor volts to three
adjustable limits by limit switch opening between input points
on the control card and negative. The lower motor volt limit
always takes priority when more than one switch input is
closed. This motor volt limit effects top speed of the SCR, but
actual truck speed will vary at any set point depending on the
loading of the vehicle. Each speed limit is adjustable by the
handset, function 11, 12, and 13, for speed limits 1, 2, and 3.
4.18. Steer Pump Contactor Time Delay

This function provides a 0.5 to 63 second time delayed drop
out of the power steering contactor when the foot pedal
switch is opened.
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4.19. Constant Current Coil Drivers and

Internal Coil Suppression
This feature allows the use of 24 volt contactor coils on
through the entire voltage range of the EV100 (24 volts to 84
volts) for the forward, rearward, 1A, power steering, and
contactors.
This feature also allows the above contactors to operate
cooler due to less current being applied to the coil after pickup.
4.20. Hourmeter Readings

This feature will display the recorded hours of use of the
traction control and pump control to the dash display each
time the key switch is turned off.
4.21. Internal Resistance Compensation

This feature is used when the Battery Discharge Indicator is
present. Adjustment of this function will improve the accuracy
of the BDI. This is adjustable by function 14.
4.22. Stored Status Code

This feature furnishes a function register (function 1) that
contains the last fault that shut down vehicle operation (PMT
type fault that is reset by cycling the key switch). This status
code will be over written each time a new status code occurs
and can be cleared from memory by adjusting the value to
zero.
4.23. On-board Diagnostics

The logic card detects the systems current operating status
which can be displayed to either the Dash Display or the
Handset. There are currently over 75 status codes that are
available with systems. The logic card is capable of reducing
the current to the control to alert the operator of a critical fault
condition.
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4.24. Battery Discharge Indication

This feature uses the latest in microprocessor technology to
provide accurate battery state of charge information and
supplies passive and active warning signals to the vehicle
operator.
Features and functions:
Displays 100 to 0 percent charge
Display blinks at 20% charge
Disables pump circuit with 10T charge
Auto ranging for 36/48 volt operation
Adjustable for use on 24 to 80 volts
4.25. Handset
This is a multi-functional tool to be used with the EV100 LX
and LXT SCR controls. The Handset consist of a Light
Emitting Diode (LED) display and a keyboard for data entry.
Features and functions:
Monitor existing system status code for traction
Monitor intermittent random status code
Monitor battery state of charge on LXT systems
Monitor hourmeter readings on traction SCR
systems
Monitor or adjust the control function
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5. General Maintenance Instructions

The SCR control, like all electrical apparatus, does have
some thermal losses. The semiconductor junctions have finite
temperature limits above which these devices may be
damaged. For these reasons, normal maintenance should
guard against any action which will expose the components
to excessive heat, such as steam cleaning; or which will
reduce heat dissipating ability of the control, such as
restricting air flow.
The following DOS and DONTS should be observed:
Any controls that will be used in ambients of 100F
(40C) or over should be brought to the attention of
the truck manufacturer.
All external components having inductive coils
must be filtered. Refer to vehicle manufacturer for
specifications.
The control should not be steam cleaned. In dusty
areas, use low-pressure air to blow off the control.
In oily or greasy areas, a mild solution of detergent
or denatured alcohol can be used to wash off the
control and then blow completely dry with lowpressure air. The control can also be cleaned with
Freon TF degreaser.
For the SCR panel to be most effective, it must be
mounted against the frame of the truck. The truck
frame, acting as an additional heat sink, will give
improved truck performance by keeping the SCR
control package cooler. The use of a heat-transfer
grease (Dow Corning 340) is recommended.
Terminal boards and other exposed SCR control
parts should be kept free of dirt and paint that
might change the effective resistance between
points.
CAUTION
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The truck should not be plugged when

the truck is jacked up and the drive
wheels are in a free wheeling position.
The higher motor speeds can create
excessive voltages that can be harmful
to the control.
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Do not hipot (or merger) the control. Unless the

terminals of each semiconductor and card are
connected together, the control may be damaged.
Refer to control manufacturer before hipotting.
Use a lead-acid battery with the voltage and
ampere hour rating specified for the vehicle. Follow
normal
battery
maintenance
procedures,
recharging before 80 percent discharged and with
periodic equalizing charges.
6. Trouble-shooting Instructions
Trouble-shooting the EV100 LX/LXT control should be quick
and easy by following the instructions outlined in the following
status code instruction sheets.
If mis-operation of the vehicle occurs, a status code will be
displayed on the Dash Display for vehicle equipped with a
Dash Display or by plugging a Handset into the logic cards
plug Y location and then reading the status code.
With the status code number, follow the procedures outlined
in the status code instruction sheets to determine the
problem.
Checking and replacement of components are also outlined
in sections of this instruction book. Please refer to these
sections as needed.
NOTE! Due to the interaction of the logic card with
all vehicle functions, almost any status code
or control fault could be caused by the logic
card. After all other status code procedures
have been followed and no problem is found,
the logic card should then be replaced as the
last option to correct the problem.
The same device designations have been maintained on
different controls but the wire numbers may vary. Refer to the
elementary and wiring diagrams for your specific control. The
wire numbers shown on the elementary diagram will have
identical numbers on the corresponding wiring diagrams for a
specific truck, but these numbers may be different from the
numbers referenced in this publication.
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WARNING Before trouble-shooting, jack up wheels,

disconnect the battery, and discharge
capacitor 1C. Reconnect the battery as
needed for the specific check.
If capacitor 1C terminals are not accessible, discharge
capacitor by connecting from SCR POS terminal to 2 REC
anode. Check resistance on Rx1000 scale from frame to SCR
power and control terminals. A resistance of less than 20,000
ohms can cause misleading symptoms. Resistance less than
1000 ohms should be corrected first.
Before proceeding, visually check for loose wiring, misaligned
linkage to the accelerator switch, signs of overheating of
components, etc.
Tools and test equipment required are: (a) 6-volt lamp, 6-volt
battery, two A14 diodes (1 Amp 400 volts), clip leads, voltohm meter (20,000 ohms per volt) and general hand tools.
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Battery Controller / Hourmeter /

Lift Interrupt
This instrument consists of a single, quartz hourmeter (H), a
10 bar multicolored battery discharge controller (BC), and a
lockout relay. The lift lockout relay is operated so that if there
is a current passing through the relay contacts when the
instrument registers empty battery the contacts stay closed
until the current ceases. There will be no lockout of the lift
during the lift operation. The hourmeter features a liquid
crystal display (LCD) which has six segment digits with a
decimal point before the last digit. This provides resolution of
0.1 hours or 6 minutes.
Battery Display LED
2 Red, 3 Yellow, 5 Green
Hourmeter LCD
2. Electrical
2.1. Voltage
This instrument is supplied as a pin selectable dual voltage
unit with the voltage of 12/48 VDC.
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2.1.1. The Contact Voltage and Current Ratings for

Switching Resistive Loads.
Open Contact Voltage
200
VDC
Max
Closed Contact Current
ADC
Max
Volt Ampere Product
50
Max
2.1.2. Memory Retention

The instrument contains an internal battery (BC) which allows
memory retention when external power is removed. Typical
battery life is 10 years. The hourmeter has a solid state, nonvolatile memory which does not require battery backup.
3. Battery Controller (BC)

3.1. General Information
The BC measures the state of the battery. The charge is
indicated on a column of ten LEDs.
Right: 1 - fully charged battery
Left:
0 - empty battery
When the battery is fully charged the LED to the right will be
illuminated. As the battery discharges LEDs to the right will
stop glowing and show the current discharge level. When the
battery is 70 percent discharged the two LEDs from the left
will flash alternately to warn the driver that he should
recharge the battery. When the battery is 80 percent
discharged the last LED is lit, and the relay is opened.
3.1.1. Discharge Adjustment
The BC features an adjustable discharge setting. The setting
designators K-U are at the rear of the gauge. The initial
factory setting is N but will depend on the battery and
machine type.
The given settings are approximate and might need to be fine
tuned to get a 100 percent correct lockout for a specific
application.
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Battery Ah
180
210
240
L-M
M-N
N-O
L-M means that you adjust on the line between L and M.

N-O means that you adjust on the line between N and O.
An hydrometer can be used for precise adjustment. When the
bottom two LEDs are flashing on and off the specific gravity of
the battery electrolyte should not be lower than 1.14. If they
start to flash at higher specific gravity the discharge U
potentiometer should be turned counterclockwise (towards
K). If the two LEDs start to flash at a specific gravity below
1.14 turn the potentiometer clockwise (towards P).
The letter designations for the voltage per cell (VPC)
multipliers at empty battery are specified as tabulated below
.
SETTING
VPC
SETTING
VPC
1.57
1.82
1.63
1.84
1.68
1.86
1.73
1.91
1.78
1.93
O
P
Q
R
S
K
DISCHARGE T
N
M
L
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PIN NO:
FUNCTION
Hourmeter (-)
Key switch (+)
Relay arm (+)
Relay NC (-)
Battery (-)
Hourmeter (+)
24 Volt (+)
48 Volt (+)
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NOTE! The discharge adjustments can be made at any

time during a working cycle before lift lockout.
However, discharge potentiometer adjustments
made late in a working cycle have little or no
effect in delaying the lift lockout in that particular
working cycle. Normally discharge potentiometer.
Adjustments are made before or at the beginning
of a working cycle to effectively change the
discharged profile of that working cycle. Once lift
lockout does occur, the gauge must be reset
before discharge potentiometer. adjustments can
have an effect.
3.2. Reset
The instrument is supplied with a fixed reset voltage setting.
This factory-set reset voltage brings the BC to full regardless
of its previous level. The reset will be done when the battery
has been charged and connected to the machine.
3.3. Key Switch

The electronics of the BC and the LCD of the hourmeter are
energized as long as the machine battery remains connected
to the gauge. The display of the BC is turned on and off by
the key switch.
12 Volt and 300 AMP Controllers
The key switch also enables timing function of the hourmeter.
With the key switch ON, the hourmeter can be activated by
the connection number 6 at the rear of the BC. With the key
switch OFF, the hourmeter will not respond to the connection
number 6, and the LCD of the hourmeter will be off.
400 AMP Controllers
The drive transistor controller enables the timing function of
the hourmeter, whenever there is current going to the drive
motor. Also, the timing function is enabled whenever S52
raise switch is closed.
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3.4. Hourmeter
Hourmeter operation is indicated by flashing of the hourglass
icon on face of LCD. The flash rate is 15 times a minute with
a duty cycle of 3 seconds on and 1 second off. When
hourmeter is not in operation the icon is visible but does not
flash.
4. Troubleshooting
This section is separated into two parts: Battery Discharge
Indicator and Hourmeter.
4.1. Battery Discharge Indicator (BDI)

4.1.1. No Reset
There are two ways to reset the instrument.
Using the open circuit reset the instrument must first have a
break in the power and then measure a voltage greater than
2.09 volts per cell across its pin 7 or 8 and pin 5. Verify that a
leakage voltage is not present across these terminals by
disconnecting one of the lines supplying battery voltage to the
instrument. Replace this connection and measure the voltage
across the gauge at its pin 7 or 8 and pin 5. It must be above
2.09 volts per cell. If it is, and the gauge does not reset to
indicate full charge, the instrument is defective.
The second method of resetting the instrument is by using the
high voltage reset. This reset function also has two
requirements to reset the instrument. The voltage across pin
7 or 8 and pin 5 must be above 2.35 volts per cell and must
remain above this level for six minutes continuously. Measure
the voltage across these pins and verify that it is greater than
2.35 volts per cell. Also, verify that it remains above this level
for a minimum of six minutes. If these two conditions are met,
and the instrument does not reset, it is defective.
4.1.2. Reset After Break in Power
If the voltage of the batteries to which the instrument is
connected is below 2.09 volts per cell, and the gauge was not
formerly indicating full, it should not reset to full after a break
in power. If it does its memory cell is depleted. This will not
affect the discharge function of the instrument if it is always
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connected to a fully charged battery and allowed to track its

discharge without break in power.
NOTE! New instruments are shipped from the factory
with a full reading in their memory. The first
time the instrument is connected to the
trucks battery it will always show a full
charge. It is either resetting to full because
the battery is fully charged or if the battery is
not fully charged it is repeating the
information in its memory which is a full
reading (typical 10 year battery life).
4.1.3. No Discharge, Gauge Does Not Run Down
The instrument monitors loaded battery values. When
connected to a partially discharged battery the gauge will not
run down until it observes that the loaded values of the
battery are at or below gauge current state. A working time of
at least 30 minutes is required for the gauge to run from full to
empty.
To verify that the instrument will run down, measure across
pin 7 or 8 and pin 5. A voltage less than 2.0 volts per cell is
required to bring the gauge indication downwards from a full
reading.
4.1.4. No Lockout
The LED display must be alternately flashing the two leftmost red LEDs for lockout to occur.
The J output functions like an SCR. At lockout, pins 3 and 4
will open as long as lift is inactive.
To test this output:
1. Remove the wire leading to pin 3 when at lockout.
2. Replace the wire, and then try to lift. If the lift ceases to
operate the instrument is good, but there is a leakage
current somewhere in the lift circuit.
3. Check across the lift switch. After replacing the wire, if
the lift operates, the instrument is defective.
4.1.5. No Lift
First, verify that the gauge is not at lockout with its two red
LEDs alternately flashing. The relay outputs should be closed
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C-code
PS
S5.3
5230
Version no
T-code
001
above lockout and should read zero ohms with an ohmmeter

across pins 3 and 4. If not at lockout test the lift switch and
contactor.
4.1.6. Early Lockout
It is very important that the instrument is installed so that its
pins are reading the true battery voltage. Any voltage drops
caused by long lines, switches, fuses, or poor connections
will be seen by the instrument as a deeper discharged
battery.
1. To check for voltage drops use a voltmeter with its
positive lead on the batterys positive terminal and the
meters negative lead on pin 7 or 8 (whichever pin B+
is connected to). Load the battery and record this
measurement.
2. Repeat this procedure with the voltmeters positive
lead on pin 5 and its negative lead on the batterys
negative terminal, and record the voltage measured.
3. Add the two voltage readings. This total should be less
than 1 percent of the nominal battery voltage. Voltage
higher than this will cause the instrument to calculate
battery state-of-charge from incorrect readings.
4.1.7. LEDs Do Not Light
The battery discharge indicator LEDs are illuminated by the
keyswitch, pin 2.
Verify that battery voltage is present across pin 2 and pin 5. If
voltage is present and the LEDs do not light, the instrument is
defective.
4.2. Hourmeter
4.2.1. No Display
The LCD of the hourmeter will illuminate when power is
applied at pin 7 or 8 and pin 5. If battery voltage is measured
across these pins and the LCD does not turn on, the
instrument is defective.
4.2.2. Hourmeter Glass Icon Does Not Flash
If the icon does not flash, the hourmeter is not accumulating
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C-code
PS
S5.3
5230
Version no
T-code
001
time. The key switch pin 2 must be on at B+, pin 7 or 8 must

be connected to B+, and one or both of the hourmeter lines
must be active. If the key switch is on, one or both inputs are
correct, and the hourmeter icon does not flash, the instrument
is defective.
4.2.3. Hourmeter Glass Icon Always Flashes
When the icon is flashing, the hourmeter is accumulating
time. Turn the trucks key switch off. This should remove
voltage from pin 2 of the instrument. Should voltage be
present at pin 2 and the hourmeters icon continues to flash,
the instrument is defective.
156
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F-code
Section
PS
S5.3
5230
Dash Display
Version no
T-code
001
OE35
C-code
Dash Display
DASH DISPLAY
The dash display is a four segment light emitting diode (LED)
display that displays the status codes, hourmeter readings,
and battery discharge indication from the controller.
Connections are made to the dash display by means of five
22 gauge wires to plug Y of each SCR control. In some
cases, shielded cable must be required to eliminate signal
interference.
PY2
PY4
PY1
PY3
1
Back View of display

5
PY3
PY5
PY1
PY4
PY2
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157
F-code
Section
C-code
PS
S5.3
Dash Display
5230
Version no
T-code
001
OE35
2. Location
The dash display is physically located on the cross member
on the mast upright. The display is viewed through windshield
when platform is in the fully lowered position.
3. Operational Checks
3.1. Checking Hourmeter
1. Turn on the key switch.
2. Push start switch button and hold in.
3. The display is hourmeter LED reading.
3.2. Checking Battery Condition (BDI).

4. Turn on the key switch.
5. Push start switch button and do not hold in.
6. Depress foot brake pedal and hold down.
7. The display is percent of battery discharge.
8. The battery condition is displayed anytime unit is in
the operating mode.
3.3. Checking Status Code (wrench).

9. Turn on the Key switch.
10. Push start switch button and do not hold in.
11. The display is a status code for failure with unit.
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F-code
Section
PS
S5.3
5230
Dash Display
Version no
T-code
001
OE35
C-code
4. Status Codes
The following status codes are items that operator should
check.
Status Code -01

Indicates that brake foot switch is not closed. Make
sure the brake foot pedal is depressed.
Status Code -02

Indicates forward switch was closed before the key
switch or start switch or brake switch was closed.
With key switch on and start switch is pressed;
return directional switch to neutral then select
direction.
Status Code -03

Indicates rearward switch was closed before the
key switch or start switch or brake switch was
closed. With key switch on and start switch is
pressed; return directional switch to neutral then
select direction.
Status Code -04

Indicates forward or rearward switch was closed
before the key switch or start switch or brake
switch was closed. Status code will change to -03 if
rearward directional switch or -02 if forward
directional switch is closed.
Status Code -05

Indicates brake foot switch is not closed. Make
sure brake foot switch is closed.
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159
F-code
Section
C-code
PS
S5.3
Dash Display
5230
Version no
T-code
001
OE35
160
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1997-12-15
F-code
Section
C-code
PS
S5.7
5410
EV100 LX Control Status Codes
Version no
000
T-code
OE35
BT Products
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Service Manual
1997-10-22
161
F-code
Section
C-code
PS
S5.7
5410
Version no
T-code
000
OE35
DESCRIPTION
STATUS CODE
- BLANK DISPLAY
No display on Dash Display or Handset.
SYMPTOM
POSSIBLE CAUSE
* Insure that with key switch on, voltage is present between
PZ7 and PZ3 (NEG), and voltage is present between TB4
and PZ3 (NEG).
No
CIRCUIT
Traction
Key Switch
Display screen on dash display or handset is blank.

Positive or negative control volts missing.
MEMOR
RECALL
Control
Fuse
EM. DISC.
Button
Open circuit between logic card plug Y and Dash Display or

Handset.
* Check for open circuit or loose connections between each

wire going between logic card plug Y and Dash Display/
Handset.
Defective Dash Display/Handset.
TB4
P
Power
Fuse
CAP.
PZ7
* Replace Dash Display/Handset.
Figure 1.
STATUS INDICATION CRITERIA
This indicates a lack of input voltage to the logic
card and/or display unit.
DESCRIPTION
STATUS CODE
-01
No foot switch input.
MEMOR
RECALL
No
CIRCUIT
Traction
SYMPTOM
Forward or reverse contactor will not pick up.
Key Switch
Foot Switch
POSSIBLE CAUSE
Mis-adjusted or defective foot switch.
* Check foot switch to insure proper switch closure.

Open circuit between battery positive TB3.
* Check for loose connections or broken wire between:

positive side of the key switch and TB3.
EM. DISC.
Button
* Check for loose connections or broken wire between

negative side of key switch and positive side of foot
switch, negative side of foot switch and TB3, voltage at
TB3.
TB4
TB3
Figure 1.
This status code will be displayed when TB3 is
less than 50% battery volts.
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F-code
Section
C-code
PS
S5.7
5410
Version no
T-code
000
DESCRIPTION
STATUS CODE
-02
OE35
Forward directional switch is closed on initial power up.
SYMPTOM
No
CIRCUIT
Traction
Foot Sw. Gate Switches
Key Switch
Forward contactor will not pick up; static return off (SRO) lock out.
MEMOR
RECALL
POSSIBLE CAUSE
Forward directional switch closed on initial power up. Battery
plugged in, key switch and foot switch closed.
Chain Switch
EM. DISC.
* Return directional switch lever to neutral and then select a

direction.
Forward directional switch is welded closed or mis-adjusted to be
held closed.
Brake Switch
* Replace or adjust directional switch to insure that it opens

when directional switch is returned to neutral.
TB4
Short circuit between TB2 and TB5.
TB3
TB2
TB5
* Disconnect wire from TB5 and check for short circuit

between TB2 and wire.
Forward Switch
Defective card
Figure 1.
* Disconnect wire at TB5; measure voltage at TB5, should be

less than 60% of battery volts.

