DOWNLOAD PDF BT Prime-Mover WSX20 WSX25 Electric Walkie Adjustable Straddle Stracker Service Manual

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WSX20/25 BT Prime-Mover

Service Manuals 304944-000 1995_December 304944-000 1997_July

Return BT Prime-Mover, Inc., 3305 N. Highway 38, Muscatine, Iowa 52761-8800 U.S.A. Tel (563) 262-7700 • Fax (563) 262-7600

012402

SERVICE MANUAL Manual Part Number 304944-000 ELECTRIC WALKIE ADJUSTABLE STRADDLE STACKER Effective Serial Number 272581AA000

Read and observe all warnings on this unit before operating it.

Read and observe all warnings in this manual before starting any service of this unit.

ISSUED DECEMBER 1995

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WSX-20/25

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Table of Contents

Introduction, service manual ............................................................. 5 Contents, section M ............................................................................ 7 General product information ............................................................. 9 Technical service data ..................................................................... 17 Ordering Spare Parts ........................................................................ 21 Contents, section P .......................................................................... 23 Introduction, maintenance ............................................................... 25 Service schedule .............................................................................. 27 Lubrication chart .............................................................................. 33 Oil and grease specification ............................................................ 35 Contents, section S .......................................................................... 37 Support arm chassis ........................................................................ 39 Transmission .................................................................................... 45 Electrical System .............................................................................. 59 Battery controller/hourmeter ........................................................... 71 Transistor Controller ........................................................................ 79 PCB Card ........................................................................................... 87 Hydraulic system .............................................................................. 91 Hydraulic system .............................................................................. 93

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Introduction, service manual The information in this Service Manual covers the truck types BT WSX20 and WSX25.

The Service Manual is divided into four separate sections, which covers different kinds of information needed for servicing these truck types. The main subject for each of the sections are as described below.

SECTION

SUBJECT

M

MACHINE INFORMATION

P

PREVENTIVE MAINTENANCE

S

SERVICE INSTRUCTIONS

O

OPTIONS

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M Contents, section M

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Contents, section M 1. MACHINE INFORMATION M1.0

OPERATOR’S MANUAL

M2.0

GENERAL PRODUCT INFORMATION

M3.0

TECHNICAL SALES DATA

M4.0

TECHNICAL SERVICE DATA

M5.0

PRODUCT IMPROVEMENTS

M6.0

PARTS ORDERING PROCEDURE

M7.0

QUALITY PARTS MANUAL (latest)

M8.0

RECOMMENDED SPARE PARTS

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General product information Valid from machine number: 270001-

1. Presentation of the pedestrian truck BT WSX20/25 The trucks BT WSX20 and WSX25 are battery powered straddle arm trucks solely to be operated by pedestrian operators when handling pallets or similar load carriers in-doors. In its standard design the truck is equipped with a steering arm with all the controls for operating the truck within easy access.

The trucks has a maximum lifting capacity of 2000 lb and 2500 lb.

These trucks are equipped with a 24V electrical system and the speed is regulated by means of a transistor controller to provide infinite control of acceleration and speed while driving.

The forks are raised by means of a powerful hydraulic unit. The control of the lift is done electrically with the push button on the steering arm. Control of the lowering speed and the positioning of the forks when stacking is done with the mechanical valve lever of the truck.

The truck can be fitted with different accessories including a battery-pack, electrical lowering of the forks and hour meter/battery indicator. The truck can also be fitted with stainless steel axles and low temperature oil if it is to be used in cool conditions.

1.1. Intended application of the truck The truck is solely designed and manufactured to handle goods.

The trucks should be fitted with the appropriate accessories relevant to the application.

1.2. Forbidden application of the truck The truck is designed for handling goods indoors. It is not permitted to use the trucks for other purposes including the following: - In areas that contain gases which can cause fires or explosions - As a towing truck for trailers - To tow other trucks - To transport/lift passengers - To drive on gravel or grass

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1.3. Truck data The table provides information regarding some technical data, which is of value with daily use of the truck.

Truck type

WSX20/25

Lifting capacity rated load, lb

2000/2500

Lift height, inches

104 - 144

Operating speed without load, mph

3.6

Operating speed with rated load, mph

3.1

Max. operating gradient with load, %

8

Service weight without battery, lb

1502 - 1599

Service weight including battery, lb (Ah)

1943 2040(240)

Turning radius (Wa), inches (fork length 45.3 inches)

59.3

Continuous noise level, dB A

< 70

The truck’s lifting capacity, lifting height and weight can be found on the truck’s type plate.