greater than 60% battery volts at initial power up.
STATUS CODE
DESCRIPTION
-03
Reverse directional switch is closed on initial power up.
MEMOR
RECALL
No
CIRCUIT
Traction
SYMPTOM
Reverse contactor will not pick up static return to off (SRO) lock
out.
Key Switch
POSSIBLE CAUSE
Reverse directional switch closed on initial power up. Battery
plugged in, key switch and foot switch closed.
EM. DISC.
Chain Switch
* Return directional switch lever to neutral and then select a

direction.
Reverse directional switch is welded closed or mis-aligned to be
held closed.
Brake Switch
* Replace or adjust directional switch to insure that it opens

when directional switch is returned to neutral.
TB4
Short circuit between TB2 and TB6.
TB3
TB2
TB5
* Disconnect wire from TB6 and check for short circuit

between TB2 and wire.
Forward Switch
Figure 1.
Defective card.
* Disconnect wire at TB6; measure voltage at TB6, should be

less than 60% of battery volts.
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greater than 60% battery volts at initial power up.
1997-10-22
163
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C-code
PS
S5.7
5410
Version no
T-code
000
OE35
DESCRIPTION
STATUS CODE
-04
Switch input low after initial start up.
SYMPTOM
Key Switch
Forward or reverse contactor will not pick-up.
MEMOR
RECALL
Yes
CIRCUIT
Traction
POSSIBLE CAUSE
Forward or reverse directional switch closed on initial start up.
* Close key and foot switch. Status code will change to 03 if

reverse directional switch or to 02 if forward directional
switch is closed. If either of these codes appear, return
directional switch to neutral and then select the desired
direction.
EM. DISC.
Chain Switch
Brake Switch
Excessive leakage from TB2 to battery negative.
* Check voltage at TB2 with key and foot switches closed

and directional switch in neutral. Voltage should be greater
than 60% of battery voltage.
TB4
TB3
TB2
TB5
* If less than 60% battery voltage; disconnect battery and

remove wire and measure resistance from wire to SCR
negative. Value should be less than 22K ohms.
Forward Switch
Figure 1.
This status code is displayed when TB2 voltage is
less than 60% of battery volts at initial start-up
(foot switch closure).
DESCRIPTION
STATUS CODE
-05
Brake switch fails to close.
MEMOR
RECALL
No
CIRCUIT
Traction
SYMPTOM
Key Switch Foot SW.
Gate Switches
POSSIBLE CAUSE
Defective brake switch circuit.
* Check brake switch to insure closure when foot pedal is

depressed.
Chain Switch
EM. DISC.
* Check for open circuit or loose connections in wiring from

foot switch to brake switch and from TB2 to brake switch.
Brake Switch
TB4
TB3 TB2
NEG.
ACCEL. POT.
Figure 1.
This status code is when TB1 is less than 2.5 volts
and TB2 is less than 60% battery volts.
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F-code
Section
C-code
PS
S5.7
5410
Version no
000
DESCRIPTION
STATUS CODE
-06
T-code
OE35
Accelerator operated with no direction selected.
MEMOR
RECALL
No
CIRCUIT
Traction
SYMPTOM
POSSIBLE CAUSE
Directional
Switch
FOR.
Defective directional switch
* Check forward or reverse switch to insure closure when

direction is selected.
REV.
TB5
TB6
Open circuit between directional switch(s) and battery positive or

between directional switch(s) and TB5 or TB6.
* Check all control wires and connections shown in diagram

below.
NEG.
Figure 1.
This status code will be displayed when TB5 and
TB6 are less than 60% of the battery volts, and
TB1 is less than 2.5 volts.
DESCRIPTION
STATUS CODE
-07
Accelerator input voltage too high.
MEMOR
RECALL
No
CIRCUIT
Traction
SYMPTOM
Forward or reverse contactor picks up but control will not operate,
when control is rotated on status code -07 is displayed then
disappears when the vehicle starts to accelerate.
POSSIBLE CAUSE
Accelerator input mis-adjusted or defective.
TB1
* Input voltage at TB1 should be less than 3.7 volts. Adjust or

replace accelerator unit to insure that the voltage at TB1
will vary from 3.5 volts to less than .5 volts when the pedal
is depressed.
Accelerator POT.
or
Voltage Supply
Open circuit between battery negative and TB1 in accelerator input

circuit.
* Check for broken wires or loose connections or open

potentiometer/voltage supply in the circuit shown in the
drawing below.
NEG.
Short circuit from battery positive to wiring in accelerator input

circuit.
* Disconnect wire from TB1 and measure voltage at wire to

negative. Should be zero volts for potentiometer type and
less than 3.7 volts for solid state type accelerator input.
BT Products
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Figure 1.
This status code will be displayed when the
accelerator input voltage at TB1 is higher than 3.7
volts, and a directional contactor is picked up.
1997-10-22
165
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C-code
PS
S5.7
5410
Version no
T-code
000
OE35
STATUS CODE
DESCRIPTION
-08
Accelerator input voltage too low on power up after initial

key switch closure.
MEMOR
RECALL
No
CIRCUIT
Traction
SYMPTOM
Forward or reverse contactor does not pick up.
POSSIBLE CAUSE
Accelerator input mis-adjusted or defective.
TB1
* Input voltage at TB1 should be more than 3.0 volts. Adjust

or replace accelerator unit to insure that the voltage at TB1
is more than 3.0 bolts before depressing pedal.
Accelerator POT.
or
Voltage Supply
Short circuit between battery negative and TB1 in accelerator input

circuit.
* Disconnect wire from TB1. Check for short circuit from wire
to battery negative. Resistance should be greater than 4.7K
ohms.
NEG.
Defective card
* Disconnect wire from TB1. Measure voltage from TB1 to

negative. Voltage should be greater than 4.5 volts, if not
replace card.
Figure 1.
This status code will be displayed when the
accelerator input voltage at TB1 is less than 3.0
volts, and any of the following connections are
opened and closed, battery plug, foot switch or
key switch.
STATUS CODE
DESCRIPTION
-09
Both forward and reverse directional switches are closed

at the same time.
MEMOR
RECALL
No
CIRCUIT
Traction
SYMPTOM
POSSIBLE CAUSE
Forward or reverse directional switch welded closed or misadjusted to be held closed.
FOR.
* Replace or adjust directional switches to insure that they

open when directional switch is returned to neutral.
Directional
Switch
REV.
TB5
TB6
Short circuit between battery positive and TB5 and/or TB6.
* Disconnect wires from TB5 and TB6 and check wires for
short circuit to positive side of directional switch.
Defective card.
* Disconnect wires and measure voltage at TB5 and TB6.

Voltage should be less than 60% of battery volts.
NEG.
Figure 1.
This status code will be displayed when TB5 and
TB6 are greater than 60% of battery volts at the
same time.
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F-code
Section
C-code
PS
S5.7
5410
Version no
000
DESCRIPTION
STATUS CODE
-15
T-code
OE35
Battery voltage too low.
MEMOR
RECALL
No
CIRCUIT
Traction
SYMPTOM
Battery
Connector
POSSIBLE CAUSE
Discharged battery
Table A
* Check battery for proper open circuit voltage as outlined in

the diagram right and charge battery if required.
Nominal
Battery
Volts
Battery
Defective battery
* Check each battery cell for proper voltage (greater than

1.95 volts at cell). Replace or repair battery.
Incorrect control card adjustment.
23.4
35.1
46.8
24
36
48
Battery
Connector
Minium
Limit
Volts
@1.95
* Check function 15 for proper adjustment for battery being

used. See handset instruction sheet for details. Adjust to
proper settings.
Figure 1.
This status code is displayed when the battery
volts are less than 1.95 volts per cell at initial start
up (see Table A in diagram below).
DESCRIPTION
STATUS CODE
-16
Battery volts too high
MEMOR
RECALL
No
CIRCUIT
Traction
SYMPTOM
Sensor
POSSIBLE CAUSE
Yellow
REC.
Incorrect control card adjustment

used. See handset instructions for details. Adjust to proper
setting.
PA4
Battery
Connector
Open circuit in regen sensor-circuit
Table A
* Check yellow wire from sensor #2 to PA4 for broken wire,

loose connections or broken weld at sensor. Check PA4 for
loose plug or pin connection.
Battery
Battery over charged or incorrect battery used.
* Check battery for proper open circuit voltage per Table A in

diagram right. If voltage excessive - check battery charger
for proper output voltage.
Battery
Connector
Nominal
Battery
Volts
24
36
48
Minium
Limit
Volts
@2.40
28.8
43.2
57.6
Figure 1.
This status code is displayed when the battery
volts are greater than 2.40 volts per cell at initial
start up (see Table A in figure).
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1997-10-22
167
F-code
Section
C-code
PS
S5.7
5410
Version no
T-code
000
OE35
DESCRIPTION
STATUS CODE
-17
Invalid card type selection
MEMOR
RECALL
No
CIRCUIT
Traction
SYMPTOM
Forward or reverse contactor will not close.
POSSIBLE CAUSE
Invalid card type selection
* Review function 17 in the Handset Instruction sheets.

Adjust and set card type value as instructed by OEM
service manual.
Defective battery
* Check each battery cell for proper voltage (greater than

1.95 volts at cell). Replace or repair battery.
Incorrect control card adjustment.

used. See handset instruction sheet for details. Adjust to
proper settings.
Figure 1.
This status code is displayed when the card type
selection value is set to an invalid number.
DESCRIPTION
STATUS CODE
-23
Forward or reverse contactor coil current low.
MEMOR
RECALL
No
CIRCUIT
Traction
SYMPTOM
Forward or reverse contactor will not pick up. Status code may
alternate between code 23 and code 24. Complete check for code
23, if the problem is not found, perform check for code 24.
+
F
POSSIBLE CAUSE
* Check for open circuit or loose connection between PB4
and positive side of F contactor coil and between PB5 and
positive side of R contactor coil.
* Disconnect battery and remove plug B. Check ohmic value
from PB4 to positive side of F coil. Value should be 10-14
ohms. Make same check for R coil.
Defective 1A or SP contactor coil.
* Disconnect battery and remove plug B. Check ohmic value

from positive side of each coil to its respective plug
connection. Value should be 10-14 ohms.
+
R
Defective F and R contactor coil circuit

PB4
SP
+
1A
PB5
PB6
PB3
Figure 1.
This status code is displayed when the current
draw in the forward or reverse contactor coil circuit
is less than 100 ma.
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F-code
Section
C-code
PS
S5.7
5410
Version no
T-code
000
OE35
STATUS CODE
DESCRIPTION
-24
T2 voltage too high. (Greater than 12% of battery volts).
SYMPTOM
MEMOR
RECALL
No
CIRCUIT
Traction
T2
SCR control does not operate. Status code may alternate between
code 23 and code 24. Complete checks for 24, if the problem is not
found, perform code 23 check.
POSSIBLE CAUSE
Field
Defective F or R contactor
* F or R power tips fail to close because:

1. Welded normally closed power tips.
2. Binding contactor tip assembly.
3. Defective F or R contactor coil. (See status code 23)
Open motor circuit
1A
SP
A1
A1
Armature
* Check for open circuit or loose connection in motor circuit

from the A1 connection to the A2 connection on the SCR
control panel.
A2
Defective 1A or SP contactor
Figure 1.
* Perform checks as outlined in status 23.

This status code is displayed when T2 volts is
greater than 12% of battery volts and the F and R
driver is energized.
DESCRIPTION
STATUS CODE
-25
1A contactor does not drop out or drops out slowly.
MEMOR
RECALL
Yes
CIRCUIT
Traction
SYMPTOM
Short tip life on F and R or 1A contactor. Status code 46 displayed

and no fault found.
POSSIBLE CAUSE
Note: This status code can only be found by using the handset and
looking at function 1. This status code is furnished as a
troubleshooting aid for status code 46.
1A
Defective 1A contactor
* Check 1A contactor for binding or slow operation when

dropping out.
T2
Figure 1.
This status code is displayed when 1A contactor
drop out time exceeds .060 seconds.
BT Products
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1997-10-22
169
F-code
Section
C-code
PS
S5.7
5410
Version no
T-code
000
OE35
DESCRIPTION
STATUS CODE
-26
Shorted coil driver for SP contactor
MEMOR
RECALL
Yes
CIRCUIT
Traction
SYMPTOM
SP contactor picks up immediately when key switch is closed.
POSSIBLE CAUSE
Defective coil driver internal to logic card
SP
* Replace logic card.
PB2
Figure 1.
This status code is displayed when there is a
shorted SP coil driver.
DESCRIPTION
STATUS CODE
-41
Open thermal protector or control over temperature.
MEMOR
RECALL
No
CIRCUIT
Traction
SYMPTOM
Reduced or no power to traction motor in SCR range.
POSSIBLE CAUSE
Open thermal protector circuit
* Check for loose connection or broken wire between:

Black wire - Thermal protector and PZ1
Gray wire - Thermal protector and PZ5.
Thermal
Protector
Gray
PZ1
Defective thermal protector.
* Disconnect wires from PZ1 and PZ5. At room temperature

(25C or 75F) measure resistance between black and gray
wire. Replace TP if ohmic value is greater than 300 ohms.
SCR is in thermal cut-back.
Black
PZ5
* Allow control to cool, status code should disappear.
Figure 1.
This status code is displayed when the voltage
between PZ1 and PZ5 is greater than 1.8 volts.
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F-code
Section
C-code
PS
S5.7
5410
Version no
T-code
000
DESCRIPTION
STATUS CODE
-42
SCR motor current sensor input missing.
OE35
MEMOR
RECALL
No
CIRCUIT
Traction
SYMPTOM
No power to traction motor in SCR range.
POSSIBLE CAUSE
A2
Open sensor wire circuit to PZ4.
* Check for loose connection or broken wire (green wire)

from current sensor to PZ4 on the logic card.
SCR
Current
Sensor
Green
PZ4
NEG.
Figure 1.
This status code is displayed when voltage
between PY7 and negative is greater than 1.6
volts with no current flowing in the motor circuit.
DESCRIPTION
STATUS CODE
-43
SCR motor current sensor input missing.
MEMOR
RECALL
No
CIRCUIT
Traction
SYMPTOM
Stall currents in SCR range higher than normal and uncontrollable
with C/L adjustment.
POSSIBLE CAUSE
A2
Open sensor wire circuit to PZ3.
* Check for loose connections or broken wire (yellow wire)

from current sensor to PZ3 on logic card.
SCR
Current
Sensor
Yellow
PZ3
NEG.
Figure 1.
This status code is displayed when voltage
between PY7 and negative is less than 0.84 volts
with no current flowing in motor circuit.
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1997-10-22
171
F-code
Section
C-code
PS
S5.7
5410
Version no
T-code
000
OE35
DESCRIPTION
STATUS CODE
-44
1REC did not turn off properly.
MEMOR
RECALL
Yes
CIRCUIT
Traction
SYMPTOM
Forward or reverse contactors open and close, then can only be
closed by opening and closing the key switch.
POSSIBLE CAUSE
Defective 5REC circuit
1REC
* Check for shorted 5REC.
2REC
* Check for shorted 5REC snubber (25REC).
Choke
T5
X1
22REC
Defective 2REC circuit.

5REC
Open choke (1X).
T4
25REC
T3
* Check for open circuit between T5 and T3. Ohm meter

should read zero ohms.
1REC defective.
* Turn off time for 1REC out of specification. No field test is

possible. Replace 1REC after above checks, show no
problem found.
Figure 1.
This status code is displayed when, during SCR
operation, 1REC fails to turn off.
DESCRIPTION
STATUS CODE
-45
1REC did not turn on properly.
SYMPTOM
Yes
CIRCUIT
Traction
Forward or reverse contactor will open and close, then open and
then can only be closed by opening and closing the key switch.
POSSIBLE CAUSE
MEMOR
RECALL
White/Blue
PZ8
1REC
PZ9
Blue

2REC
* Check for open circuit or loose connections between 1REC

and PZ8 (white/blue wire).
* Check for open circuit or loose connections between 1REC
(3REC snubber) and PZ9 (blue wire).
22REC
Defective 1REC
* Intermittent or open 1REC gate. Field test may or may not

show defect. Replace 1REC after above checks, show no
problem found.
Figure 1.
This status code is displayed when 1REC fails to
gate on.
172
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F-code
Section
C-code
PS
S5.7
5410
Version no
000
DESCRIPTION
STATUS CODE
-46
Look ahead test for T2 volts. (Greater than 85% of

battery volts)
T-code
OE35
MEMOR
RECALL
No
CIRCUIT
Traction
SYMPTOM
POSSIBLE CAUSE
1REC
Defective 1REC

* Check for defective 1REC insulator (co-therm) that may
short 1REC heat sink to base plate.
1A
Defective 1A contactor
* Check for welded 1A contactor power tips.

T2
Figure 1.
This status code is displayed when the voltage at
T2 is greater than 85% of battery volts.
DESCRIPTION
STATUS CODE
-47
2REC does not turn on properly
SYMPTOM
then can only be closed by opening and closing the key switch.
Bus A
POSSIBLE CAUSE
Spider
MEMOR
RECALL
Yes
CIRCUIT
Traction
5REC
Bus B
* Check that 2REC will gate on
White/Red
Wire
* Check for open circuit or loose connection between 2REC

gate and PZ10. (white/red wire)
Red Wire
2REC
PZ10
* Check for open circuit or loose connection 1REC and 1C

through the 2REC circuit.
White/Red
F or R contactor or power tips bouncing open.
* Check that power tips on F and R contactor power tips do

not bounce open during operation (ie: travel over speed
bumps or dockplates).
T5
X1
2REC
Figure 1.
This status code is displayed when the 2REC fails
to turn on.
BT Products
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Service Manual
1997-10-22
173
F-code
Section
C-code
PS
S5.7
5410
Version no
T-code
000
OE35
DESCRIPTION
STATUS CODE
-48
Look ahead test for T2 volts (less than 12% battery

volts).
MEMOR
RECALL
No
CIRCUIT
Traction
SYMPTOM
T2
POSSIBLE CAUSE
S2
S1
Defective forward or reverse contactor
* Check for welded forward or reverse contactor power tips

* Check for sluggish operation of forward or reverse
contactor.
Field
A1

23 Filter
* Check for shorted 3REC
A2
3REC
A2
SCR
Current
Sensor
NEG.
Figure 1.
This status code is displayed when the voltage at
T2 is less than 12 % of battery volts.
DESCRIPTION
STATUS CODE
-49
5REC does not turn on properly.
SYMPTOM
then can only be closed by opening the key switch.
MEMOR
RECALL
Yes
CIRCUIT
Traction
White/Violet
PZ12
PZ14
Orange
Wire
White/Violet
POSSIBLE CAUSE
Choke
2REC T5 X1
* Check for shorted 5REC

* Check for shorted 5REC snubber (25REC)
5REC
* Check that 5REC will gate on
Reactor
T4
* Check for open circuit or loose connection between 5REC

gate and PZ12 (white/violet wire).
T3
25REC
Shorted 2REC circuit
* Check for 2REC and 2REC snubber (22REC) for short

circuit.
2REC
Orange
Wire
T5
T4
T3
Reactor
Defective capacitor circuit
* Check for open capacitor

* Check for loose connections at capacitor terminals.
Figure 1.
This status code is displayed when 5REC circuit
fails to turn on.
174
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Service Manual
1997-10-22
F-code
Section
C-code
PS
S5.7
5410
Version no
T-code
000
OE35
DESCRIPTION
STATUS CODE
-50
Capacitor volts low
SYMPTOM
MEMOR
RECALL
No
CIRCUIT
Traction
Bus A
Forward or reverse contactor picks up. Control does not operate.
POSSIBLE CAUSE
5REC
Spider
Bus B
* Open circuit or loose connection between spider assembly

and 5REC (BUS A).
White/Red
Wire
* Open circuit or loose connection between 5REC and

2REC.
Red Wire
2REC
PZ10
* Open circuit or loose connection between 2REC and PZ11

(red wire) and between 2REC gate and PZ10 (white/red
wire).
White/Red
* Check 2REC to insure that it will gate on.
T5
X1
2REC
Figure 1.
This status code is displayed when 2REC circuit
fails to turn on at initial start up.
STATUS CODE
DESCRIPTION
-51
Excessive capacitor voltage when motor current is high.
MEMOR
RECALL
Yes
CIRCUIT
Traction
SYMPTOM
T2

R
S1
POSSIBLE CAUSE
Excessive source inductance
S2
Field
* Tag lines without filters are being used.

* Battery cables are too long.
A1
High peak current in motor

A2
* Check for shorted field winding.

* Check for shorted armature winding.
A2
SCR
Current
Sensor
NEG.
Figure 1.
This status code is displayed when capacitor volts
exceed 225 volts and motor current is greater than
300 amps.
BT Products
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Service Manual
1997-10-22
175
F-code
Section
C-code
PS
S5.7
5410
Version no
T-code
000
OE35
DESCRIPTION
STATUS CODE
-52
Excessive capacitor voltage when motor current is low.
MEMOR
RECALL
Yes
CIRCUIT
Traction
T2
SYMPTOM
F
S1
POSSIBLE CAUSE
Excessive source inductance
S2
Field
* Tag lines without filters are being used.

A1
* Battery cables are too long.

3REC
A2
A2

* Check for open circuit or loose connection in 4REC circuit.
Defective 3REC circuit.
* Check for open circuit or loose connection in 3REC circuit.
4REC
SCR
Current
Sensor
NEG.
Figure 1.
This status code is displayed when capacitor volts
exceed 225 volts and motor current is less than
200 amps.
DESCRIPTION
STATUS CODE
-53
1REC fails to turn off during plugging cycle.
MEMOR
RECALL
Yes
CIRCUIT
Traction
SYMPTOM
Forward or reverse contactor opens and closes, then opens and
can only close by opening and closing the key switch.
POSSIBLE CAUSE
T2
R
F
S1
1 REC turn off failure not related to plugging
* Stall vehicle in both directions and note any status codes

displayed that may more closely define the failure mode.
Troubleshoot per new status code.
S2
Field
A1
1 REC turn off related to plugging
* Check 4 REC circuit for open 4 REC, loose or open cable/

bus connection.
* Check current sensor for loose or open connection in
power circuit. Check yellow and green wire form sensor to
logic card for open and loose connection.
Defective motor circuit
* Check motor circuit for open or loose connections.

* Check motor brushes for proper seating.
A2
4REC
A2
SCR
Current
Sensor
PZ4
PZ3
NEG.
Figure 1.
This status code is displayed when any failure of 1
REC to turn off during plug cycle.
F or R contactor power bouncing open
* Insure that F and R contactor does not bounce open during

vehicle operation (ie: traveling over speed bumps and dock
plates).
176
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Service Manual
1997-10-22
F-code
Section
C-code
PS
S5.7
5410
Version no
000
DESCRIPTION
STATUS CODE
-54
Shorted F, R or 1A contactor coil driver.
T-code
OE35
MEMOR
RECALL
Yes
CIRCUIT
Traction
SYMPTOM
Control will not operate
POSSIBLE CAUSE
Defective logic card
* Replace logic card
Figure 1.
This status code is displayed when either the
forward, reverse or 1A contactor coil driver is
shorted internal to the logic card.
DESCRIPTION
STATUS CODE
-57
Current sensor output voltage polarity check
MEMOR
RECALL
Yes
CIRCUIT
Traction
SYMPTOM
A1
POSSIBLE CAUSE
Reversed yellow and green current sensor wires
A2
* Insure that the green wire connects to PZ4 with no open

circuits and the yellow wire connects to PZ3 with no open
circuits or loose connections.
A2
Reversed power cable connection

Green
SCR
Current
Sensor
* Insure that the battery negative cable connects to SCR

NEG and the motor A2 cable connects to SCR A2.
Yellow
PZ4
PZ3
NEG.
Figure 1.
This status code is displayed when the voltage
input to PZ4 and PZ3 is the wrong polarity.
BT Products
Return
Service Manual
1997-10-22
177
F-code
Section
C-code
PS
S5.7
5410
Version no
T-code
000
OE35
178
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Service Manual
1997-10-22
F-code
PS
Section
C-code
S5.3
5230
SCR Component Checks
Version no
T-code
001

1. Main Logic Card
All troubleshooting is written to check all outside devices and
eliminate them as the source of the symptoms. The
conclusion being then that the card is faulty.
1.1. Instructions for Removal of Control

Card.
Remove control wires on the screw terminals 1

through 6 as required.
Unplug A, B, and Z plugs by pressing down on tab with

wide blade screwdriver and rotating 90 degrees.
Remove the two mounting screws and lift card box.

NOTE! Do not attempt to remove circuit broad from
card box.
Reverse procedure to install new control card.

Z Plug
Y Plug
B Plug
Terminal 1-6
A Plug
Mounting Screw
BT Products
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Service Manual
1997-04-15
179
F-code
Section
C-code
PS
S5.3
5230
Version no
T-code
001
2. Capacitor 1C
Disconnect the battery and discharge the capacitor. Measure
ohms Through the capacitor using the Rx10,000 scale. Meter
should read zero and the swing slowly to above 100,000
ohms. Replace the capacitor if above reading is not obtained.
3. Contactors Forward, Rearward, 1A,

Power Steering, and Pump
150 ampere contactors instruction sheets.
300 ampere contactors instruction sheets.
NOTE! Control is arranged so that the forward and
rearward contactors do not break current.
Check to see that the 1A contactor drops
before the forward and rearward contactor.
NOTE! Most contactor coils are polarity sensitive.
The left-hand terminal must be connected to
positive.
4. Potentiometer in Accelerator
To check operation of potentiometer, disconnect the battery
and disconnect the wire #29 at control card TB1. Connect a
VOM to the wire that was removed from TB1 and to negative.
Place the VOM on the Rx100 scale. With the accelerator in
the creep speed position, the ohms reading should be 4800
to 6000 ohms. With the accelerator in the top speed position,
the ohm reading should be 50 ohms or less. With the wire
disconnected as above, check for resistance of 1 megohm or
higher from pot wire to the truck frame.
5. SCRs (1REC, 2REC, 5REC)

These are silicon controlled rectifiers. Before checking,
disconnect the battery and discharge capacitor 1C.
Disconnect gate leads of SCRs at the SCR terminal.
180
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F-code
PS
Version no
Section
C-code
S5.3
5230
T-code
001
NOTE! These tests may not prove a bad SCR. If in

doubt, replace the SCR.
To check an SCR, it is necessary to have a 6 volt battery and
2 a-14 diodes.
Connect the positive lead to the anode, connect the negative
lead to the cathode as shown below.
Anode
Cathode
Gate
Anode
Gate
Cathode
1. The lamp should not light. If the lamp does light, the
SCR is shorted and must be replaced.
2. If check (1) was satisfactory, test the SCR for its ability
to be turned on by the gate. Connect positive through
two diodes to the gate terminal. If the gate is operative,
the lamp will come on and remain on when the gate is
removed. Some SCRs will operate correctly even if
the lamp dose not remain on, particularly with a weak
battery.
3. If the lamp cannot be lit under step 2 the SCR is open
and must be replaced.
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181
F-code
Section
C-code
PS
S5.3
5230
Version no
T-code
001
NOTE! If you do not have a test light to check the

SCRs as described above, they may be
checked for shorts and opens by use of the
VOM.
NOTE! Measure resistance from anode to cathode
(Rx100 scale. If SCR is shorted (zero ohms),
it must be replaced.
NOTE! Measure resistance from the gate terminal to
the cathode and then from the cathode to the
gate terminal (Rx100 scale). If resistance
reads either zero ohms (short) or infinity
ohms (open), replace the SCR. When
resembling SCRs, refer to TABLE 5.
6. Rectifiers (3REC, 4REC, Diode Blocks)

When checking diodes, disconnect battery and discharge
capacitor 1C. When replacing rectifiers, refer to TABLE 5. For
3REC and 4REC, disconnect one lead or flexible connection.
3REC and 4REC are diodes with about 7 to 12 ohms in the
conducting direction (anode to cathode) measure on the
Rx100 scale, and 10,000 ohms or higher, in the nonconducting direction (cathode to anode) measured on the
Rx10,000 scale.
7. Thermal Protector (TP)

Remove both the GRAY and BLACK wires from the Z plug
that connects to the control card. Read the resistance
between these two wires with the VOM set on the Rx100
scale. VOM should read 100 to 200 ohms if the 1REC
heatsink is at room temperature (75F or 25C). Set the VOM
to the highest ohm scale and read from each wire end to the
1REC heatsink. Reading should be infinity.
182
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F-code
PS
Version no
Section
C-code
S5.3
5230
T-code
001
8. Filter Block (23FIL, etc.)

To check, disconnect all wires from the filter block on removal
from panel. With VOM on the Rx10,000, touch the leads to
the filter terminals change the filter. After a few seconds,
reverse the meter leads and touch the filter terminal. The
VOM needle will deflect and return to infinity. If this capacitor
action is not observed, replace the filter block.
9. Filter Block (23FIL, etc.)

Filter block test 4K is only to detect an open or shorted filter. If
the control has symptoms as in 1E, interchange 22REC and
25REC and try again. If the problem is corrected, the old
25REC is marginal and should be replaced. If the problem is
not corrected, replace both filters.
10. 1X Choke and Reactor T3-T4

Refer to panel wiring diagram to locate windings. With VOM
on Rx1 scale, measure choke or reactor winding. Reading
should be less then 1 ohm.
11. Replacement of EV100

Components
When replacing stud semiconductors such as 3REC and
4REC, it is not necessary to torque these devices to a specific
valve.
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1997-04-15
183
F-code
Section
C-code
PS
S5.3
5230
Version no
T-code
001
NOTE! The use of heat-transfer grease (such as GE

Versilube G-350-M or equivalent) is
recommended.
When replacing module semiconductors such as:
11.1. 1REC, 2REC or 5REC

1 Remove all module connections. (As required)
2 Remove module by backing out the two screws at the
device sides.
3 Clean the insulator surface with a clean rag and
isopropyl alcohol.
4 Inspect the insulator surface for tears or cracks. If
defective, replace. Wipe a light layer of machine oil on
the base and smooth the insulator into position.
NOTE! Insulator not required for 2REC and 5REC.
5 Coat insulator with a light coat of heat-transfer grease
similar to GE-350.
6 Set new module on insulator and start screws back
into base. Be sure to use the original screws and
washers. Run screws into base finger tight.
7 Check that the bottom of the module is flat against the
insulator or base.
8 Alternately tighten the two screws by 1/4 turn until firm.
9 Replace all connections removed in step 1.
11.2. Capacitor
184
Return
Remove nuts from capacitor connections and remove

wires.
Remove hold down brackets and lift out.
Reverse procedure to replace capacitor.
Service Manual
1997-04-15
F-code
PS
Section
C-code
S5.3
5230
Version no
T-code
001
11.3. 22REC, 23REC and 25REC

Remove mounting screws and lift out.

NOTE! When replacing these devices, use the
original hardware in the same holes, as the
insert are used for electrical connections.
12. Instructions - EV100 Plugs

12.1. General
The plug system used in the GE EV-100 utilizes AMP
(Ampmodu 1) pins and receptacles (wire terminals). The
plugs are sealed to provide protection in the electric vehicle
environment.
NOTE! Normally the plugs do not require
maintenance, but should the need arise to
assemble or disassemble the plugs, correct
tools and procedures must be followed to
prevent damage to the plug body, wire
terminals or the EV-100 terminal board.
12.2. Procedures
To unplug harness from EV-100
Depress latch on plug.
Grasp plug body and pull plug from terminal board. If
the plug has a shoulder near the terminal board, insert
a medium size flat blade screwdriver in this gap and
gently pry out the plug, alternating sides.
Lockin
Ledge
Removal
Tool
To remove a terminal from the plug body
Figure 1
BT Products
Return
Referring to Figure 1, insert the terminal removal tool

into the plug body (which depresses the terminal
locking lance). With a gentle push-pull motion on the
wire, remove the wire.
USE AMP REMOVAL TOOL - 91065-1.
Service Manual
1997-04-15
185
F-code
Section
C-code
PS
S5.3
5230
Version no
T-code
001
To insert a terminal into the plug body.
Orient Plug
Check lance height
Insert Until
Check sound is heard
Referring to Figure 2, orient the plug body as shown

with the latch up, and terminal locking lance up.
Check that the locking lance protrudes .030 to .060
inches (.8 to 1.5mm). If not, adjust the lance. Insert the
terminal into the plug body until it latches. A "CLICK"
sound will be heard when the terminal latches. Check
for correct latching by moving the wire gently - with a
push-pull motion.
Check with Gentle

Push-pull motion
on the wire
12.3. Reference
Figure 2
186
Return
A Plug
27694-00
B Plug
27702-02
Receptacle
AMP #102103-3 (Loose) AMP

#102099-5 (Reel, side-feed)
Crimp Tool
AMP #90274-2 (wire size, 18-22)
Removal Tool
AMP 91065-1
Terminal Lube
AMP #561232-1
Service Manual
1997-04-15
F-code
Section
PS
C-code
S5.7
5440
Direction Contactor
Version no
T-code
000
Direction Contactor
1
2
3
4
5
8
26 9
25
10
24
24
13
9
11
23
12
14
15
27
16
22
17
21
20
19
BT Products
Return
POS.
NO
DESCRIPTIO
POS.
NO
Base, magnet
10
Spring
19
Bar, bus
Coil
11
Insulation
20
Lockwashe
Frame, magnet
12
Locknut
21
Tip, contact
Spring
13
Clamp
22
Clamp
Armature
14
Tip, contact
23
Washer, flat
Base, bus
15
Cover
24
Seat
Tip, contact
16
Lockwasher
25
Carrier
Tip, contact
17
Screw
26
Bushing
Tip, movable
18
Screw
27
Tip, contact
Service Manual
DESCRIPTION
1997-07-15
POS.
NO
18
DESCRIPTION
187
F-code
Section
PS
S5.7
Direction Contactor
Version no
C-code
5440
T-code
000
1. Check armature and movable contacts for freedom of
movement by depressing movable arm with a
screwdriver or small rod.
Check for any restrictions to movement and for return
of parts by action of spring.

2. Inspect contact tips. Look for any worn or eroded
surfaces. Look for evidence of tip welding. Inspect for
evidence of any contaminants on tips (paint, dirt, paper
or cloth material, etc.) which would impair operation.
Do not use sandpaper or file tips. Any damage must
be corrected by tip replacement.

Tips must be replaced before they wear through and
damage copper base.
2. Remove / replace contact tips

NOTE! Before attempting to disassemble a
contactor to install a new contact tip set,
carefully observe location and orientation of
each part.
1. Disconnect power cables from contactors. Remove
bolts with washers, lockwashers and spacers from
contacts. Move power cables out of the way.
2. Disconnect connecting bus bars from contacts.
3. Disconnect wiring from contactor coil terminals.
4. Remove mounting bolts securing Forward and Reverse
Contactor Assembly to the control panel base plate that
is attached to the truck. Remove assembly from truck.
5. Disassemble the contactors. Loosen cover screws on
both contactors. There are four screws per cover.
Note location of contacts so the new ones may be
installed to the same location as the old ones.
6. Press downward on Cover (15) and completely back out
screws until they are free of the contactor base. Do not
remove cover yet.
188
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PS
Version no
Section
C-code
S5.7
5440
Direction Contactor
T-code
000
7. Press downward on the other Cover (15) and

disconnect screws from base. Holding pressure on one
Cover (15) and then remove Cover (15) from the
assembly. Set cover and screws to one side.
8. Now remove Cover (15) and screws.
Note locations of the bus bars, contacts and the large
side insulators (13) for ease of reassembly.
9. Remove and discard upper contacts.
10. Remove and inspect Insulators (13) for cracks and
damage. An insulator found to be cracked or broken
should be replaced with a new one.
11. Remove and discard lower contacts.
12. Hold Bracket (3) with one hand and remove support
sub-assembly (armature, contacts, etc.). The return
spring should come off with the armature as it fits into a
recess in the bottom of the armature.
13. Secure support in a vice equipped with soft jaws using
minimum pressure to hold support.
14. Loosen and remove nut freeing core parts (washer,
insulators, movable contacts, spring seats and spring).
Note the position and location of each part for proper
reassembly. Remove these parts.
15. Pull insulator and core bushing from core.
16. Remove armature core with spring from bottom of
support and remove support from vice.
17. Remove Bracket (3) from coil and base.
18. Remove coil from base.
19. Disassemble the opposite (reverse) contactor in same
manner.
20. Inspect armature core insulators for cracks, breaks, etc.
If parts are found to be damaged, they should be
replaced with new ones.
21. Inspect springs for damage. Replace damage parts with
new ones.
22. Inspect spring seats for damage (cracks, breaks, etc.).
Replace damaged parts with new.
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189
F-code
Section
PS
S5.7
Direction Contactor
Version no
C-code
5440
T-code
000
23. Inspect the thin washer located on the armature for

cracks, etc., and security of mounting.
Material on the armature stem has been up set in
four places to retain the washer. Inspect all four places

to be certain this thin washer is properly retained and
free to rotate about the armature stem.
Inspect the cone surface of the armature and the
corresponding surface in the base plate for scoring,

etc.
Inspect the small white bushing for wear. The bushing
I.D. must be perfectly round. If the bushing becomes

egg shaped (out-of-round), it should be replaced with
a new bushing.
NOTE! The coil has four blind alignment holes in the
top and two in the bottom. These holes must
properly align with the off-set pins in the
bracket and contactor base at reassembly.
24. Inspect coil for damage.
Inspect alignment holes to be certain they are perfectly
round and not egg shaped (damaged).

Inspect coil terminals for damage.
Replace damaged parts with new ones.
25. Reassembly The Contactors. Install both coils onto

contactor base.
Terminal connections must point outward away from
center of base. Be certain the coils are properly located
over the base alignment pins.
26. Locate Brackets (3) on each coil and onto the base. Be
certain the bracket alignment pins properly seat in the
holes on the top side of each coil.
27. Now, secure the Forward Contactor Assembly Support
into the vice using minimum pressure to hold the
support.
Install spring into coil recess.
Locate white bushing over armature stem and insert
armature through bottom of support positioning
190
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F-code
PS
Version no
Section
C-code
S5.7
5440
Direction Contactor
T-code
000
armature tab into support slot.

Install lower insulator, lower movable contact, and
lower spring seat over armature stem.

Install spring and upper spring seat, upper contact,
upper insulator, lockwasher and nut onto armature

stem. Torque nut to 18-20 in.-lb [2.0-2.4 N$m].
28. Remove support and movable contact assembly from
the vice.
29. Assemble the Reverse Contactor Support and Movable
Contact Assembly in the same manner.
30. Now locate the Forward Contactor Support and Movable
Contact Assembly over Bracket (3).
NOTE! Be certain the armature tab is pointing
inward toward the center of the contactor
base when positioning support over bracket.
Refer to the boxed illustration on opposite
page.
31. Now locate the Reverse Contactor Support and
Movable Contact Assembly over its bracket.
Again, be certain the armature tab is pointing inward
toward the center of the contactor base.
32. Install the long lower bus bar and stationary contacts
(having threaded holes in one end) into the grooves
located on the top side of each contactor support. The
cable end of the bus bar should extend outward on the
right hand side of the forward contactor support and
extend outward on the left hand side of the reverse
contactor support. Be certain the notches in the bus bar
and stationary contacts properly seat with the screw
guides of each contactor support.
33. Install the short bus bar and stationary contacts (having
threaded holes in one end) in the same manner as
previously described.
Be certain the notches in each bar fit properly to the
screw guides of each support.
34. Position Insulators (13) over the bus bar/contacts and
supports as shown in illustration on opposite page. Be
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191
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Section
PS
S5.7
Direction Contactor
Version no
C-code
5440
T-code
000
certain the openings in the bottom of the insulators face

downward and that the insulators are properly seated in
the slots of the supports.
35. Assemble spacer, upper bus bar/contacts over the
insulators. Make certain the contacts are seated
properly in the insulators.
36. Assemble covers (15). Make certain covers, bus bars
and contacts are in alignment and press both covers
downward with one hand...hold in this position and
install all cover screws until snug. Check to be sure all
parts are in proper alignment, and position the power
cable bolts (with lockwashers, and washers) through the
upper bus bar/contacts and spacers. Tighten bolts finger
tight into the lower bus bar/contacts.
37. Tighten cover screws to: 14-18 in.-lb [1.6-2.0 Nm].
38. Use a bar or rod to move contacts. Be sure movement is
free of binding and that tips are in correct orientation
and tips contact correct mating parts.
39. Install Forward and Reverse Contactor Assembly to
panel base plate.
192
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F-code
Section
PS
C-code
S5.7
5450
1A Speed Contactor
Version no
T-code
000
OE35
1A Speed Contactor
1
2
3
4
5
10
15
12
13
16
9
19
17
11
14
18
BT Products
Return
POS.
NO
DESCRIPTIO
POS.
NO
Base, magnet
Bushing
15
Clamp
Coil
Carrier
16
Lockwashe
Frame, magnet
10
Tip, movable
17
Screw, machine
Spring
11
Cap
18
Suppression
Armature
12
Spring
19
Seat
Base, bus
13
Washer, flat
Tip, contact
14
Nut, lock
Service Manual
DESCRIPTION
1997-10-29
POS.
NO
DESCRIPTION
193
F-code
Section
PS
S5.7
1A Speed Contactor
Version no
T-code
000
OE35
C-code
5450


damage copper base.
2. Disassembly
each part.
bolts with washers, and lockwashers from contacts.
Move power cables out of the way.
3. Remove mounting bolts securing contactor assembly to
the control panel base plate that is attached to the truck.
Remove assembly from truck.
4. Remove clamps (15), screws (17), and lockwashers
(16).
5. Remove and discard contacts (7).
6. Remove and inspect bus base (6) for cracks and
7. Remove support sub-assembly (armature, contacts,
etc.). The return spring should come off with the
194
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1997-10-29
F-code
PS
Section
C-code
S5.7
5450
1A Speed Contactor
Version no
T-code
000
OE35
armature as it fits into a recess in the bottom of the

armature.
13. Inspect all armature parts for cracks, breaks, etc. If parts
are found to be damaged, they should be replaced with
new ones.


etc.

a new bushing.

BT Products
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Service Manual
1997-10-29
195
F-code
Section
PS
S5.7
1A Speed Contactor
Version no
T-code
000
OE35
C-code
5450
3. Assembly
1. Install coil on contactor base.
base. Be certain the coil is properly located over the
base alignment pins.
2. Locate Bracket (3) on coil and on the base. Be certain
the bracket alignment pins properly seat in the holes on
the top side of each coil.
3. Secure the contactor assembly support into the vice
using minimum pressure to hold the support.

Install bus base (6), movable contact (10), and spring
seat over armature stem.


stem. Torque nut to 18-20 lb-in. (2.0-2.4 N$m).
the vice.
5. Now locate the contactor support and movable contact
assembly over Bracket (3).
6. Install the stationary contacts into the grooves located
on the top side of contactor support. Be certain the
notches in the stationary contacts properly seat with the
screw guides of contactor support.
7. Assemble clamps (15). Make certain clamps, bus bars
and contacts are in alignment and press clamps
install all clamp screws until snug. Check to be sure all
cable bolts (with lockwashers, and flat washers) through
196
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1997-10-29
F-code
PS
Section
C-code
S5.7
5450
1A Speed Contactor
Version no
T-code
000
OE35
the bus bar/contacts. Tighten bolts finger tight into bus

bar/contacts.
8. Tighten cover screws to: 14-18 lb-in. (1.6-2.0 Nm).
10. Install contactor assembly to panel base plate.
BT Products
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Service Manual
1997-10-29
197
F-code
Section
PS
S5.7
1A Speed Contactor
Version no
T-code
000
OE35
198
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C-code
5450
Service Manual
1997-10-29
F-code
Section
C-code
PS
S5.4
5460
Electrical System Troubleshooting
Version no
001
T-code
OE35
Electrical Syste
Troubleshooting
Troubleshooting can be broken down into Control Circuits
and Power Circuits. By knowing the exact symptoms of the
truck operation, many hours of troubleshooting time can be
saved. If the proper contactor operates for the chosen
direction and speed then the problem can be found in the
Power Circuits troubleshooting procedures. If a particular
contactor does not operate when a function is chosen then
the problem can be found in the Control Circuits
troubleshooting procedures.
To use this troubleshooting guide go to the appropriate
section, and locate the symptom that best describes the truck
operation. Follow the instructions for the tests that are
outlined. All tests, unless otherwise specified, instruct the
technician to test for battery voltage at a particular point. If the
proper voltage is present, continue with the next point in the
testing procedure. If the voltage is not present, or if the
voltage is too low, perform the repairs listed directly below the
test procedure.
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 you
must 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, 37.8 for a 36 volt system. If the battery voltage is
below 22 volts (24 volt system) and 33 volts (36 volt system)
(with no load) then the controller may not operate properly.
You will then have to charge the battery before starting the
troubleshooting procedure.
When testing voltage the positive side of any component
refers to the terminal on that component that is closest
electrically to the 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. It
is possible, and in many cases desirable, to measure battery
voltage on the negative side of a component.
Forward direction refers to travel with forks trailing.
Reverse direction refers to travel in the fork direction.
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1996-10-15
199
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PS
S5.4
5460
Version no
T-code
001
OE35
After the final test is completed the truck should be repaired

and operating properly. If it is not then you must verify your
test results and possibly re-evaluate the failure symptoms. If
you still have not repaired the truck then you should call your
local dealer for assistance. Authorized dealers may contact
the factory for assistance. When you call the following
information is required: Truck model and serial number,
service meterhours, actual battery voltage (open circuit and
at hydraulic operation under full load), the precise operating
symptoms and the exact results of the testing you have done.
The first steps of any troubleshooting procedure are to:
1. Inspect the truck for physical damage or
mechanical malfunction. Contactors must be free
to move and the tips must not be welded or burnt.
2. Check for ground faults from the electrical system
to the frame with an ohmmeter. A minimum of
20,000 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 operating symptoms. Do not forget that
these systems are equipped with safety circuits
that prevent operation in the event of improper
operating procedures.
200
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1996-10-15
F-code
Section
C-code
PS
S5.4
5460
Version no
001
T-code
OE35
1. Control Circuits and Power Circuits

Most control circuit problems show up as a contactor failing to
close at the proper time. Most power circuit problems show
up as the truck failing to travel or lift after the proper contactor
has closed. The tests that follow instruct the technician to test
the voltage at various components at particular times during
truck operation. All voltage tests are made with the negative
lead of the test meter connected to battery negative. At no
time should the frame of the truck be connected to either
battery positive or battery negative.
WARNING The truck must be lifted and blocked with
the drive tire off the ground. Failure to do
so may result in the truck moving suddenly
causing serious injury or death!
The functions should be adjusted to the following values:
Function #
Setting #
Function #
Setting #
10
10
200
11*
128
12
12*
150
95
13*
177
80
14
10
130
15
Set a voltage of truck (24 or 36)
10
16
40
10
17
22
10
18
18
* These functions control the speed of the truck when raised.

The function should be adjusted to the prescribed setting and
then the speed of the truck should be checked and the
function readjusted, if necessary.
Function 11 controls the speed at lift heights 24 inches. The
top speed of the truck must be 2.5 MPH.
Function 12 controls the speed at lift heights above 150
inches when travelling in a straight line. The top of the truck
must be 1.0 MPH.
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1996-10-15
201
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Section
C-code
PS
S5.4
5460
Version no
T-code
001
OE35
Function #13 controls the speed at lift heights above 150

inches when the truck is steered beyond 10 degrees off
center and when above 226 inches. The truck must not travel
although contactors will close.
The travel speed is most easily determined by timing the
truck through a 50 foot run. At 2.5 MPH the vehicle will take
13 seconds to travel 50 feet. At 1.0 MPH the vehicle will take
34 seconds to travel 50 feet.
The speed limiting function is vital to the safety of the vehicle
and must never be bypassed or set above the specifications
here stated.
202
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1996-10-15
F-code
Section
C-code
PS
S5.4
5460
Electrical System Troubleshooting Charts
Version no
T-code
001
OE35
Electrical Syste
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, move on directly to the next test; or
follow the special instructions given.
NOTE! Troubleshooting chart is to be used in
conjunction with wiring schematic for the
truck.
1.1 Emergency Disconnect Contactor
1.1.1 Emergency disconnect contactor will not close.
Conditions for test: Battery plugged, battery fully
charged, key switch in start position.
Check for battery voltage at:
1. Positive side of fuse 3.
0 volts, repair open wiring from battery to fuse
3.
2. Negative side of fuse 3.
0 volts, replace fuse 3.
3. Positive side of key switch.
0 volts, repair open wiring from fuse 3 to key
switch.
4. Negative side of key switch, wire #14 (ON
position).
0 volts, replace key switch.
5. Positive side of start switch
0 volts, repair open wiring from key switch to
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1996-10-15
203
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PS
S5.4
5460
Version no
T-code
001
OE35
start switch.
6. Negative side of start switch (push button
engaged).
0 volts, replace start switch.
7. Positive side
contactor coil.
of
emergency
disconnect
0 volts, repair open wiring from push button to

contactor coil.
8. Negative side of emergency disconnect
contactor coil.
0 volts, replace contactor coil, check for
mechanical binding of contactor.
Battery volts, repair open wiring from contactor
coil to battery negative, wire #22.
1.1.2 Emergency disconnect contactor closes, but drops
out when start switch is released.
Condition for test: Battery plugged in, key switch
ON position.
Test for battery volts at:
1. Negative side of key switch, wire #14.
0 volts, replace key switch.
2. Positive side of emergency disconnect push
button.
0 volts, repair open wiring from key switch to
emergency disconnect push button.
3. Negative side of emergency disconnect push
button.
0 volts, replace push button.
4. Positive
204
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side
of
emergency
disconnect
1996-10-15
F-code
Section
C-code
PS
S5.4
5460
Version no
001
T-code
OE35
interlock switch.
0 volts, repair open wiring from push button to
interlock switch.
Battery volts, push start button, check interlock
switch for proper mechanical operation.
5. Disconnect wire #11 from negative side of
interlock switch. Push start button contactor
closed, check for battery voltage at this
terminal.
0 volts, replace interlock switch.
1.1.3 Emergency disconnect contactor closes with push
start button and remains closed when start button
is released; but truck will not operate - no lift, no
travel.
Condition for testing:
- Battery connected to truck
-
Key switch in ON position, start button pressed

and released with emergency disconnect
contactor closed
Negative lead of volt meter connected to

negative stand off terminal on SCR panel. (for
this test only).
Test for battery voltage at:

1. Positive side of 300 AMP and 400 AMP power
fuses, fuse 1 and fuse 2.
0 volts, repair faulty negative connection
between SCR panel negative stand off
terminal and battery negative.
Possible failure - Emergency disconnect
contactor tips.
2. Negative side of 300 AMP power fuse, fuse 2.
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1996-10-15
205
F-code
Section
C-code
PS
S5.4
5460
Version no
T-code
001
OE35
0 volts, replace 300 AMP fuse.

3. Negative side of 400 AMP power fuse, fuse 1.
0 volts - replace 400 AMP fuse.
1.2 Steering and Brake Release Pump
1.2.1 Steering pump will not run, contactor does not
close.
Conditions for test: Battery plugged in, key switch
ON, start button pushed and released, emergency
disconnect contactor closed, foot pedal depressed.
1. Positive side of steer pump contactor coil.
0 volts, repair open wiring from emergency
disconnect button to contactor coil.
2. Negative side of steer pump contactor. Refer
to status code 23 and 24 in section 1.4 of this
manual.
1.2.2 Brakes will not release, steering okay, lift okay.
Condition for test: Battery plugged in, key switch
disconnect contactor closed, foot pedal switch
closed, steer pump running.
1. Positive side of brake pump solenoid valve
coil.
0 volts, repair open wiring or diode from foot
pedal switch to solenoid valve coil.
2. Negative side of solenoid valve coil.
0 volts, repair solenoid valve coil.
Battery volts, repair open wiring to battery
206
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Section
C-code
PS
S5.4
5460
Version no
001
T-code
OE35
negative.
1.2.3 Power circuit, steering pump does not run, brakes
do not release, no travel, lift/lower okay.
Condition for test Emergency disconnect contactor
closed, foot pedal switch closed, steering pump
contactor closed.
1. Positive bus bar on SP contactor.
0 volts, repair open cable from fuse 1.
2. Motor side bus bar on SP contactor.
0 volts, repair SP contactor, replace tips.
3. A1 terminal on SP motor.
0 volts, repair open cable 4 from SP contactor.
4. S2 terminal on SP motor.
0 volts, repair SP motor.
5. Repair open cable 13 to battery negative.
1.3 Travel
1.3.1 No travel, lift-lower okay, steering pump motor
runs.
disconnect contactor closed, foot pedal switch
closed, gate switches closed, brake switch closed,
directional switch closed.
1. Positive side of brake interlock switch.
0 volts, repair open wire #17 from staging
chain tension to brake switch.
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1996-10-15
207
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PS
S5.4
5460
Version no
T-code
001
OE35
2. Negative side of brake interlock switch.

0 volts, replace brake interlock switch.
3. Positive side of directional switches.
0 volts, repair open wiring from brake switch to
directional switches.
4. Negative side of directional switches with wire
disconnect.
0 volts, repair directional switch.
5. Positive side of directional contactor coil.
0 volts, repair open wiring from brake switch to
contactor coil.
6. Negative side of directional contactor coil with
wire disconnect.
0 volts, replace contactor coil.
7. Test all limit switches for proper operation.
8. Refer to EV-100 handset instructions.
1.4 Lift
1.4.1 No lift, lift pump (LP) contactor does not close.
Condition for test: Battery plugged in, key switch in
on position, start button pushed and released,
emergency disconnect contactor closed, foot pedal
switch closed, platform gate switches closed, lift
switch activated to lift.
1. Positive side of foot pedal switch, wire #14.
0 volts - repair open wiring from key switch to
foot pedal switch.
2. Negative side of foot pedal switch.
208
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Section
C-code
PS
S5.4
5460
Version no
T-code
001
OE35
0 volts - adjust or replace foot pedal switch.

3. Positive side of platform gate switch wire #35.
0 volts - repair open wiring from foot pedal
switch to gate switch.
4. Negative side of gate switch.
0 volts - adjust or replace gate switch.
5. Positive side of second gate switch, wire #20.
0 volts - repair open wiring from first gate
switch to second gate switch.
6. Negative side of second gate switch.
0 volts - adjust or replace second gate switch.
7. Positive side of lift switch.
0 volts - repair open wiring from second gate
switch to lift switch.
8. Negative side of lift switch.
0 volts - replace lift switch.
9. Positive of lift pump contactor coil.
0 volts - repair open wiring from lift switch to
contactor coil.
10. Negative side of contactor coil.
0 volts - check contactor for mechanical
binding, replace contactor coil.
Battery volts - repair open wiring to battery
negative.
1.4.2 No high speed lift, low speed lift okay.
Condition for test: Battery plugged in, key switch in
on position, start button pushed and released,
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209
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Section
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PS
S5.4
5460
Version no
T-code
001
OE35
switch closed, gate switches closed, lift activated

for high speed lift, lift platform raised minimum of 4
inches.
1. Positive side of platform lift chain tension
switch, wire #19.
0 volts - repair open wiring from gate switch to
platform chain tension switch.
2. Negative side of platform chain tension switch.
0 volts - adjust or replace chain tension switch
under platform.
3. Positive side of staging chain tension switch
on mast column crossbar.
0 volts - repair open wiring between platform
chain tension switch and mast column chain
tension switch.
4. Negative side of staging chain tension switch.
0 volts - replace staging chain tension switch.
5. Positive side of high speed lift switch.
0 volts - repair open wiring from staging chain
tension switch to high speed lift switch.
6. Negative side of high speed lift switch.
0 volts - replace high speed lift switch.
7. Positive side of lift pump solenoid valve coil.
0 volts - repair open wiring from high speed lift
switch to lift pump solenoid valve coil.
8. Negative side of lift pump valve coil.
0 volts - replace solenoid valve coil.
Battery volts - repair open wire to battery
210
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Section
C-code
PS
S5.4
5460
Version no
001
T-code
OE35
negative.
1.4.3 No lift, travel okay; lift pump (LP) contactor closes.
Conditions for test: Battery connected, key switch
in on position, start button pushed and released,
emergency disconnect closed. Foot, raise and gate
switches closed. Lift pump contactor closed.
1. Positive side of contactor bus bar.
0 volts - repair open cable #5 from fuse 1, 400
AMP>
2. Pump motor side of contactor bus bar.
0 volts - repair contactor, replace tips.
3. A1 terminal on lift pump motor.
0 volts - repair open cable 20 from LP
contactor.
4. S2 terminal on motor.
0 volts - repair motor.
Battery volts - repair open cable 13 to battery
negative.
1.5 Lowering
1.5.1 No low speed lowering, low and high speed raise
okay.
in on position, start button pushed and engaged,
switch closed, gate switches closed, platform
raised above 24 inches, slow speed lowering
switch activated.
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211
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PS
S5.4
5460
Version no
T-code
001
OE35
1. Positive side of slow speed lowering switch,

wire #17.
0 volts - repair open wire #17 from mast
column chain tension switch to slow speed
lowering switches.
2. Negative side of slow speed lowering switch.
0 volts - replace switch.
3. Positive side of 31 lowering solenoid valve coil
(with red manual lowering button).
0 volts - repair open wiring from lowering
control switch to solenoid valve coil.
4. Negative side of #1 lowering solenoid valve
coil.
0 volts - replace coil.
Battery volts - repair open wire from solenoid
valve coil to battery negative, wire #22.
1.5.2 No high speed lowering, low speed lowering okay.
in on position, start button pushed and released,
emergency disconnect contactor closed, gate
switches closed, foot pedal switch closed, platform
raised above 24 inches, high speed lowering
switch activated.
1. Positive side of high speed lowering switch.
0 volts - repair open wiring from low speed
switch to high speed switch.
2. Negative side of high speed lowering switch.
0 volts - replace high speed switch.
3. Positive side of 24 inch limit switch, wire #54.
212
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Section
C-code
PS
S5.4
5460
Version no
001
T-code
OE35
0 volts - repair open wiring from high speed

lowering switch to 24 inch limit switch.
4. Negative side of 24 inch limit switch.
0 volts - adjust or replace 24 inch limit switch.
5. Positive side of #2 lowering valve coil, wire
#53.
0 volts - repair open wiring from 24 inch limit
switch to #2 lowering valve coil.
6. Negative side of #2 lowering valve coil.
Battery volts - repair open wire from lowering
valve coil to battery negative, wire #22.
BT Products
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1996-10-15
213
F-code
Section
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PS
S5.4
5460
Version no
T-code
001
OE35
214
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Service Manual
1996-10-15
F-code
Section
PS
S5.7
5610
Pump Contactor
Version no
T-code
000
OE35
C-code
Pump Contactor
1
2
3
4
5
10
15
12
13
16
9
19
17
11
14
18
BT Products
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POS.
NO
DESCRIPTIO
POS.
NO
Base, magnet
Bushing
15
Clamp
Coil
Carrier
16
Lockwashe
Frame, magnet
10
Tip, movable
17
Screw, machine
Spring
11
Cap
18
Suppression
Armature
12
Spring
19
Seat
Base, bus
13
Washer, flat
Tip, contact
14
Nut, lock
Service Manual
DESCRIPTION
1997-10-29
POS.
NO
DESCRIPTION
215
F-code
Section
C-code
PS
S5.7
Pump Contactor
5610
Version no
T-code
000
OE35


damage copper base.
2. Disassembly
each part.
(16).
216
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1997-10-29
F-code
Section
PS
S5.7
5610
Pump Contactor
Version no
T-code
000
OE35
C-code

armature.
new ones.


etc.

a new bushing.

BT Products
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Service Manual
1997-10-29
217
F-code
Section
C-code
PS
S5.7
Pump Contactor
5610
Version no
T-code
000
OE35
3. Assembly



the vice.
218
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1997-10-29
F-code
Section
PS
S5.7
5610
Pump Contactor
Version no
T-code
000
OE35
C-code

bar/contacts.
BT Products
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1997-10-29
219
F-code
Section
C-code
PS
S5.7
Pump Contactor
5610
Version no
T-code
000
OE35
220
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1997-10-29
F-code
PS
Section
C-code
S5.7
5610
Steering Pump Contactor
Version no
T-code
000
OE35

1
2
3
4
5
10
15
12
13
16
9
19
17
11
14
18
BT Products
Return
POS.
NO
DESCRIPTIO
POS.
NO
Base, magnet
Bushing
15
Clamp
Coil
Carrier
16
Lockwashe
Frame, magnet
10
Tip, movable
17
Screw, machine
Spring
11
Cap
18
Suppression
Armature
12
Spring
19
Seat
Base, bus
13
Washer, flat
Tip, contact
14
Nut, lock
Service Manual
DESCRIPTION
1997-10-29
POS.
NO
DESCRIPTION
221
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Section
C-code
PS
S5.7
5610
Version no
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000
OE35


damage copper base.
2. Disassembly
each part.
(16).
222
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PS
Section
C-code
S5.7
5610
Version no
T-code
000
OE35

armature.
new ones.


etc.

a new bushing.

BT Products
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1997-10-29
223
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Section
C-code
PS
S5.7
5610
Version no
T-code
000
OE35
3. Assembly



the vice.
224
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F-code
PS
Section
C-code
S5.7
5610
Version no
T-code
000
OE35

bar/contacts.
BT Products
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1997-10-29
225
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Section
C-code
PS
S5.7
5610
Version no
T-code
000
OE35
226
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1997-10-29
F-code
PS
Section
C-code
S5.5
5710
EV100 Handset Operation
Version no
T-code
000

The Handset is a multi-functional tool to be used with the
EV100 LX and LXT SCR controls. The Handset consist of a
Light Emitting Diode (LED) display and a keyboard for data
entry.
BT Products AB
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227
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PS
S5.5
5710
Version no
T-code
000
2. Purpose
The purpose of the Handset is to allow authorized personal
to perform the following functions:
Monitor existing system fault codes for both traction

SCR systems.
Monitor intermittent random status code.
Monitor battery state of change on LXT systems.
Monitor hourmeter reading on traction SCR systems.
Monitor or adjust the following control functions:

- Creep speed
- Controlled Acceleration and 1A time
- Current Limit
- Steer pump time delay
- Plugging distance (Current)
- Pedal position plug range or disable
- A drop out current or disable
- Speed limit points (SL1,SL2, and SL3)
- Internal resistance compensation for battery state of
charge indication
- Battery voltage (36/48 volts is auto ranging)
Selection of card operation type:

- Standard traction card selection:
- Standard traction with Field Weakening
- Standard traction with speed limits
- Standard traction with Regan/Field Weakening
- High or Low current limit for all of the above.
228
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PS
Section
C-code
S5.5
5710
Version no
T-code
000
3. Operation
WARNING Before connecting or disconnecting the
handset tool, jack up the drive wheels of
the truck, turn off the key switch, unplug
the battery and discharge the capacitors.
At the SCR control traction card, unplug the Y plug if dash
display is in use and plug in the handset to the plug location
Y on the control card. After installing the handset tool, plug
in the battery and turn on the key switch. The following is the
start-up display sequence that will occur:
Start-up Display Sequence
Key Switch ON
Verify Display Seqments for

one second
8888
BDI Display
or
Blank Display
(No BDI used)
Diagnostics
override
with fault
Run Mode
BDI Display
or
Blank Display
(No BDI used)
Diagnostics
override
with fault
Key Switch OFF
Display traction
hourmeter for
four seconds
NOTE! The truck can be operated with the handset

connected, however, the adjustment knob
must be set fully clockwise to insure the
control operates at top speed.
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PS
S5.5
5710
Version no
T-code
000
4. Function Set-Up Procedures

WARNING Before making any adjustments to the
control you must consult the operating and
maintenance instructions supplied by the
vehicle manufacturer. Failure to follow
proper set up instructions could result in
mis-operation or damage to the control
system.
With the Handset connected, hold down the CONT key and
turn on the key switch. This will place you in the set up mode,
ready or monitor or adjust control function settings.
NOTE! The term push, means to depress key for
approximately one second.
Set Up Mode
Action
Display shows
Remarks
Hold down CONT, turn on key
8888
Segment check displayed
Push function number
U 005
Selected function number is displayed
After one second time delay
085
Stored value for the function is displayed
Push CONT
088
Displayed valve will blink
Charge value with adjustment knob
0125
Value changes while blinking
Push STORE
0125
New valve stored and blinking stops
Push ESC
8888
Segment check displayed
At this point another function can be monitored/changed by

pushing another function number, or the truck can be placed
in the run mode by holding the ESC key down for one second
or longer. The display will return to either the diagnostics
mode or the BDI display or a blank display (if BDI is not used
and there are no fault codes). The truck can now be operated
with the handset connected or the handset can be
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Section
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S5.5
5710
Version no
T-code
000
disconnected before operation.

NOTE! You can return to the segment check mode
at any time, by holding down the ESC key
until 8888 appears in the display.
BT Products AB
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1997-09-15
231
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Section
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PS
S5.5
5710
Version no
T-code
000
5. Description and Location
232
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PS
Section
C-code
S5.5
5710
Version no
T-code
000
6. Function Numbers for Controllers

IC3645EVLXCD1TT
IC3645EVLXCD1TX
6.1. Function 1
Stored Fault Code (Push 1)
This function register contains the last fault that shut down
truck operation (PMT type fault that is reset by cycling the key
switch). This fault code will be over written each time a new
fault occurs and be cleared from memory by adjusting the
value to zero.
6.2. Function 2
Creep Speed (Push 2)
This function allows for the adjustment of the creep speed of
the truck. A constant creep speed frequency will be
maintained when an accelerator input voltage between 3.7
and 3.5 volts or an accelerator ohmic input between 6K and
4.7K ohms is provided.
Range
Set
Resolution
Example:
5% to 15% on time
0 to 255
.03% per set unit
Setting of 20 = 5.6% on time
6.3. Function 3
Controlled Acceleration and 1A Time (Push 3)
This function allows for the adjustment of the rate of time it
takes for the control to accelerate to 96 percent applied
battery voltage to the motor on hard acceleration. The 1A
contactor will automatically close 0.2 seconds after the
controlled acceleration stops and the accelerator input is less
then 0.5 volts or less then 50 ohms.
Range
Set
Resolution
Example:
BT Products AB
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0.1 to 22.0 seconds

0 to 255
0.084 seconds per set unit
Setting of 20 = 1.8 seconds C/A
and 2.0 1A time.
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5710
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000
6.4. Function 4
Current Limit (Push 4)
This function allows for the adjustment of the current limit of
the control. The rating of the control will determine the range
of adjustment for this function. Please refer to the operating
instructions for the control used in this truck.
Range
Set
Example:
See control C/L curves

0 to 255
0 = minimum current
255 = maximum current
6.5. Function 5
Plugging Distance (Current) (Push 5)
This function allows for the adjustment of the plugging
distance of the truck. The larger the current setting, the
shorter the stopping distance.
Range
Set
Resolution
Example:
200 to 1000 amps

0 to 255
3.14 amps per set unit
Setting of 20 = 1263 amps
WARNING Plug settings must be in accordance with

control
operating instructions.
An
excessively high setting could cause
damage to control system or drive motor.
6.6. Function 6
1A Drop Out Current (Push 6)
This function allows for the adjustment of the 1A contactor
drop out current. The 1A contactor will be dropped out and
the vehicle motor torque will be limited to SCR current limit
when the set drop out current is reached.
Range
450 to 1260 amps
Set
0 to 250
Resolution 3.24 amps per set unit
Settings above 250 set units will disable 1A drop out function
(1A will not drop out).
Example:
234
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Section
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S5.5
5710
Version no
T-code
000
6.7. Function 11
Speed Limit 1 (SL1) (Push 11)
This function allows for the adjustment of the speed limit
(maximum battery volts to motor) when the SL1 limit switch is
normally closed switch connected to battery negative, the
switch opening enables speed limit.
Range
Set
96% to 0% battery volts

0 to 180
Setting of 0 set units will disable speed limit function and

allow top speed with no limit switch connected.
6.8. Function 12
Same as function 11 except using SL2 limit switch for input.
6.9. Function 13
Same as function 11 except using SL3 limit switch for input.
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PS
S5.5
5710
Version no
T-code
000
6.10. Function 14
Internal Resistance Compensation (Push 14)
This function is used when the Battery Discharge Indicator is
present. Adjustment of this function will improve the accuracy
of the BDI. In order to make this setting the voltage drop of
the battery under load must first be determined by following
the steps listed below.
1. Load the drive motor to 100 amps in 1A and record the
voltage (VO) at the SCR positive and negative power
terminal.
2. Load the drive motor to 200 amps in 1A and record the
voltage (VL) at the SCR positive and negative power
terminal.
3. Calculate voltage drop (VD) as follows:
VD=VO-VL
4. Use the table below to determine the setting using the
calculated VD as a reference.
EV100
Setting
VD
236
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EV100
Setting
VD
EV100
Setting
VD
EV100
Setting
VD
11.44
10
02.28
18
01.27
26
00.88
07.60
11
02.08
19
01.20
27
00.85
05.72
12
01.90
20
01.14
28
00.82
04.57
13
01.76
21
01.09
29
00.79
03.81
14
01.63
22
01.04
30
00.76
03.27
15
01.52
23
00.99
31
00.74
02.86
16
01.43
24
00.95
02.54
17
01.34
25
00.91
Service Manual
1997-09-15
F-code
PS
Section
C-code
S5.5
5710
Version no
T-code
000
6.11. Function 15
Battery Volts (Push 15)
This function allows for the adjustment of voltage range for
controls equipped with the Battery Discharge Indication
function. In order for the BDI to operate properly, the setting
as shown in the table must be entered.
Battery volts
Set units
24 volts
Between 0 and 31
36 volts
Between 32 and 44
The following functions have function numbers larger than the

numbers on the Handset keyboard. To access these
functions, push the CONT key and the number shown in the
following instructions at the same time.
6.12. Function 16
Pedal Position Plug (Push CONT and 1)
This function will allow the adjustment of the pedal position
plug range. Pedal position will reduce the plugging current to
the current value set by this function as the accelerator is
returned to the creep speed position. Maximum plug current
is obtained with the accelerator in the top speed position.
Range
Set
Resolution
Example
100 to 930 amps

0 to 255
3.2 amps per set unit
To disable the pedal position plug function, adjust the current

value to the same current value as the plug distance current.
Example: If plug distance current Function 5 is set at 500
amps, then set pedal plug current at 500 amps. With this
setting pedal position will have no effect on plugging distance.
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Section
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PS
S5.5
5710
Version no
T-code
000
6.13. Function 17
Card Type Selection (Push CONT and 2)
This function allows for the selection of the card type used for
your vehicle's application. The table below shows the setting
to select card application type depending on which control
card is used.
EV100
Standar
Speed
Function
with F
Limit
Regen/FW
STD C/L
0 to 4
20 to 24
40 to 44
High C/L
5 to 9
25 to 29
45 to 49
10 to 14
30 to 34
50 to 54
15 to 19
35 to 39
55 to 59
EV200
Standar
Speed
Function
with F
Limit
Regen/FW
STD C/L
64 to 68
84 to 88
104 to 108
74 to 78
94 to 98
114 to 118
STD C/L
(Auto plug)
High C/L
(Auto plug)
STD C/L
(Auto plug)
Settings for these functions should be made in between the

values shown.
WARNING These settings must be changed by
authorized personnel only, following
instructions supplied by the manufacturer.
Card type selection must be made within
the capabilities of the SCR control panel
used and the supporting electromechanical devices. Failure to comply with
proper application standards could result
in mis-operation or damage to the control
and/or motors.
238
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Section
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S5.5
5710
Version no
T-code
000
6.14. Function 18
Steer Pump Time Delay (Push CONT and 3)
This function allows for the selection of steer pump contactor
pick up input, either seat switch or directional switch closing
and adjustment of the time delay for the contactor drop out.
Pick up on foot pedal switch closure and time delay drop out
on foot pedal switch opening.
Range
Setting
Resolution
Example:
BT Products AB
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1.5 to 65 seconds
Between 0 and 128
.5 seconds per set unit
Setting of 20 = 10.5 seconds
1997-09-15
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S5.5
5710
Version no
T-code
000
240
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Service Manual
1997-09-15
F-code
Section
PS
M6.0
6000
Hydraulic System
Version no
T-code
001
OE35
C-code
Hydraulic System
1. Hydraulic Schematic
Component Enclosure
Reservoir (Vented)
Hydraulic Lines Joining
Cylinder (Single Acting)
Motor (Electric)
Cylinder (Double Acting)
Hydraulic Pump
Check Valve
Hydraulic Lines Crossing
Filter
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241
F-code
Section
PS
M6.0
Hydraulic System
Version no
T-code
001
OE35
C-code
6000
The hydraulic system consists of a compact hydraulic pump
unit, including a electric solenoid valve, pressure relief valve
and a cylinder(s) for lifting the platform.
2.1. Lift/lower
During lifting the duplex pump is turned by a single electric
motor. Oil is drawn from the reservoir into the inlet ports of
both pumps.
Oil flow from the pump outlet goes into the lift/lower control
valve block. For low speed lift, the oil entering the lift/lower
control valve block passes through a normally open solenoid
valve, a restrictor, and one way check valve and is directed
out of the valve block through hoses to the lift cylinders. For
high speed lift the normally open solenoid valve is electrically
closed and the normally closed solenoid valve is electrically
opened, the oil entering the lift/lower control valve block
passes through the normally closed solenoid valve and one
way check valve and is directed out of the valve block through
hoses to the lift cylinders. Oil flowing into the lift cylinder acts
upon all the internal surfaces of the cylinder. The pressure of
the oil forces the cylinder rod to extend out the top of the
cylinder. All lift cylinders are the positive-displacement type.
The only seals are in the cylinder head (gland nut). There are
no seals on the cylinder rod piston.
Equal oil pressure is applied to both the freelift and the
staging cylinders. The freelift cylinder rises first because it
has less weight to lift. The staging cylinder must raise the
same thing as the freelift cylinder plus the weight of the freelift
cylinder and the mast rails. The cylinders will continue to rise
as long as the pump motor is turned on and the oil is flowing
into the cylinders.
A nitrogen filled accumulator is used to soften the effects of
sudden pressure changes within the system. The lift/lower
control valve block contains a pressure relief valve. In the
event that pressure from the pumps exceeds the relief valve
setting then the excess pressure and flow is diverted back tot
he hydraulic reservoir.
When the pump motor is turned off lifting stops. The oil in the
lift cylinder is trapped by a check valve and two lowering
valves in the lift/lower control valve block.
242
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F-code
Section
PS
M6.0
6000
Hydraulic System
Version no
T-code
001
OE35
C-code
When lowering, the lowering solenoid valves in the lift/lower

control valve block are electrically activated. One of the
solenoid valves also has a manual release mechanism that
can be used to activate the valve without electrical control.
When the lowering solenoids are activated, oil is forced by
the weight of the load on the lift cylinders to flow from the lift
cylinders back to the reservoir. As the oil passes through the
lift/lower control valve block the amount of flow is regulated to
control the speed of descent.
2.2. Power Steering

The brake release pump and the steering pump are
contained in a duplex pump assembly driven by a single
motor. Separate adjustable pressure relief valves are built
into the pump housings. The upper pump is used for power
steering.
Fluid from the pump is directed to the power steering torque
generator. The torque generator is a sophisticated valve and
pump assembly that multiplies input torque and transfers it to
the output shaft. It operates on demand only and, when not
steering, the oil is allowed to return freely to the reservoir. The
input shaft of the torque generator is operated by a series of
cables, chains and pulleys from the operators steering
wheel. Mechanical stops are on these chains so that when
the steering wheel is turned to full stop no demand is made
on the torque generator.
2.3. Brake Release

The brake release pump and the steering pump are
contained in a duplex pump assembly driven by a single
motor. Separate adjustable pressure relief valves are built
into the pump housings. The lower pump, with smaller gears,
is used for the brake release. The brake pump also has a
normally open solenoid valve.
When the pump motor contactor is energized the solenoid
valve on the brake pump is energized and closes. With the
pump rotating and the solenoid valve closed, oil pressure is
directed to the pump outlet. This oil pressure operates the
brake release cylinder and pushes the brake actuator arm
BT Products
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1997-10-23
243
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Section
PS
M6.0
Hydraulic System
Version no
T-code
001
OE35
C-code
6000
inside the transmission to release the brakes. A pressure

relief valve holds the oil pressure at 180 psi.
When the pump motor is turned off the solenoid is deenergized and opens back up. This allows oil pressure in the
cylinder to be released and brakes are applied by springs
inside the transmission.
3. Maintenance
The hydraulic fluid level must be checked periodically. (See
the Planned Maintenance Schedule.) If the reservoir regularly
requires the addition of oil to maintain the proper level, then 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 the lift, lower and
other hydraulic functions for proper operation. If the truck will
not lift a full load, then the pressure relief setting should be
checked and adjusted. During normal operation, the pressure
relief setting will not change. As the pump wears with age,
some loss performance will be experienced. When this loss
becomes severe, the pump should be replaced.
4. Adjustments
The only adjustment to the hydraulic system is the pressure
relief setting. This adjustment is made by removing the screw
cap on the pressure relief valve and turning the screw to
make the adjustment. Turning the screw in clockwise, will
increase the pressure relief setting. The relief pressure is
properly set when the truck will lift its rated weight capacity
plus 10%.
244
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1997-10-23
F-code
PS
Section
C-code
M6.0
6000
Hydraulic Troubleshooting
Version no
T-code
001
OE35
1. Troubleshooting Chart
Troubleshooting hydraulic system will require both the
electrical and hydraulic troubleshooting. For instance,
solenoid valve coils should be suspected. Therefore, this
hydraulic troubleshooting section should be used until if has
been determined that the problem is not electrical.
Electrical troubleshooting is found in the electrical section.
The truck uses two separate hydraulic systems with a
common reservoir and return line filter. One duplex pump and
motor assembly supplies oil under pressure for the power
steering and brake release. A single pump and motor
assembly supplies oil under pressure to the lift/lower control
valve for lifting and lowering the platform.
NOTE! Proper care and cleanliness should be
observed in servicing to insure the oil does
not become contaminated with dirt or other
foreign material. Contaminants can be drawn
into the pump so as to stick or score pump
which will cause failure of the pump
assembly.
IF HYDRAULIC PUMP ASSEMBLY DOES NOT OPERATE
PROPERLY, A FEW PRELIMINARY CHECKS SHOULD BE
MADE:
1. Proper oil level
2. All electrical connections tight
3. Battery fully charged
After the preliminary check is accomplished, install a 0-3000
PSI pressure gauge on the quick coupler in the pressure line
from the pump. NPTF outlet port in the adapter. The
installation of the pressure gauge is required to insure proper
observation of what is occurring in the unit during trouble
shooting. Raise the cylinder to its upper limit stops to develop
maximum pressure of the unit, which will normally be passing
all flow over the relief valve. The pressure gauge should be
reading the set pressure of the relief valve. Remove pressure
on the system by actuating the solenoid operated release
valve.
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245
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Section
C-code
PS
M6.0
6000
Version no
T-code
001
OE35
The normal troubles that may occur with the pump assembly
have been grouped under three headings: Failure to (A)
Raise (B) Hold (C) Lower the load. One or more of the listed
trouble sources may be causing improper operation. Refer to
the proper heading (i.e. relief valve) for detailed instructions
for disassembly, check and adjustment of parts to remedy the
trouble.
A. If pump operates but will only develop low pressure or
slow lift:
1. Relief valve seat scored, foreign particles under
ball or relief valve out of adjustment (See relief
valve).
2. Dirt in solenoid-operated release (See solenoid
operated release valve).
3. Pump worn - replace pump.
B. If pump develops pressure but will not hold:
1. Dirt in solenoid-operated release (See solenoid
operated release valve).
2. Relief valve seat scored, foreign particles under
ball or relief valve out of adjustment (See relief
valve).
C. If pump develops pressure but will not release load:
1. No electrical contact to solenoid operated release
valve (See solenoid operated release valve).
2. Solenoid in
burned out.
solenoid-operated
release valve
3. Relief valve bottomed causing pressure to go

beyond the unloading limit of the solenoid release
valve (See relief valve).
Lift
A. No lift; pump motor runs.
1. Hydraulic fluid reservoir low or empty.
Check hydraulic fluid level, fill to within 2 in. of filler
tube with new clean oil.
2. Manual lowering valve open or leaking.
Close or replace manual lowering valve.
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PS
Section
C-code
M6.0
6000
Version no
T-code
001
OE35
3. Lowering solenoids stuck open, one or both.

Replace lowering solenoids.
4. Relief pressure too low.
Check pressure relief setting.
Rated weight capacity plus 10 percent.
5. Overloaded truck.
Reduce load to capacity.
6. Mechanical binding or failure in mast.
Repair mast.
7. No oil flow or pressure from pump.
Check flow from pump.
Check supply oil to pump, hoses, and strainer.
Check pump to motor coupling.
Check internal pump parts.
B. No high speed lift
Low speed lift okay but lift speed does not increase as
lift button is pressed to high speed position.
1. Solenoid valve not closing/opening.
Verify correct electrical operation; replace solenoid
valve.
2. Internal damage in pump.
Repair or replace pump.
C. No low speed lift
Pump motor runs, high speed lift appears okay.
1. Check lift solenoid valve.
Repair or replace solenoid valves.
2. Check adjustable restrictor.
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1997-10-23
247
F-code
Section
C-code
PS
M6.0
6000
Version no
T-code
001
OE35
248
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Service Manual
1997-10-23
F-code
Section
PS
C-code
M6.1
6140
Lift Pump Assembly
Version no
T-code
001
OE35
Lift Pump Assembly

Torque Screws to
34-38 ft./lbs.
Bronze Face Toward Gears
10
11 12
9
7
6
5
2
13
14
Bronze Face Toward Gears
POS.
NO
1K
BT Products
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DESCRIPTION
Seal, shaft
POS.
NO
DESCRIPTION
POS.
NO
DESCRIPTION
6K
Plate, wear
11
Washer, flat
Gear, drive
12
Screw, cap
Body
Pin, dowel
8K
Plate, thrust
13
Plug, pipe
4K
Nylatron
9K
Seal, gasket
14
Gear, driven
5K
Spacer, rubber
10
Cover-side, port
Kit, seal
Service Manual
1997-12-15
249
F-code
Section
C-code
PS
M6.1
Lift Pump Assembly
Version no
T-code
001
OE35
6140
1. Removal
The hydraulic pump and motor assembly must be removed
from the truck in order to separate the pump and motor. The
platform must be fully lowered before removing pump.
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.
Pump
Motor

parking brake is applied.
2. Lower platform to release pressure in hydraulic
system.
4. Open access door fully to gain access to the
hydraulic pump and motor assembly.
Pump
Washer
Screw
Hydraulic pump and motor
5. Remove hydraulic line(s) from hydraulic pump

assembly and cap ends to prevent contaminants
from entering the hydraulic system.
6. Disconnect electrical power cables from motor and
mark their position.
7. Remove the screws securing the hydraulic pump
and motor assembly to the frame.
8. Thoroughly clean exterior of hydraulic pump and
motor assembly before disassembly can begin.
reduced to less than 30 psi. and then only
250
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1997-12-15
F-code
PS
Section
C-code
M6.1
6140
Lift Pump Assembly
Version no
T-code
001
OE35
2. Disassembly
assembly.
1. Before disassembly, clean exterior of the hydraulic
pump and motor assembly in a cleaning solvent to
2. Set unit in vertical position with pump end up.
3. Scribe a line on both pump and motor to aid when
reassembling.
4. Remove two screws and washers securing pump
to motor.
5. Tap pump lightly to loosen. Lift pump off.
6. Clean exterior of pump in a cleaning solvent to
7. Scribe a line on both body and base of pump to aid
when reassembling.
8. Secure pump in vise (with soft jews use light
clamping pressure) with shaft end down, remove
screws (12) and washers (11).
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1997-12-15
251
F-code
Section
PS
M6.1
Lift Pump Assembly
Version no
T-code
001
OE35
C-code
6140
NOTE! During disassembly, take special note of the

wear patterns on wear plate (8), thrust plate
(6), and body (2). Relate these patterns th
the inlet and outlet sides of the pump. The
large port in the rear cover (10) always
corresponds to the inlet side of the pump.
The inlet side can be further identified by the
gear contact patterns in the body (gear)
bore. The wear plate (8) wwill have a
somewhat heavier wear pattern on the inlet
side. The thrust plate (6) will also have a
pattern that can be established for
reassembly. Also note that the long journal
of the driven gear (14) is toward the front of
the pump.
9. Separate rear cover (10) from body (2) by
supporting pump, shaft end up, on the mounting
flanges and pressing on drive shaft end in arbor
press, or tap drive shaft with a plastic mallet.
WARNING Use one hand to support rear cover from
underneath, since cover and internal parts
will drop suddenly when dowels are
disengaged.
10. An alternative method of removing the rear cover is
to pry simultaneously with two large screwdrivers
in relieved areas between body and cover.
WARNING At no time should screwdrivers be inserted
further into the pump body more then the
depth of the relieved areas. Any burr mast
be removed from the body (2) and/or cover
(10) after this operation to assure a good
seal between body and cover.
11. Holding pump, shaft end down, remove rear cover
(10). Dowel pins (3) may remain either with body or
rear cover.
NOTE! Seal gasket (9) and thrust plate (8) may remain
with rear cover (10). Should they remain with
body (2), remove gasket (9) and lift out thrust
plate (8) before proceeding.
252
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1997-12-15
F-code
PS
Section
C-code
M6.1
6140
Lift Pump Assembly
Version no
T-code
001
OE35
12. Lift out drive gear (14), drive gear (7), and wear
plate (6).
13. Invert pump body with shaft seal up. Remove shaft
seal (1) by prying it out with a large screwdriver.
WARNING Care should be taken not to damage (gouge
the shaft seal bore, this will result in shaft
seal leakage.
BT Products
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1997-12-15
253
F-code
Section
PS
M6.1
Lift Pump Assembly
Version no
T-code
001
OE35
C-code
6140
3. Inspection
assembly.
1. Thoroughly clean all parts and remove all nicks
and burrs with emery cloth.
2. Inspect wear plate (8) and thrust plate (8). Replace
if scoring or uneven wear is found.
NOTE! Somewhat heavier wear pattern is normal on
the lower pressure (inlet) side of the plates
(6 and 8). However, there should be no
heavy scoring in this area.
3. Remove pressure loading seal (5) and Nylatron (4)
from wear plate. This seal may be two-piece or
one-piece design. In either case, discard old seal
or seals. All replacement seals are two-piece
design and should be installed into groove. The
seal should extend a minimum of 0.005 in. (0.127
mm) beyond surface of wear plate. Do not push
seals below wear plate surface at any point.
4. Inspect bushings in body and cover. Replace cover
or body if bushings are heavily scored or burned.
5. Inspect gear journals and faces. Replace if journals
or faces are scared or worn.
6. Inspect body for wear and scoring. If gear contact
wear on low pressure side (inlet) exceeds 0.005 in.
(0.127 mm) depth, replace pump. If the body is
254
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Service Manual
1997-12-15
F-code
PS
Section
C-code
M6.1
6140
Lift Pump Assembly
Version no
T-code
001
OE35
usable, remove wipe burr with suitable de-burring

tool.
BT Products
Return
Service Manual
1997-12-15
255
F-code
Section
PS
M6.1
Lift Pump Assembly
Version no
T-code
001
OE35
C-code
6140
4. Assembly
assembly.
1. All parts should be cleaned and dried thoroughly.
Metal parts should be lightly oiled prior to
reassembly.
NOTE! The installation of new parts contained in
seal kit are recommended at each time
pump is overhauled.
2. Place body (2) on flat plate with shaft seal bore up.
Install new shaft seal (1). Press seal into bore until
it is to approximate depth shown. Pack the area
between the double lip of the seal with Lubriplate
or equivalent.
3. Invert body so that gear bores are up. Install wear
plate (8) in bottom of bore, making sure that
pressure loading seals (4) and (5) are positioned
properly in seal grooves and installed against
bottom of bore surface. Ensure outside of W seal
is exposed to the discharge pressure (or legs of
W seal pointing toward the suction port).
4. Lubricate bushings in body and face of wear plate
with SAE 10 oil.
5. Apply Lubriplate or equivalent to outer surface of
drive shaft installation sleeve. Insert sleeve into
shaft seal from front of pump until sleeve contacts
256
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Service Manual
1997-12-15
F-code
PS
Section
C-code
M6.1
6140
Lift Pump Assembly
Version no
T-code
001
OE35
drive gear bushing. Install drive gear (7) and driven

gear (14), with long journal toward the shaft seal of
the pump.
6. Lubricate rear gear faces and journals with SAE 10
oil and install trust plate (6) in its original position,
bronze face toward the gears.
7. Apply a small amount of grease to rear cover seal
(9) and install seal into groove.
8. Lubricate rear cover bushings with SAE 10 oil.
9. Position pump with shaft end down, install the rear
cover (3), aline scribe marks on cover and body.
10. Insert cap screws (12) and washers in pump body.
Torque screws to 34 to 38 ft-lb.
11. Check that drive shaft turns with adjustable wrench
without evidence of mechanical bind.
BT Products
Return
Service Manual
1997-12-15
257
F-code
Section
PS
M6.1
Lift Pump Assembly
Version no
T-code
001
OE35
258
Return
C-code
6140
Service Manual
1997-12-15
F-code
Section
PS
S7.0
7110
Mast, 2 Stage
Version no
T-code
001
OE35
C-code
Mast, 2 Stage
POS.
NO
BT Products
Return
DESCRIPTION
POS.
NO
DESCRIPTION
Platfor
Pin, dowel
Column, inner
Screw, cap
Screw, cap
Pin
Column, outer
Pin, cotte
Service Manual
1996-10-15
259
F-code
Section
C-code
PS
S7.0
Mast, 2 Stage
7110
Version no
T-code
001
OE35
1. Shimming Mast on Truck.

WARNING When blocking mast columns to prevent
lowering, always block both sides of the
column. Otherwise, the truck could tip over
on its side.
1.1. Shimming the Platform.

1. Disconnect battery and remove battery from truck.
2. Attach a hoist to top of platform and hoist to loosen
lift chains. This will allow removal of lift chain
anchor pins and electrical cable.
3. Thoroughly clean off all outside dirt around mast
roller bearings.
4. With platform hoisted to the top of the inner
channel, determine the number of shims required
by prying the platform to one side and slipping
shims between the bearings and web on column.
Add shims by hand until no more may be added.
5. Divide shims as equally as possible between the
two bearings and install under bearings.
6. Hydraulically lift up inner column to remove the
platform.
7. Lower platform down inner column to expose the
bearings. Remove bearings to install shims behind
bearings.
8. Raise platform up inner column as far as it will go
under normal operation. Check bearing shimming
as platform is raised.
260
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Service Manual
1996-10-15
F-code
Section
PS
S7.0
7110
Mast, 2 Stage
Version no
T-code
001
OE35
C-code
Remove shims as required if tight spots are

encountered where platform cannot move
smoothly. Check for excessive bearing clearance
with platform in lowered position by prying platform
to one side and checking with a 0.030 in. shim.
Maximum clearance must not exceed 0.030 in.
9. Lower platform to install lift chain anchor pins,
steering wheel chain, and electrical cable. When
installing lift chains, chains are to be free of twist
and adjusted for equal tension with adjusting nut
and locknut torqued to 200 ft-lb. (271 Nm). Chains
are to be centered on sheave within 1/32 in.
10. Remove truck from stands and test operation of
unit. Check operation first with no load, then with
capacity rated load.
11. Install and connect battery to truck.
1.2. Shimming the Rails

In order to shim the mast rails, the platform will have to be
removed.
1. Disconnect battery and remove from unit.
WARNING Always make sure unit is on level surface
before work can begin.
2. The truck will have to be hoisted and blocked a foot
off floor.
3. Attach a hoist to top of platform and raise platform
to loosen lift chains.
4. Remove chain anchor pins, steering wheel chain,
and electrical cable. Hydraulically raise inner
column just enough to get platform out through the
bottom. Lower platform down and out of inner
column.
Set platform away from truck.
5. Attach a hoist to top of inner column and hoist to
loosen lift chains. This will allow removal of lift
chain anchor pins.
BT Products
Return
Service Manual
1996-10-15
261
F-code
Section
C-code
PS
S7.0
Mast, 2 Stage
7110
Version no
T-code
001
OE35
6. Remove cap screw on top of inner column which

secures lift cylinder. Once column is lifted with
hoist, the lift cylinder is free to move or fall. Secure
lift cylinder in place.
7. Determine the number of shims required by prying
inner column to one side and slipping shims
between bearing and web on column. Add shims
by hand until no more may be added.
two bearings on both top and bottom of column
and install under bearings.
9. Lower inner column down and out of the outer
column to expose the two bottom bearings, two top
bearings and install shims under bearings.
10. Raise inner column up outer column as far as it will
go under normal operation. Check bearing
shimming as inner column is raised. Remove
shims as required if tight spots are encountered
where mast cannot move smoothly. Check for
excessive bearing clearance with columns in
closed position by prying column to one side and
check with a 0.030 in. shim. Maximum clearance
must not exceed 0.030 in.
11. Attach a hoist to top of platform frame and place
platform in inner column.
12. Hoist platform up inner column to attach lift chain
anchor pins. When installing lift chains, chains are
to be free of twists and adjusted for equal tension
with adjusting nuts and locknuts torqued to 200 ftlb (271 Nm). Chains are to be centered on sheave
within 1/32 in.
13. Connect lift chains, steering wheel chain, and
electrical cable.
14. Remove hoist from mast and lower unit to floor.
15. Install and connect battery to unit.
16. Loosen locking nuts on chain anchors. Adjust nuts
until both chains are free of twist and of equal
tension. Tension is correct if you can force lift
chains sideways approximately 1/2 in. to 1 in.
262
Return
Service Manual
1996-10-15
F-code
Section
PS
S7.0
7110
Mast, 2 Stage
Version no
T-code
001
OE35
C-code
before platform raises slightly.

Retighten locknuts on chain anchors.
17. Test operation of mast and check for tight or loose
spots and reshim as needed. Check operation first
with no load, then with capacity rated load.
BT Products
Return
Service Manual
1996-10-15
263
F-code
Section
C-code
PS
S7.0
Mast, 2 Stage
7110
Version no
T-code
001
OE35
2. Two Stage Mast

2.1. Removal
2. The truck will have to be hoisted and blocked about
6 inches off the floor.


and electrical cable.
Hydraulically raise inner column enough to remove
platform. Lower platform down and out inner
column. Lower to floor and place out of the way.
5. Attach a hoist to top of mast through both inner and
outer columns.
6. Before disassembling hoses and fittings from
cylinder, make sure cylinder is in lowered position
and thoroughly clean off all outside dirt around
fittings. After disconnecting hose, immediately cap
ports on both cylinder and hose.
7. Disconnect electrical cable from mast.
8. Remove four mast mounting bolts and hoist to
remove mast from unit.
264
Return
Service Manual
1996-10-15
F-code
Section
PS
S7.0
7110
Mast, 2 Stage
Version no
T-code
001
OE35
C-code
2.2. Installation
1. Install mast on unit using four mast mounting bolts
secure mast in place. Torque mounting bolts to 200
ft-lb. (271 Nm).
2. Connect hydraulic hose to lift cylinder.
3. Hydraulically lift inner column enough to get
platform in.
4. Hoist platform and slide up inner column.
5. Connect lift chain anchor pins.
6. Connect steering wheel chain and electrical cable
to unit.
until both chains are free of twists and of equal
tension. Tension is correct if you can force lift chain
sideways approximately 1/2 in. to 1 in. before
platform raises slightly.
8. Retighten locknuts on chain anchors.
9. Grease all chain sheaves.
10. Bleed air from cylinder.
11. Install and connect battery and test operation of
mast and unit.
BT Products
Return
Service Manual
1996-10-15
265
F-code
Section
C-code
PS
S7.0
Mast, 2 Stage
7110
Version no
T-code
001
OE35
2.3. Disassembly
1. Lower mast assembly to a horizontal position
2. Remove lift chain anchors, lift chain, electrical
cable and hydraulic hose from mast.
3. Remove a cap screw from top of inner column
securing cylinder rod end. Remove two cap screws
and clamp from bottom of cylinder and remove
cylinder assembly.
NOTE! Lift cylinder(s) can be repaired at this time, if
needed.
4. Remove chain anchor bolts.
5. Remove chain sheaves and cable sheaves from
inner column.
6. Pull inner column straight forward until it stops (hits
bearings) and then 90 degrees straight up from
outer column.
7. Remove mast bearings and shim washers from
both columns.
9. Thoroughly clean all parts.
266
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Service Manual
1996-10-15
F-code
Section
PS
S7.0
7110
Mast, 2 Stage
Version no
T-code
001
OE35
C-code
2.4. Assembly
1. Thoroughly clean all parts and air dry.
2. Install mast roller bearing on both the inner and
outer columns.
3. Assemble inner column in the outer column and
slide columns together.
the inner column to one side and slipping shims
between the bearing and web on the mast. Add
shims by hand until no more can be added.
6. Extend inner column through outer column as far
as it will go under normal operation. Check bearing
shimming as column is extended. Remove shims
as required, if tight spots are encountered where
assembler cannot roll mast by hand.
Check for excessive clearance with columns in the
fully closed position by prying column to one side
and checking with a 0.030 in. shim. Maximum
clearance must not exceed 0.030 in.
Check for excessive bearing clearance with
columns in the fully extended position by prying
column to one side and checking with a 0.030 in.
shim. Maximum clearance must not exceed 0.030
in.
7. Install lift cylinder assembly.
8. Install grease fittings in pins, if removed.
BT Products
Return
Service Manual
1996-10-15
267
F-code
Section
C-code
PS
S7.0
Mast, 2 Stage
7110
Version no
T-code
001
OE35
9. Press roller bearings in lift chain sheaves, grease

roller bearings, and slide inner races in roller
bearings.
10. Install shim washers on either side of lift chain
sheaves and install in inner column. Slide pins
through sheaves and secure pins with two cap
screws and lockwashers, do this to both chain
sheave pins.
11. Install bearing in electrical sheave, grease bearing
and install spacers on either side of bearing.
12. Install electrical sheave in proper location on inner
column and secure with one cap screw and
lockwasher.
13. Install bearings in steering chain sheaves, grease
bearings. Install spacer between sheaves and on
outside of sheaves.
14. Install steering sheaves in proper location on inner
column and secure with one cap screw and
lockwasher.
15. Push inner and outer columns together and install
cap screw in inner column to secure lift cylinder.
16. Install lift chain anchors through outer column and
thread wheel nut on anchors and secure with jam
nut.
17. Install lift chain on chain anchors and secure with
chain pins. After chain pins have been installed,
run lift chain over chain sheaves, making sure
chain and sheaves are properly aligned.
18. Lubricate the grease fittings with Tex. Ref. C & C
No. 880 using a standard lube gun.
268
Return
Service Manual
1996-10-15
F-code
Section
PS
S7.1
7110
Mast, 3 Stage
Version no
T-code
001
OE35
C-code
Mast, 3 Stage
POS.
NO
BT Products
Return
DESCRIPTION
POS.
NO
DESCRIPTION
Platfor
Screw, cap
Column, inner
Pin
Column, intermediate
Pin, cotte
Column, outer
Service Manual
1996-10-15
269
F-code
Section
C-code
PS
S7.1
Mast, 3 Stage
7110
Version no
T-code
001
OE35
1. Shimming Mast on Truck.

on its side.
1.1. Shimming the Platform.

1. Disconnect battery and remove battery from truck.
2. Attach a hoist to top of platform and hoist to loosen
lift chains. This will allow removal of lift chain
anchor pins and electrical cable.
3. Thoroughly clean off all outside dirt around mast
roller bearings.
the rear of platform to one side and slipping shims
between the bearings and web on the column. Add
shims by hand until no more can be added.
6. Hydraulically lift up inner column enough to remove
platform.
7. Lower platform down inner column to expose
bearings. Remove bearings to install shims behind
bearings.
8. Raise platform up inner column as far as it will go
under normal operation. Check bearing shimming
as the platform is raised. Remove shims as
required If tight spots are encountered where
assembler cannot move platform smoothly. Check
270
Return
Service Manual
1996-10-15
F-code
Section
PS
S7.1
7110
Mast, 3 Stage
Version no
T-code
001
OE35
C-code
for excessive bearing clearance with platform in

fully lowered position by prying platform to one side
clearance must not exceed 0.030 in. Check for
excessive bearing clearance with platform in the
fully raised position by prying platform to one side
9. Lower platform to install lift chain anchor pins, and
electrical cable. When installing lift chains, chains
are to be free of twists and adjusted for equal
tension with adjusting nuts (wheel nuts) and
locknuts (jam nuts) torqued to 200 ft-lb. (271 Nm).
Chains are to be centered on sheave within 1/32
in.
10. Remove hoist from platform and test operation of
unit. Check operation first with no load, then with
capacity rated load.
11. Install and connect battery to truck.
1.2. Shimming the Rails.

In order to shim the mast rails, the platform will have to be
removed.
2. The truck will have to be hoisted and blocked a foot
off the floor before work can begin.
and electrical cable. Hydraulically lift up inner
column enough to remove platform.
Lower platform down and out inner column. Place it
away from truck.
BT Products
Return
Service Manual
1996-10-15
271
F-code
Section
C-code
PS
S7.1
Mast, 3 Stage
7110
Version no
T-code
001
OE35
5. Attach hoist to top of inner column and hoist to

loosen lift chain. This will allow removal of lift chain
anchor pins.
6. Before disconnecting hoses and fittings from inner
column, thoroughly clean off all outside dirt around
fittings. After disconnecting hoses, immediately
cap ports on tubes and hoses to prevent
contaminants from entering the hydraulic system.
NOTE! Make note of which port the hoses are from
for easier installation.
7. Raise inner column.
inner column to one side and slipping shims
between bearings and web on column. Add shims
10. Lower inner column down and out the intermediate
column to expose two bottom bearings and install
shims under bearings.
two bearings on top of intermediate column and
install under bearings.
12. Raise inner column up intermediate column as far
shimming as inner column is raised. Remove
shims as required, if tight spots are encountered
where assembler cannot move mast smoothly.
columns in lowered position by prying column to
one side and check with 0.030 in. shim. Maximum
13. Attach a hoist to top of both inner and intermediate
column.
272
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Service Manual
1996-10-15
F-code
Section
PS
S7.1
7110
Mast, 3 Stage
Version no
T-code
001
OE35
C-code
14. Remove cap screws which secure lift staging

cylinders at the top of the intermediate column.
Once columns are lifted with hoist, the lift cylinders
is free to move or fall. Secure lift cylinders in place.
intermediate column to one side and slipping shims
between bearing and web on column. Add shims
17. Lower intermediate column down and out the outer
column to expose the two bottom bearings and
install shims under bearings.
18. Raise intermediate column up outer column as far
shimming as intermediate column is raised.
Remove shims as required if tight spots are
encountered where assembler cannot move mast
smoothly. Check for excessive bearing clearance
with columns in the fully lowered position by prying
column to one side and check with a 0.030 in.
in.
Check for excessive bearing clearance with inner
column in fully raised position by prying column to
one side and checking with a 0.030 in. shim.
Maximum clearance must not exceed 0.030 in.
19. Push intermediate and outer columns together and
install cap screw in intermediate column to secure
lift staging cylinder and attach a hoist to top of lift
platform frame into place in inner column.
20. Hoist platform up inner column to attach lift chain
anchor pins. When installing lift chains, chains are
to be free of twists and adjusted for equal tension
with adjusting nuts (wheel nut) and locknuts (jam
nuts) torqued to 200 ft-lb. (271 N m). Chains are to
be centered on sheaves within 1/32 in.
21. Connect electrical cable and attachment hydraulic
hoses.
BT Products
Return
Service Manual
1996-10-15
273
F-code
Section
C-code
PS
S7.1
Mast, 3 Stage
7110
Version no
T-code
001
OE35
22. Remove hoist from mast and lower unit to floor.

23. Install and connect battery to unit.
24. Loosen locking nuts on lift chain anchors. Adjust
nuts until both chains are free of twists and of equal
tension. Tension is correct if you can force lift
chains sideways approximately 1/2 in. to 1 in.
before lift platform raises slightly.
Retighten locknuts on chain anchors.
25. Test operation of mast by checking for tight or
loose spots and reshim if found. Check operation
first with no load, then with rated load.
274
Return
Service Manual
1996-10-15
F-code
Section
PS
S7.1
7110
Mast, 3 Stage
Version no
T-code
001
OE35
C-code
2. Three Stage Mast

2.1. Removal
2. The truck will have to be hoisted and blocked 6 in.
off the floor before work can begin.
and electrical cable. Hydraulically raise inner
column enough to remove platform. Lower platform
down and out inner column and set out of way.
5. Attach a hoist to top of mast through all three mast
columns.
6. Before disassembling hoses and fittings from
cylinders, make sure cylinders are down and
thoroughly clean off all outside dirt around fittings.
After disconnecting hose, immediately cap ports on
both cylinder and hoses.
7. Disconnect electrical cable
hydraulic hoses from mast.
and
attachment
8. Remove four mast mounting bolts and hoist to

remove mast from unit.
BT Products
Return
Service Manual
1996-10-15
275
F-code
Section
C-code
PS
S7.1
Mast, 3 Stage
7110
Version no
T-code
001
OE35
2.2. Installation
1. Install mast on unit using four mast mounting bolts
securing mast in place. Torque to 260 ft-lb. (350
Nm).
2. Connect hydraulic hoses to lift cylinders.
3. Hydraulically raise inner column enough to get
platform in.
4. Hoist platform and slide up inner column.
5. Connect lift chain anchor pins, steering wheel
chain, and electrical cable to platform.
6. Connect electrical cable and attachment hydraulic
hoses to unit.
until both chains are free of twists and of equal
tension. Tension is correct if you can force lift chain
sideways approximately 1/2 in. to 1 in. before lift
platform raises slightly.
8. Retighten locknuts on chain anchors.
9. Grease all chain sheaves.
10. Bleed air from cylinders.
11. Install and connect battery and test operation of
mast and unit.
276
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Service Manual
1996-10-15
F-code
Section
PS
S7.1
7110
Mast, 3 Stage
Version no
T-code
001
OE35
C-code
2.3. Disassembly
1. Lower mast assembly to a horizontal position
2. Remove lift chain anchors, lift chain, hydraulic
hoses and electrical cable from mast.
3. Remove freelift chain anchor, two cotter pins, and
two cylinder anchor pins from inner column.
Remove four bolts from freelift cylinder mounting
bracket, then remove freelift from inner column.
NOTE! Free lift cylinder can be repaired at this time,
if needed.
4. Remove chain sheaves and cable sheaves from all
columns.
5. Remove column stops from outer column.
6. Pull inner column straight forward until it stops (hits
bearings) and then 90 degrees straight up from
intermediate column.
7. Remove cap screws from top of intermediate
column and remove staging cylinder assemblies by
pushing intermediate column forward.
NOTE! Staging cylinders can be repaired at this
time, if needed.
8. Pull intermediate column straight forward until it
stops (hits bearings) and then 90 degrees straight
up from outer column.
9. Remove mast bearings and shim washers from all
columns.
10. Thoroughly clean all parts.
BT Products
Return
Service Manual
1996-10-15
277
F-code
Section
C-code
PS
S7.1
Mast, 3 Stage
7110
Version no
T-code
001
OE35
2.4. Assembly
1. Thoroughly clean all parts and air dry
2. Install mast roller bearings
intermediate and outer columns.
on both the
3. Assemble intermediate column in the outer column

and slide columns together.
between bearing and web on the mast. Add shims
by hand until no more can be added.
6. Extend intermediate column through outer column
as far as it will go under normal operation. Check
bearing shimming as column is extended. Remove
where assembler cannot roll mast by hand.
column to one side and checking with a 0.030 in.
in.
7. Assemble inner column in the intermediate column
and slide columns together.
278
Return
Service Manual
1996-10-15
F-code
Section
PS
S7.1
7110
Mast, 3 Stage
Version no
T-code
001
OE35
C-code

between bearing and web on the mast. Add shims
by hand until no more can be added.
10. Extend inner column through intermediate column
as far as it will go under normal operation. Check
bearing shimming as column is extended. Remove
where assembler cannot roll mast by hand.
column to one side and checking with a 0.030 in
in.
11. Install column stops in outer column and torque to
260 ft-lb. (350 Nm).
12. Install staging lift cylinder assembly in intermediate
column lower end.
13. Press roller bearings in lift chain sheaves, grease
roller bearings, and slide inner races in roller
bearings.
14. Install shim washers on either side of lift chain
sheaves and install in intermediate column. Slide
pins through sheaves and secure pins with two cap
screws and lockwashers. Do this to both chain
sheave pins.
15. Install bearing in electrical sheave, grease bearing
and install spacers on either side of bearing.
16. Install electrical sheave on intermediate column
and secure with a cap screw and lockwasher.
17. Push intermediate and outer columns together and
install cap screw in intermediate column to secure
staging lift cylinder.
BT Products
Return
Service Manual
1996-10-15
279
F-code
Section
C-code
PS
S7.1
Mast, 3 Stage
7110
Version no
T-code
001
OE35
18. Install lift chain anchors through outer column and

thread wheel nut on anchors and secure with jam
nut.
19. Install lift chain on chain anchors and secure with
chain pins. After chain pins have been installed,
run lift chain over chain sheaves, making sure
chain and sheaves are properly aligned.
20. Install freelift cylinder assembly on inner column
and secure with four cap screws and nuts.
21. Connect hydraulic lines to lift cylinder.
22. Lubricate the grease fittings with Tex. Ref. C & C
No. 880 using a standard lube gun.
280
Return
Service Manual
1996-10-15
F-code
Section
PS
C-code
S7.3
7310
Lift Cylinder, 2 Stage
Version no
T-code
000
OE35
Torque to
250/300 ft./lbs.
POS.
NO
DESCRIPTION
Tube, cylinder
Retainer
Pin
Spring
Ball
POS.
NO
6
7K
DESCRIPTION
Piston
POS.
NO
11
DESCRIPTION
Bearing
Ring, wear
12K
Ring, wear
Rod, cylinder
13K
Seal
9K
O ring
14K
Wiper
10K
Ring, backup
Kit, seal
The lift cylinders are the positive displacement type, meaning

there are NO seals on the lower end of the cylinder rod. The
lift cylinder can be resealed without removing from the truck.
NOTE! CLEANLINESS! Perform procedures in a
clean environment. Make sure all parts are
cleaned before disassembly and kept clean
during assembly.
BT Products
Return
Service Manual
1997-12-15
281
F-code
Section
PS
S7.3
Version no
T-code
000
OE35
C-code
7310
1. Cylinder Repair
1.1. Removal
1. Park the truck on a level surface and apply the
brake.
2. Fully extend the cylinder to inspect the rod (8) for
gouges or pits. If gouges or pits are detected, then
the cylinder must be removed for repair.
3. Raise the cylinder rod approximately 6 inches.
Block the mast to prevent lowering.
on its side.
4. Remove cap screw on top of inner column securing
cylinder rod to inner column.
5. Lower cylinder so the chains, hoses, and electric
cables are loose. Disconnect the battery
6. Remove cylinder bar securing cylinder assembly to
bottom of inner column.
7. Remove cylinder assembly from mast and truck.
8. Clean the exterior of the lift cylinder.
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1.2. Disassembly
1. Remove bearing (11) from the cylinder tube (1).
2. Remove and discard packing, back-up ring, O ring,
rod wiper and bearing retainer from the bearing
(11). Use care NOT to damage the inside of the
bearing (11).
1.3. Assembly
1. Install new bearing, seals and rod wiper in the
gland. The lip of the wiper must face outward. It is
not necessary to replace wear ring (7), unless the
rod (8) was removed for repair.
1.4. Installation
1. Install cylinder assembly in bottom of mast and
secure cylinder assembly with cylinder bar using
two cap screws.
2. Lower mast and secure top of cylinder assembly
with cap screw though inner column and cylinder
rod.
3. Check hydraulic oil level in tank and fill if needed.
4. Connect battery.
5. Test for proper operation.
6. Recheck hydraulic oil level in tank after air is
removed from hydraulic system and fill if needed.
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7310
Freelift Cylinder, 3 Stage
Version no
T-code
000
OE35

Torque to
250/300 ft./lbs.
POS.
NO
Return
POS.
NO
Retainer
Pin
8K
Spring
4
5
6K
BT Products
DESCRIPTION
DESCRIPTION
DESCRIPTION
13K
Wiper, cylinder
O ring
14
Tube, cylinder
9K
Ring, backup
15
Screw
Ball, steel
10
Bearing
16
Washer, seal
Piston
11K
Ring, wear
Kit, seal
Ring, wear
12K
Seal
Service Manual
Rod, cylinder
POS.
NO
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The lift cylinders are the positive displacement type, meaning

there are NO seals on the lower end of the cylinder rod. The
lift cylinder can be resealed without removing from the truck.
NOTE! CLEANLINESS! Perform procedures in a
clean environment. Make sure all parts are
cleaned before disassembly and kept clean
during assembly.
1. Freelift Cylinder Repair

1.1. Removal
brake.
2. Fully extend the cylinder to inspect the rod (7) for
3. Raise the cylinder rod approximately 6 inches.
Block the mast to prevent lowering.
on its side.
4. Lower cylinder so the chains, hoses, and electric
cables are loose. Disconnect the battery
5. Remove chains, hoses, and electric cables from
the crosshead.
6. Remove the crosshead from the cylinder rod.
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1.2. Disassembly
1. Remove gland nut (10) from the cylinder tube (14).
2. Remove and discard packing, back-up ring, O ring,
rod wiper and bearing retainer from the gland nut
(10). Use care NOT to damage the inside of the
gland nut (10).
1.3. Assembly
1. Install new bearing, seals and rod wiper in the
gland. The lip of the wiper must face outward. It is
not necessary to replace wear ring (6), unless the
rod was removed for repair.
1.4. Installation
1. Install crosshead, chains, hoses and electric
cables.
2. Connect battery.
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Staging Cylinder, 3 Stage
Version no
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000
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POS.
NO
BT Products
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DESCRIPTION
POS.
NO
DESCRIPTION
Screw
Ring, wear
Washer, seal
10
Piston
Cylinder tube, 1 Port
11
Ring, retainer
Cylinder tube, 2 Port
12
Rod, cylinder
Plugger assembly
13
O ring
Spring
14
Bearing
Plug
15
Seal, rod
O ring
16
Wiper
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1.1. Removal
brake.
2. Fully extend the cylinders to inspect the rod (12) for
3. Lift mast so inner column is raised approximately
12 inches. Securely block mast, using 4 in. x 4 in.
blocks under each side of the inner columns.

column. If both sides are not blocked,
the truck could tip over on its side.
4. Remove bolts from top end of staging cylinder

rods. Lower cylinder rods hydraulically.
WARNING Be extremely careful when working

with solvent. Even a small explosion or
fire could cause injury or death.
1.2. Disassembly
1. Remove gland nut (12) from the cylinder tube.
2. Remove and discard all seals, rod wiper (15) and
bearing (14) from the gland nut (12). Us care NOT
to damage the inside of the gland nut.
1.3. Assembly
1. Install new bearing (14), seals and rod wiper (16) in
the gland. The lip of the wiper must face outward.
It is not necessary to replace wear ring (9), unless
the cylinder was removed for rod repair.
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1.4. Installation
1. Install crosshead, chains, hoses, and electric
cables.
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Micro 70 Wire Guidance Important Information
Version no
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001
OE35
Micro 70 Wire Guidance Important

Information
CAUTION
This unit is shipped with the N.D.C.

Wire Guidance Controller disengaged to
prevent damage. The wire guidance
controller must NOT be engaged until
the trucks industrial battery is installed.
Failure to heed this instruction will result
in damage to the N.D.C. Controller and
void warranty.
1. Powering Up:
Installed at customer location
1. Disconnect battery from truck.
2. On the center relay move wire #84 from relay
terminal position #1 to relay terminal position #4.
3. Install 1A & 20A fuse in their proper position as
shown below. Wire #94 is on 1A fuse Wire #72 is
on 20A fuse
4. Connect battery to truck.
2. Powering Down:
Transporting the truck: (Not using an industrial battery)
1. Disconnect battery from truck.
2. Remove 1A & 20A fuse from holder.
3. On the center relay move wire #84 from relay
terminal position #4 to relay terminal position #1.
4. Connect temporary battery to truck.
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Micro 70 Wire Guidance Important Information
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Move wire #84

from Position #1
to Position #4
1A Fuse
1A Fuse
20A Fuse
20A Fuse
Drawing showing location of fuses and wire
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Micro 70 Wire Guidance
Version no
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NOTE! Items represented with dashed lines are
options that may not be present on all
models.
See Truck Electrical Schematic Part 2 for further information.
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24 Volt N.D.C Electrical Schematic Part 3
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5. Cautions and Warnings

When operating a truck equipped with the N.D.C Micro 70
guidance system, it is essential to read and understand the
following cautions and warnings. They are critical to the safe
operation of the truck.
WARNING The Micro 70 system is designed to steer
the truck without the operator controlling
the steering
mechanism.
Steering
components may move suddenly and
without warning. Extra caution should be
taken when working on or around the
steering components of this vehicle to
insure the safety of the technician and
other persons nearby.
WARNING Perform a daily operational check of the
vehicle. Do not operate a malfunctions
vehicle. Report all malfunctions to your
supervisor or foreman. Operation of a
malfunctioning vehicle could result in
person injury or property damage.
CAUTION
When charging the truck battery, make

sure that the charger is connected to
the battery and not the truck. Failure to
do so will result in damage to the N.D.C
Micro 70 components and/or other
vehicle components.
WARNING Do not use the manual mode of operation

within the guided aisle. Use of the manual
mode within the guided aisle could result
in personal injury or property damage.
WARNING Stay clear of raised platforms or forks and
rotating or moving parts. Failure to do so
could result in personal injury or property
damage.
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WARNING Do not operate a truck in the auto mode if

any of the antennae are damaged.
Operation with damaged antennae could
result in personal injury or property
damage.
WARNING Never leave the truck unattended while in
the automatic mode. Personal injury or
property damage could result.
WARNING Keep hands clear of the steering wheel
when operating the truck on the guidewire
and in the automatic mode. Failure to do
so could result in personal injury.
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CAUTION
Disconnect battery from vehicle before

disconnecting or connecting any cable
plugs or components.
CAUTION
All steering and guidance system

components must be properly mounted
and the battery properly charged before
making any adjustments to the
guidance system and components.
CAUTION
There are conditions outside of the

Micro 70 controller that can cause
controller damage. i.e.: shorted wires or
damaged antennas. If a test indicates a
failed Micro 70 controller it is
recommended that the remaining tests
be completed and all test results written
down. After the tests are completed call
the BT Prime-Mover service department
before replacing the Micro 70 controller.
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6. Operation Information
6.1. Modes of operation.
There are two modes of operation for the N.D.C Micro 70 wire
guided steering system on the BT OE35 order selector.
1. Automatic mode
Used for on-wire guidance of the truck in the guided
aisle. In this mode of operation the truck operator
controls the travel direction and speed as well as lift
and lower. The steering of the truck is controlled by
the Micro 70 system. Additionally, this mode is used
for acquisition of the guide wire.
2. Manual mode
The truck operator controls all functions of the truck.
Automatic guidance is not enabled in the manual
mode. Manual mode is intended for use outside of
the guided aisle only and should never be used
when operating the truck within the guided aisle.
The truck operator chooses the mode of operation
with a push button switch on the operator's console.
Prior to operating the truck it is essential that the
operator become familiar with all switches and
indicators on the console. Only trained and
authorized operators are permitted to operate this
truck.
6.2. Acquiring the guide wire.

1. In steer wheel direction of travel.
a. Drive the truck in manual mode to the beginning of
the selected aisle. Position the truck to enter the
aisle in the steer wheel direction of travel. The center
line of the truck may be to either the left or the right
side of the guide wire. There should be no other
guide wires between the selected aisle and the truck.
b. Position the steer wheel so that the truck will move to
the guide wire.
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NOTE! The approach angle of the truck must not be

greater than 20 degrees when acquiring the
guidewire. If the truck approaches the
guidewire at too great an angle or too high a
speed the Micro 70 system may not acquire
the guidewire.
c. Move the manual/auto switch to the auto position by

pushing the button one time. The manual light will
turn off and the auto light will turn on. This indicates
that the wire guidance system is enabled but does
not mean that steering is automatic.
d. Slowly drive the truck to the guide wire. When the
Micro 70 system senses the guide wire it will
automatically take over the steering in the auto
mode. The on wire light will turn on and the
steering will be automatically controlled by the Micro
70 system.
If the guide wire is not acquired as the truck moves
over the guide wire the steering may return to the
acquisition mode and the on wire light will not turn
on.
If the guide wire is acquired and then lost the parking
brake will automatically set and the loss of wire
light will turn on and an audible alarm will sound.
To reset the Micro 70 system after loss of wire has
occurred the manual/auto button must be pushed
one time to return to manual mode. Repeat steps c
and d to re-acquire the guide wire.
NOTE! When in the auto mode the truck's steering
mechanism will be turned by the Micro 70
system components. As the truck is
acquiring the guidewire the truck operator
will feel a tug on the steering wheel and the
steering wheel will be turned in the required
direction to steer the truck over the
guidewire.
e. Drive the truck into the guided aisle allowing the
Micro 70 system to control the steering. The truck
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must be moved at least two truck lengths after the

on wire light has turned on before the travel
direction can be reversed.
2. In the load wheel direction of travel.
a. Drive the truck in manual mode to the beginning of
the selected aisle. Position the truck so that it is
centered over the guide wire.
b. Move the manual/auto button to the auto position by
pushing the button one time. The manual light will
turn off and the auto light will turn on. This indicates
that the wire guidance system is enabled but does
not mean that steering is automatic.
c. Slowly drive the truck along the guide wire. When the
Micro 70 system senses the guide wire it will
automatically take over the steering in the auto
mode. The on wire light will turn on and the
steering will be automatically controlled by the Micro
70 system.
If the guide wire is not acquired as the truck moves
over the guide wire the steering may return to the
acquisition mode and the on wire light will not turn
on.
If the guide wire is acquired and then lost the parking
brake will automatically set and the loss of wire
light will be turn on and an audible alarm will sound.
To reset the Micro 70 system after "loss of wire" has
occurred the manual/auto button must be pushed
one time to return to manual mode. Repeat steps a,
b, and c to re-acquire the guide wire.
NOTE! When in the auto mode the truck's steering
mechanism will be turned by the Micro 70
system components. As the truck is
acquiring the guidewire the truck operator
will feel a tug on the steering wheel and the
steering wheel will be turned in the required
direction to steer the truck over the
guidewire.
d. Drive the truck along the guided aisle allowing the
Micro 70 system to control the steering. The truck
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must be moved at least two truck lengths after the

"on wire" light has turned on before the travel
direction can be reversed.
6.3. Daily operational checks

Operational checks are performed for operator safety and to
prevent damage to the facility or truck. If any problems are
noticed during daily inspections notify your foreman or
supervisor to take corrective action. These checks are in
addition to any checks recommended in the vehicle
operator's manual.
1. Check for oil leaks, missing or damaged parts, or
other conditions that may prevent the truck from
operating satisfactorily.
2. Inspect cables, hoses, tires, and mechanical
components for physical damage.
3. Check antennas for physical damage.
4. Insure that all truck functions are working properly.
This should include brakes, lift controls, steering,
and travel controls. Check for any unusual noises or
other indications of potential trouble.
5. Make sure the truck battery is fully charged at the
beginning of each work shift. The N.D.C Micro 70
guidance system will not function properly with a
battery charge that is too low.
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7. Component Function and

Relationship
The Micro 70 controller is the center of the guidance system.
The Micro 70 controller consists of a single printed circuit
board mounting an INTEL 80C196 Microprocessor. There are
no mechanical trim pots on the Micro 70 controller to be
adjusted. The logic board has a number of digital, analog,
and encoder inputs and outputs incorporated into the ten
plug-in connectors. All of the operating software and design
parameters come pre-loaded onto the CPU. A long life lithium
battery maintains the memory in the CPU.
The CRA 70 antenna is an active receive antenna. Two
antennas are used to send a signal back to the Micro 70
controller relating the position of the truck in relation to the
guide wire. One antenna is mounted on the frame skirt
directly in front of the drive unit and one is located in the area
between the outriggers, behind the mast columns and in front
of the load wheels. The two antennas are identical with the
exception of the cable connections into the antenna. Both
antennas should be mounted on the truck with the epoxy side
facing away from the center of the truck. One antenna is used
for guidance in the steer wheel direction of travel and both
antennas are used for guidance in the load wheel direction of
travel.
The steering feedback potentiometer sends a signal to the
Micro 70 controller to indicate the position of the drive unit
relative to a centered position of the drive unit.
The tachometer is used to determine the travel speed of the
truck and the travel direction. It is mounted to drive directly off
the drive motor. It outputs a signal of 7 volts DC per 1000
RPM. Any change of tachometer polarity will result in a
change of the connection of the CRA 70 antennae within the
Micro 70 system.
The signals from the steering feedback potentiometer and the
travel tachometer are fed to the Micro 70 controller through a
feedback/tachometer interface (FTI 7). Mounted on the FTI 7
is a mechanical zero potentiometer that is used to fine tune
the steering feedback potentiometer signal as it goes into the
Micro 70 controller. The FTI 7 also selects the multiplier for
the feedback signal to the controller. When the system is in
the acquisition mode the feedback signal is amplified to the
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controller at a 1X gain for better wire acquisition. After the

system has acquired the wire this signal is amplified to a 10X
gain for better guidance while on wire.
The FSA Mobicon Steering Servo Amplifier and the steer
motor are the output components of the Micro 70 guidance
system. The Micro 70 controller generates an output signal or
steering correction. This signal is received by the FSA
Mobicon Steering Servo Amplifier and the amplified signal
from the FSA is sent to the steer motor to turn the mechanical
components of the truck steering mechanism. The FSA is
fuse protected. Three control relays are used. CR1 is used to
disconnect the steer motor whenever the truck is not moving.
CR2 is used to engage the parking brake through a solenoid
if a steering malfunction occurs; i.e. loss of wire. CR3 is used
to enable a truck speed limit when the system is in acquisition
mode to reduce the possibility of guide wire overshoot.
The control panel on the operator console consists of a
pushbutton auto/manual switch, an indicator light for 'on wire/
loss of wire' condition while in the auto mode, and an audible
alarm if a 'loss of wire' condition occurs. The truck parking
brake automatically applies if a 'loss of wire' condition occurs.
The Micro 70 controller 'fails safe' if switch failure occurs and
the parking brake applies.
The Micro 70 controller can be easily changed without
opening the control box to accept guide wire frequencies of
2.2 KHz, 5.2 KHz, 6.25 KHz, or 7 KHz. These are all the
common frequencies used by other guidance system
manufacturers.
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8. Truck Set Up On Site

New trucks delivered from the BT factory with N.D.C Micro 70
guidance systems have been fully assembled, test run, and
adjusted at the factory. The load wheel antenna and
mounting bracket has been removed for shipping.
When setting up a new truck remount the antenna and
bracket. The mounting holes closest to the end of the bracket
are used for three stage masts. The second set of mounting
holes are for two stage masts.
After the antenna is reconnected (see the Micro 70 power up
instructions on pa ge293) drive the truck to the guided aisle
and test run in the auto mode. Only minor adjustments to the
load wheel antenna should be needed.
Use the following instructions if the truck has had repairs or
component replacement in the Micro 70 system.
1. Drive truck so that the truck is centered over guide
wire and steering wheel is straight ahead as near as
possible.
2. Verify correct antenna mountings. The antennas
must be mounted directly over and level and square
to the guide wire. Both antennas must be 1.5 in.
above the floor. The epoxy side of the antennas
must face away from the center of the truck.
3. With battery connected and key switch "on" verify
green "power on" LED indicators on the Micro 70
controller and the FSA steering servo amplifier.
5. Unplug Feed-back Potentiometer cable from FTI 7
connector K2.
6. Reconnect battery and restart truck.
7. Connect volt meter between battery negative and
FTI 7 connector K3, pin 2.
8. Rotate the Zero Potentiometer on the FTI 7 to set the
Zero Potentiometer at the centered voltage value of
5 volts DC.
10. Reconnect the
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cable
from
the Feed-back
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Potentiometer to FTI 7 connector K2.

12. Connect volt meter between battery negative and
FTI 7 connector K3, pin 3.
13. Loosen set screw on Feed-back Potentiometer to
unlock potentiometer shaft.
14. Rotate the shaft of the Feed-back Potentiometer to
set the Feed-back Potentiometer at the centered
voltage value of 5 volts DC.
15. Tighten the set screw
Potentiometer.
on
the
Feed-back
16. Remove volt meter.

18. Disconnect plug K8 from Micro 70 controller and
remove wire from pin position 3. Reconnect plug K8.
This will remove the inhibit signal from the FSA and
allow the Micro 70 system to try to correct the angle
of the steer wheel even though the truck is not
traveling.
20. Push the Auto/Manual button on the console and
turn the guidance system on to Auto.
21. Step on the Foot Pedal to start the Power Steering
Motor running.
22. Adjust the Zero Potentiometer so that the steering
motor is holding the steer tire in alignment with the
guide wire and is not trying to steer the truck off the
wire. If the power steering motor times out and turns
off simply push the foot pedal down again.
24. Reinstall the wire into pin 3 of plug K8 on the Micro
70 controller.
26. Operate the truck in Auto mode in the steer wheel
direction of travel. Note the steering corrections
made by the Micro 70 system during truck operation.
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Make small adjustments to the Zero Potentiometer

as needed so that the truck guides with a minimum
amount of correction. It is normal for the truck to
wander from side to side over the guidewire as much
as 1 in. to either side. If the truck runs off the
guidewire to the right side then the Zero
Potentiometer will require adjustment in the
clockwise direction. If the truck runs off the guidewire
to the left side then the Zero Potentiometer will
require adjustment in the counter-clockwise
direction.
27. Operate truck in Auto mode in load wheel direction
of travel and observe position of load wheel antenna
and truck in relation to the guidewire. Adjust load
wheel antenna from side to side as necessary to
keep truck centered over guide wire. If the truck runs
off guidewire or to one side of the guidewire in the
load wheel direction of travel move the load wheel
antenna towards that same side of the truck.
For instance, if the truck runs to the left side of the
guidewire in the load wheel direction of travel then
move the load wheel antenna towards the left side of
the truck.
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9. Troubleshooting Information
To use this troubleshooting guide go to the appropriate chart
that best describes the symptoms of the failure. Perform the
checks indicated to trace the possible causes of the failure.
In the troubleshooting charts the connections on the Micro 70
controller are identified by the connector number and the pin
number within the connector. For example, K8-3 indicates the
number 3 pin in the number 8 connector on the Micro 70
controller. There are ten connectors on the Micro 70
controller and they are numbered from left to right. Therefore
the three-pin connector on the far left of the controller is K1
and the computer plug connector on the far right is K10.
The FTI 7 also has three connectors; K1, K2, and K3. These
will be specified as FTI 7 connectors when first named in any
test.
The steering servo amplifier has the label "FSA 23" on it.
Because of the length of the component name and the ease
of identification the steering servo amplifier will be referred to
as the "FSA" in the troubleshooting charts.
It is critical that the Micro 70 components be properly
installed. In particular the antennas must be installed so that
the epoxy filled side is facing away from the center of the
truck.
The Micro 70 frequency must match the frequency of the line
driver. The Micro 70 frequency can be adjusted with
connections on the Micro 70 controller at connector K6 pin
numbers 7 and 8. By changing the arrangements of how K6-7
and K6-8 are connected, the Micro 70 controller can be
adjusted to guide on a frequency of 2.2 KHz, 5.2 KHz, 6.25
KHz or 7.0 KHz. There are wires in the wiring harness
provided for making these connections. These wires are
routed through the wiring harness to be hidden behind the
Micro 70 controller. It is unlikely that these connections would
be changed by unauthorized persons because the wires are
taped down to the harness. For 2.2 KHz both connections
should be open. For 5.2 KHz the wire from K6-7 should be
connected to battery negative wire 13; the wire from K6-8
should be left open. For 6.25 KHz the wire from K6-8 should
be connected to battery negative wire 13; the wire from K6-7
should be left open. For 7.0 KHz both wires from K6-7 and
K6-8 should be connected to battery negative wire 13.
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The first steps of any troubleshooting procedure should be:

1. Inspect the truck and components for physical
damage and mechanical malfunction. Wires must
not be chafed or cut. Relays must be free to move
and the contact tips must not be burnt or welded.
2. Check for ground faults from the electrical system to
the frame using an ohmmeter. A minimum of 20,000
(20K) ohms resistance from the frame to any and all
wiring and electrical components is acceptable.
3. Check that the battery is fully charged and
connected.
4. Operate the truck in all modes to determine the exact
operating symptoms. Do not forget that these
systems are equipped with safety circuits that
prevent operation in the event of improper operating
procedures or component failure.
It is inevitable that some problems may occur whose fault
cannot be found by normal troubleshooting procedures.
When this happens the technician is reduced to the task of
changing parts until the failed part is replaced and the truck
begins to operate properly. Even when the technician
becomes a parts changer there are certain rules to follow.
Never install an obviously damaged component on any truck.
A damaged component installed on a previously good
operating truck may very well cause damage to other
components. Likewise, never install new or known good
components on a malfunctioning truck to test the truck. It is
preferable to install undamaged components from the failed
truck onto a known good operating truck. In this way the
possibility of collateral damage to other components is
decreased.
The following tools and equipment are required for
troubleshooting and repair:
1. A digital multimeter (DVOM) such as a Fluke 8060A
or equivalent.
2. Common mechanic's hand tools.
3. Wiring diagrams and repair manual.
4. A functioning line driver and guide path.
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The following is a list of operating symptoms of failed trucks.

Find the symptom that best describes the operation of the
failed truck and then follow the instructions for testing in the
chart. If the required voltage is present go to the next test in
the chart. If the required voltage is not present follow the
directions for repair listed at that test. Unless otherwise
specified all voltage measurements are made with respect to
battery negative wire 22 and all tests are testing for positive
(+) voltage DC unless the test says different. The truck key
must be turned on and the emergency disconnect contactor
must be energized (closed).
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10. Troubleshooting Charts

1. Alarm sounds and parking brake remains set when truck
is turned on; manual/auto switch seems to have no
function.
The following tests are to be made with the truck power
on and the Micro 70 system in the auto mode.
a. Check for 24 volts at Micro 70 connector K6-2. If not
24 volts, recheck operating symptoms and go to the
proper chart.
b. Check for 24 volts at wire 76 connected to back of
auto/manual switch. If not 24 volts, repair open wire
76 between Micro 70 controller and auto/manual
switch.
c. Check for zero volts at wire 13 connected to back of
auto/manual switch. If not zero volts, repair open
wire 13 between auto/manual switch and truck wiring
harness.
d. Replace auto/manual switch.
2. Alarm sounds and parking brake is set in all modes of
operation; auto and manual lights turn on in turn each
time the auto/manual button is pushed.
Tests are to be made with Micro 70 system in manual
mode.
a. Check for battery volts on wire 2 at fuse holder of
fuse 1, 1 amp control fuse. If not battery volts, repair
open wire 2 to fuse holder.
b. Check for battery volts on wire 94 at fuse holder of
fuse 1, 1 amp control fuse. If not battery volts,
replace fuse 2.
c. Check for battery volts at wire 94 connected to
emergency disconnect contactor interlock switch. If
not battery volts, repair open wire 94 between fuse 1
and emergency disconnect contactor interlock
switch.
d. Check for battery volts at wire 96 connected to
emergency disconnect contactor interlock switch. If
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not battery volts, replace emergency disconnect

contactor interlock switch. (Emergency disconnect
contactor must be closed and interlock switch
activated.)
NOTE! Tests e and f are for 36 volt trucks only.
e. Check for battery volts at wire 96 connected to
terminal 4 of voltage regulator. If not battery volts,
repair open wire 96 between emergency disconnect
contactor interlock switch and voltage regulator.
f.
Check for 24 volts at wire 70 on terminal 2 of voltage

regulator. If not 24 volts check integrity of negative
wire 13 to voltage regulator terminal 3 then replace
voltage regulator. The tests that follow are for all
voltage trucks. These voltage tests should be made
with the negative lead of the volt meter connected to
Micro 70 connector K1-2.
g. Check for battery volts on wire 2 at fuse holder of

fuse 1, 1 amp control fuse. If not battery volts repair
open wire 13 from Micro 70 connector K1-2 to truck
negative wire 13.
h. Check for 24 volts at wire 70 on Micro 70 connectors
K1-1, K6-12 and K8-10. If not 24 volts, repair open
wire 70 between emergency disconnect contactor
interlock switch (24 volt trucks), or voltage regulator
(36 volt trucks), and Micro 70 connectors. If still not
24 volts possible Mlcro 70 controller failure. Check
for 24 volts at Micro 70 connector K8-2. If not 24
volts, replace Micro 70 controller.
i.
Check for 24 volts at wire 75 connected to terminal A

on #2 control relay. If not 24 volts, repair open wire
75 between Micro 70 connector K8-2 and 2 control
relay.
k. Check for zero volts at wire 13 connected to terminal

8 of #2 control relay. If not zero volts, repair open
wire 13 from 2 control relay to truck negative wire 13.
l.
Replace #2 control relay.
m. Re-check truck symptoms and continue with other

test. Call BT Prime-Mover service department with
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test results before replacing Micro 70 control unit.

3. Truck operates normally in manual mode, but the alarm
sounds and parking brake sets when truck operator
chooses auto mode. Tests are to be made with Micro 70
system in auto mode but with truck away from
guidewire.
a. Begin testing by driving truck, in manual mode, away
from guidewire and then pushing the auto/manual
switch until the "auto" light comes on.
b. Check for 24 volts at Micro 70 connector K8-2. If not
24 volts, replace Micro 70 controller.
c. Re-evaluate symptoms; possible chart 2 needed for
troubleshooting.
4. The truck will not guide in auto mode. Truck operates
normally in manual mode but, when switched to auto
mode and the guidewire is acquired (green "on wire"
light comes on), The Micro 70 system will not make any
steering corrections; steering effort is same in manual
and auto modes.
This chart is meant for a truck that will not make any steering
corrections even though the "on wire" light comes on. If the
truck even tries to make steering corrections go to chart 6.
a. Drive the truck in manual mode and take note of the
effort required to turn the steering wheel.
Now drive the truck along the guidewire in auto
mode with the green on wire light on. Take note of
the effort required to turn the steering wheel when
the green on wire light is on. If the steering efforts
are the same continue with step b below. If the
steering effort is harder in auto mode, with the green
on wire light on, go to chart 5.
b. Inspect mechanical coupler between electric
steering motor for Micro 70 system and hydraulic
torque generator on truck. Make repairs as needed
and re-evaluate symptoms.
Make the following tests with the Micro 70 system in the auto
mode and the truck over the guidewire so that the green "on
wire" light is on. The foot pedal must be depressed so that the
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power steering motor is running.

c. Check for battery volts at wire 2 on fuse 2, 20 amp
slow blow control fuse. If not battery volts, repair
open wire 2 between battery positive and fuse 2.
d. Check for battery volts at wire 72 on fuse 2, 20 amp
slow blow control fuse. If not battery volts, replace
fuse 2, 20 amp slow blow control fuse.
e. Check for battery volts on wire 72 at terminal A on 1
control relay. If not battery volts repair open wire 72
between fuse 2 and 1 control relay.
f.
Check for zero volts on wire 93 at terminal 8 on #1

control relay. If not zero volts repair open wire 93, or
open diode in wire 93, between terminal 8 on #1
control relay and wire 60 at terminal PB3 on SCR
control card.
g. With the power on as described above in test c,

unplug the #1 control relay and check for the
mechanical operation of the relay. If no mechanical
operation of relay replace #1 control relay.
h. Check for battery volts on wire 72 at positive (+)
terminal on FSA. If not battery volts repair open wire
72 between fuse 2, 20 amp slow blow control fuse,
and positive (+) terminal on FSA.
The following tests require that the front antenna (steer wheel
antenna) be removed from the truck and moved across the
guidewire while voltage tests are being made. Also the inhibit
signal to the FSA must be disconnected so that the Micro 70
system may try to steer the truck even though the truck is not
actually moving. Unplug the truck battery before
disconnecting or reconnecting any component to the Micro 70
controller.
h1. Unplug truck battery.
h2. Disconnect and remove front antenna (steer
wheel antenna) from truck. Reconnect antenna
after it is removed from truck.
h3. Disconnect white wire from K8-3.
h4. Reconnect truck battery and make the following
tests with the Micro 70 system in the auto mode
and the truck over the guidewire so that the green
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on wire light is on. The foot pedal must be

depressed so that the power steering motor is
running.
i.
With the truck power on as shown above in h4, hold

the steer wheel antenna one and a half inches (1.5
in.) over the guidewire and move the antenna from
one side of the guidewire to the other; about two
inches (2 in.) of total movement.
Measure the voltage between terminals K8-11, S+
red wire, and K8-15, S- black wire, on the Micro 70. It
does not matter which wire the positive lead or
negative lead of the volt meter is connected to.
As the antenna is moved across the guidewire check
for the voltage between S+ and S- to change from
positive ten volts (+ 10 volts) to negative ten volts (10 volts). If the voltage does not change as stated
the Micro 70 controller is likely failed.
j.

Measure the voltage between S+ red wire, and Sblack wire, on the FSA. It does not matter which wire
the positive lead or negative lead of the volt meter is
connected to.
positive ten volts (+ 10 volts) to negative ten volts (10 volts). If the voltage does not change as stated
repair open red wire or black wire between Micro 70
controller and FSA.
k. With the truck power on as shown above in h4, hold

Measure the voltage between terminals MO and M1
on the FSA. It does not matter which wire the
positive lead or negative lead of the volt meter is
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connected to.
for the voltage between MO and M1 to change from
positive to negative up to battery volts. If the voltage
does not change as stated replace the FSA.
I.

Measure the voltage between the white and the
black wires connected to the electric steering motor.
It does not matter which wire the positive lead or
for the voltage between the white and black wires
connected to the electric steering motor to change
from positive to negative up to battery volts. If the
voltage does not change as stated repair the open
wire or open #1 control relay tips between the FSA
and the electric steering motor.
m. Replace electric power steering motor.

5. The truck will not guide in auto mode. Truck operates
mode and the guidewire is acquired (green on wire
light comes on), the Micro 70 system will not make any
steering corrections; steering effort is harder in auto
mode.
This chart is meant for a truck that will not make any
steering corrections even though the "on wire" light
comes on. If the truck even tries to make steering
corrections go to chart 6.
a. Drive the truck in manual mode and take note of the
effort required to turn the steering wheel.
Now drive the truck along the guidewire in auto
mode with the green on wire light on. Take note of
the effort required to turn the steering wheel when
the green on wire light is on. If the steering effort is
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harder in auto mode, with the green on wire light

on, continue with tests below. If the steering effort is
the same in manual and auto modes use chart 4.
b. Inspect mechanical coupler between electric
steering motor for Micro 70 system and hydraulic
torque generator on truck. Make repairs as needed
and re-evaluate symptoms.
Make the following tests with the Micro 70 system in the
auto mode and the truck over the guidewire so that the
green "on wire" light is on. The foot pedal must be
depressed so that the power steering motor is running.
The following tests require that the front antenna (steer
wheel antenna) be removed from the truck and moved
across the guidewire while voltage tests are being
made. Also the inhibit signal to the FSA must be
disconnected so that the Micro 70 system may try to
steer the truck even though the truck is not actually
moving. Unplug the truck battery before disconnecting
or reconnecting any component to the Micro 70
controller.
b1. Unplug truck battery.
b2. Disconnect and remove front antenna (steer
wheel antenna) from truck. Reconnect antenna
after it is removed from truck.
b3. Disconnect white wire from K8-3.
b4. Reconnect truck battery and make the following
tests with the Micro 70 system in the auto mode
and the truck over the guidewire so that the green
on wire light is on. The foot pedal must be
depressed so that the power steering motor is
running.
C. With the truck power on as shown above in b4, hold
Measure the voltage between terminals K8-11, S+
red wire, and K8-15, S-black wire, on the Micro 70. It
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does not matter which wire the positive lead or

positive ten volts (+10 volts) to negative ten volts (10 volts). If voltage does change as stated use chart
4 troubleshooting. If voltage does not change as
stated continue with tests below.
d. Check for positive (+) 12 volts between K7-6 and K79 on the Micro 70 controller. K7-6 should be positive
on the volt meter leads and K7-9 should be negative.
If not 12 volts +/- 0.5 volts, the Micro 70 controller is
likely failed.
e. Check for positive (+) 12 volts between FTI 7
connectors K3-1 and K3- 5. K3-1 should be positive
on the volt meter leads and K3-5 should be negative.
If not 12 volts +/- 0.5 volts, repair open red or black
wire between FTI 7 and Micro 70 controller.
f.
Check for positive (+) 5 volts between K2-1 red wire

and K2-3 black wire on FTI 7. The red wire on K2-1
should be positive on the volt meter leads and the
black wire on K2-3 should be negative. If not 5 volts
+/- 0.5 volts, replace FTI 7.
g. Check for positive (+ ) 5 volts between the red wire

on terminal 1 of the steering feedback potentiometer
and the black wire on terminal 3 of the steering
feedback potentiometer. If not 5 volts +/- 0.1 volts,
repair open red or black wire between FTI 7 and
steering feedback potentiometer.
The following tests use K1-2 on the Micro 70 controller
for the volt meter negative connection.
h. With the steering in the straight ahead position check
for 2.5 volts on the white wire on terminal 2 of the
steering feedback potentiometer. If not 2.5 volts, try
adjusting feedback potentiometer to obtain a
centered voltage value of 2.5 volts. (See Truck Set
Up On Site.) If unable to obtain 2.5 volts, replace
steering feedback potentiometer.
i.
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for 2.5 volts on the white wire at the FTI 7 K2-2

connector. If not 2.5 volts, repair open white wire
between steering feedback potentiometer and FTI 7.
j.

for 5 volts at FTI 7 connector K3-2. If not 5 volts, try
adjusting zero potentiometer on FTI 7 to obtain 5
volts. If unable to obtain 5 volts, replace FTI 7.
6. Truck will not guide in auto mode. Truck operates

mode and the guidewire is acquired in the steer wheel
direction (green on wire light comes on), the Micro 70
system will start to make steering corrections but quickly
looses the wire and sets the parking brake with an
audible alarm.
Before beginning any testing be sure to read and
understand the Micro 70 system operation. Operating
instructions can be found in this manual under
"Operation." It is possible for the Micro 70 system to
start to make steering corrections without fully acquiring
the guidewire if the approach angle is too great.
Also go to the section in this manual "Truck Set Up On
Site" and go completely through all of the adjusting
procedures again before beginning any testing.
a. Check for 12 volts between K7-6 and K7-9 on the
Micro 70 controller. K7-6 should be positive on the
volt meter leads and K7-9 should be negative.
b. Check for 12 volts between K3-1 and K3-5 on the
FTI 7. K3-1 should be positive on the volt meter
leads and K3-5 should be negative. If not 12 volts +/.5 volts, repair open red or black wire between FTI 7
and Micro 70 controller.
c. Check for 5 volts between K2-1 red wire and K2-3
black wire on FTI 7. The red wire on K2-1 should be
positive on the volt meter leads and the black wire on
K2-3 should be negative. If not 5 volts, replace FTI 7.
d. Check for 5 volts between the red wire on terminal 1
of the steering feedback potentiometer and the black
wire on terminal 3 of the steering feedback
potentiometer. If not 5 volts repair open red or black
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wire between
potentiometer.
FTI
7 and
steering
feedback
The following tests use K1-2 on the Micro 70 controller

for the volt meter negative connection
e. With the steering in the straight ahead position check
for 5 volts on the white wire on terminal 2 of the
steering feedback potentiometer. If not 5 volts, try
adjusting feedback potentiometer to obtain a
centered voltage value of 5 volts. (See Truck Set Up
On Site.) If unable to obtain 5 volts, replace steering
feedback potentiometer.
f.

for 2.5 volts on the white wire at the FTI 7 K2-2
connector. If not 2.5 volts, repair open white wire
between steering feedback potentiometer and FTI 7.
g. Check for smooth voltage transition on the white wire

at FTI 7 K2-2 as the truck is steered left and right of
straight ahead. If not a smooth voltage transition
replace feedback potentiometer.
h. With the steering in the straight ahead position check
for 5 volts between K3-2 and K3-5 on the FTI 7. K3-2
should be positive on the volt meter leads and K3-5
should be negative. If not 5 volts, repair open white
or black wire between the FTI 7 and the Micro 70
controller.
I.
Tests indicate possible failed Micro 70 controller. Reevaluate symptoms and retest.
7. Truck will not guide in auto mode in either direction.

Truck operates normally in manual mode but, when auto
mode is chosen the Micro 70 system does not detect
guidewire, on wire light does not come on and Micro
70 does not try to correct steering.
This chart is meant for a truck that will not make any
steering corrections and the "on wire" light will not even
flicker on. If the truck even tries to make steering
corrections go to chart 6. If problem occurs only in load
wheel direction go to chart 8.
Before beginning any testing be sure to read and
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understand the Micro 70 system operation. Operating

instructions can be found in this manual under
"Operation". It is possible for the Micro 70 system to
start to make steering corrections without fully acquiring
the guide wire if the approach angle is too great.
a. Verify that frequency of line driver matches
frequency of Micro 70 system.
The Micro 70 frequency must match the frequency of
the line driver. The Micro 70 frequency can be
adjusted with connections on the Micro 70 controller
at connector K6 pin numbers 7 and 8. By changing
the arrangements of how K6-7 and K6-8 are
connected, the Micro 70 controller can be adjusted
to guide on a frequency of 2.2 KHz, 5.2 KHz, 6.25
KHz or 7.0 KHz. There are wires in the wiring
harness provided for making these connections.
These wires are routed through the wiring harness to
be hidden behind the Micro 70 controller. It is
unlikely that these connections would be changed by
unauthorized persons because the wires are taped
down to the harness. For 2.2 KHz both connections
should be open. For 5.2 KHz the wire from K6-7
should be connected to battery negative wire 13; the
wire from K6-8 should be left open. For 6.25 KHz the
wire from K6-8 should be connected to battery
negative wire 13; the wire from K6-7 should be left
open. For 7.0 KHz both wires from K6-7 and K6-8
should be connected to battery negative wire 13.
b. Verify operation of the line driver and integrity of
guidewire loop.
This can be done by measuring the current, in
milliamps, flowing through the guidewire. A reading
of zero milliamps indicates an open wire in the
guidewire loop or a failed line driver. Depending on
the line driver, the frequency, and the length of the
guidewire loop the current flow in the guidewire loop
can be from 75 to 150 milliamps.
c. Check for damaged antennas and properly mounted
antennas. If damaged, replace antennas.
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turned on and the Micro 70 system in auto mode.

d. Check for negative (-) 12 volts between K4-1 and
K4-4 on the Micro 70 controller. The positive lead of
the volt meter should be on K4-1 and the negative
lead on K4-4. If not negative (-) 12 volts, then
possible Micro 70 controller failure.
e. Check for negative (-) 12 volts between pin 1 and pin
4 of steer wheel (front) antenna. The positive wire of
the volt meter should be on pin 1 and the negative
lead on pin 4. If not negative (-) 12 volts, repair open
black or open common wire between Micro 70
controller and steer wheel antenna.
f.
Check for positive (+) 12 volts between K4-2 and K44 on Micro 70 controller. The positive lead of the volt
meter should be on K4-2 and the negative lead on
K4-4. If not positive (+) 12 volts, then possible Micro
70 controller failure.
g. Check for positive (+) 12 volts between pin 2 and pin

4 of steer wheel (front) antenna. The positive wire of
the volt meter should be on pin 2 and the negative
lead on pin 4. If not positive (+) 12 volts, repair open
red or open common wire between Micro 70
controller and steer wheel antenna.
h. Verify integrity of other leads from antenna to Micro
70 controller.
i.
Replace steer wheel (front) antenna and readjust

Micro 70 system.
Charts 8 through 10 are for trucks that will not guide

properly only in the load wheel direction; manual mode
and auto mode in the steer wheel direction work
properly. If the truck does not operate normally in the
manual mode or does not guide properly in the steer
wheel (forward) direction then use the other charts.
8. Truck will not guide in load wheel direction. Parking
brake sets and audible alarm sounds as soon as load
wheel direction is sensed and truck is located over
guidewire with steer wheel in straight ahead position.
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on and the Micro 70 system in auto mode.

a. Check for negative (-) 12 volts between K3-1 and
K3-4 on Micro 70 controller. The positive lead of the
volt meter should be on K3-1 and the negative lead
on K3-4. If not negative (-) 12 volts, then possible
Micro 70 controller failure.
b. Check for negative (-) 12 volts between pin 1 and pin
4 of load wheel antenna. The positive lead of the volt
meter should be on pin 1 and the negative lead on
pin 4. If not negative (-) 12 volts, repair open black or
open common wire between Micro 70 controller and
load wheel antenna.
c. Check for positive (+) 12 volts between K3-2 and K34 on Micro 70 controller. The positive lead of the volt
meter should be on K3-2 and the negative lead on
K3-4. If not positive (+) 12 volts, then possible Micro
70 controller failure.
d. Check for positive (+) 12 volts between pin 2 and pin
4 of load wheel antenna. The positive lead of the volt
meter should be on pin 2 and the negative lead on
pin 4. If not positive 12 volts, repair open red or open
common wire between Micro 70 controller and load
wheel antenna.
e. Verify integrity of other leads from load wheel
antenna to Micro 70 controller.
f.
Replace load wheel antenna and readjust Micro 70

controller.
9. Truck will not guide in load wheel direction. "On wire"

light is on but truck is not centered over guidewire and
parking is not set.
turned on and the Micro 70 system in auto mode.
Unless otherwise specified, the tests in this chart use
K3-5 on the FTI 7 as the negative connection for the volt
meter.
a. Check for 5 volts at K1-2 on the FTI 7. If not 5 volts,
+/- 0.1 volts, disconnect K1 on FTI 1 and retest. If
still not 5 volts, replace FTI 7 and readjust system.
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b. Check for 5 volts at the black wire on terminal 1 of

the tachometer. If not 5 volts, +/- 0.1 volts, repair
open black wire between FTI 7 and tachometer.
c. Check for 5 volts at the red wire on terminal 2 of the
tachometer. If not 5 volts, +/- 0.1 volts, replace
tachometer.
d. Check for 5 volts at K1-1 on the FTI 7. If not 5 volts,
+/- 0.1 volts, repair open red wire between FTI 7 and
tachometer.
e. While driving the truck in the forward (steer wheel)
direction, check for the voltage at K1-1 to decrease
below 5 volts. The voltage should change smoothly
with a larger change at higher travel speeds. If
voltage does not decrease smoothly replace
tachometer.
f.
While driving the truck in the reverse (load wheel)

direction, check for the voltage at K1-1 to increase
above 5 volts. The voltage should change smoothly
voltage does not increase smoothly, replace
tachometer.
g. With the truck standing still check for 5 volts at K3-4

on the FTI 7. If not 5 volts, +/- 0.1 volts, replace FTI 7
and readjust system.
h. While driving the truck in the forward (steer wheel)
direction, check for the voltage at K3-4 to decrease
below 5 volts. The voltage should change smoothly
voltage does not decrease smoothly replace FTI 7.
i.
While driving the truck in the reverse (load wheel)

direction, check for the voltage at K3-4 to increase
above 5 volts. The voltage should change smoothly
voltage does not increase smoothly replace FTI 7.
j.
With the truck standing still check for 5 volts at K6-9

on Micro 70 controller. If not 5 volts, +/- 0.1 volts,
repair open wire between FTI 7 and Micro 70
controller.
k. If truck not repaired possible failure of Micro 70

controller.
326
Return
Service Manual
1997-10-24
F-code
PS
Section
C-code
S8.0
8200
Version no
T-code
001
OE35
10. Truck will not guide in load wheel direction. Truck will
travel some distance (3 to 30 feet) in the load wheel
direction before loosing the wire.
All guidance problems in which the truck acquires the
guide wire and travels in auto for a short distance before
loosing the wire are an indication that the guidance
system needs fine tuning. See the section in this book
Truck Set Up On Site.
a. If the truck runs off the wire with both antennas to the
same side of the wire the problem is likely in the
adjustment of the steering feedback potentiometer or
zero potentiometer.
b. If the truck runs off the wire with the antennas on
opposite sides of the guidewire the problem is likely
in the adjustment of the antennas.
BT Products
Return
Service Manual
1997-10-24
327
F-code
Section
C-code
PS
S8.0
8200
Version no
T-code
001
OE35
328
Return
Service Manual
1997-10-24
Return
BT Prime-Mover, Inc., 3305 N. Highway 38, Muscatine, Iowa 52761-8800 U.S.A

Tel (319) 262-7700 Fax (319) 262-7600
Return

301460-003 1998 - January PDF

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Service Manual

WARNING Read and observe all warnings on this unit

Date: January 29, 1998

Drive Gear / Transmission

Brake / Wheel System

Hydraulic / Pneumatic System

Operating Function-lifting Mast / Cylinders

Peripheral / Installation Equipment

Technical Service Data ................................................................................ 33

Lubrication Chart ......................................................................................... 51

Drive Motor 24 Volt ......................................................................................

Drive Motor 36 Volt ......................................................................................

Transmission Disassembly / Assembly ..................................................... 87

Torque Generator ........................................................................................ 107

Battery Controller / Hourmeter / Lift Interrupt ..........................................

Dash Display ................................................................................................

EV100 LX Control Status Codes ................................................................ 159

Direction Contactor ..................................................................................... 185

Steering Pump Contactor ...........................................................................

EV100 Handset Operation ..........................................................................

Hydraulic System ........................................................................................

Hydraulic Troubleshooting ........................................................................ 243

Mast, 2 Stage ............................................................................................... 257

OPEN FLAMES PROHIBITED

Introduction, Service Manual

GENERAL PRODUCT INFORMATION

TECHNICAL SERVICE DATA

ORDERING SPARE PARTS

General Product Information

1.1. Intended Application of the Trucks

1.2. Forbidden Application of the Truck

Do not use in areas that contain gases which can

Do not use as a towing truck for trailers

Do not use to tow other trucks

Do not use to transport/lift passengers

Do not use to drive on gravel or grass

1.3. Truck Data

Lifting capacity rated load, lb

Lift height, inches

Operating speed without load, mph

The trucks lifting capacity, and weight can be found on the

1.4. OE35 Dimensions

1.5. Data Plate

Truck model number

1.6. U.L. Construction Type

15. Data plate

20. Circuit circuit fuses

Main Components Chart

Inch (SAE) and Metric Fasteners

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

WARNING When fasteners must be replaced the new

Table 1. Bolt and Screw Designations

Strength Levels: Property Classes

* Markings Not Required

Hex Head Bolts

Hex Socket Head

Markings Not Required

Table 2. Stud and Nut Designations

Strength Levels: SAE Grades

Strength Levels: Property Classes

* Markings Not Required

* Markings Not Required