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1.4. Truck dimensions The diagram shows external dimensions for the truck in its standard design.

71.3"91.1" 53"

4"

2"

45.3"

MIN 32.1" MAX 51.2"

28.5" 17.8"

59.3" 4"

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1.5. Type plate The diagram shows the type plate used on the truck.

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2. Main components 1. Tiller arm: The truck is to be controlled by the operator walking. 204 degrees steering angle.

The brake is applied in the upper and lower position of the tiller arm.

2. Type plate: With type designation,manufacturing number, year of manufacture, service weight, battery weight, classified lifting capacity, battery voltage and manufacturer.

3. Hoods: Removable which provides good accessibility when servicing.

4. Instrument: (accessory) Combined hour meter/battery guard or hour meter only.

5. Hydraulic control: For controlling lifting and lowering functions.

6. Hydraulic unit: Pump motor, pump, valves and oil tank integrated in a compact unit.

7. Hydraulic valves: The valves are located to provide easy access.

8. Drive unit with brake: Fixed drive unit with a spring loaded brake, drive motor, gear and drive wheel combined into a compact unit. Steering bearings between motor and gear.

9. Machine number: The manufacturing number plate fitted to the chassis.

10. Electric panel: Removable, which provides good access when servicing. 24 volt electrical system. The speed is variably controlled by means of a transistor.

11. Battery: 24V with different Ah values. The truck can also be equipped with a battery pack (4x6V) with an integrated charger (accessorie).

12. Battery isolator/Recharging connector: The battery is recharged via the removable charging connector. If the truck is equipped with a battery pack The batteries are charged by connecting the removable charging connector to the integrated charger.

13. Mast: Covered by a finger protection which covers the operators normal range of reach from the operating position.

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3. Warning and information signs The figure shows the position and significance of the signs located on the truck.

1. Hydraulic control: Lifting 2. Signal/Horn 3. Lifting capacity 4. Machine signs 5. General warning /informations sign 6. Hydraulic control: Lowering 7. Hydraulic oil level 8. Machine number 9. Maximum lift height for rated capacity 10. Do not stand on the forks/Do not walk under lifted load 11. Lifting points 12. Pinch point

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Technical service data Valid from machine number: 270001 -

MODEL WSX20

WSX25

DRIVE MOTOR Type

TTL 1403-M2

TTL 1403-M2

Power

1.2 kW

1.2 kW

Duty ctor

60%

60%

Min carbon brush length

0.5 inch

0.5 inch

Min commutator diameter

1.85 inch

1.85 inch

Part no

134397

134397

Type

2-step angular

2-step angular

Gear ratio

19.43:1

19.43:1

Oil volume

1 quart

1 quart

Oil type

Hypoid oil

Hypoid oil

Normal temperature

SAE 80W/90

SAE 80W/90

< -15oC

SAE 75W

SAE 75W

Drive wheel

Dia215x70 mm

Dia215x70 mm

Wheel pressure without load

1342 lb

1342 lb

Wheel pressure with rated load

1420 lb

1542 lb

Torque wheel bolts

47 ft-lb

47 ft-lb

Fork wheel

Dia 100x75 mm

Dia 100x75 mm

Axle pressure with rated load

2412 lb

3110 lb

TRANSMISSION/GEAR

WHEELS

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MODEL WSX20

WSX25

HYDRAULIC UNIT Power

2.0 kW

2.0 kW

Revolutions/min at work pressure

2600

2400

Duty factor

9%

9%

Min carbon brush length

0.5 inch

0.5 inch

Min commutator thickness/ diameter

1.7 inch

1.7 inch

Pressure at rated load

2090 psi

2610 psi

Relief pressure

2300 psi

2870 psi

Pump flow

6,4 litre/min at 2090 psi

5,9 litre/min at 2610psi

Tank volume

0.92 gallons

0.92 gallons

Oil type

Hydraulic oil

Hydraulic oil

Normal temperature

ISO-L-HM32

ISO-L-HM32

< -15oC

ISO-L-HV32

ISO-L-HV32

Drive motor circuit

29228

29228

Amperage

100 A

100 A

Pump motor circuit

29223

29223

Amperage

160 A

160 A

Control circuit

122308-075

122308-075

Amperage

7.5 A

7.5 A

Dimension WxLxH

196x645x570 mm

196x645x570 mm

Capacity

240 Ah

240 Ah

Weight

440 lb

440 lb

Part No

134365

134365

FUSES

BATTERIES

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MODEL WSX20

WSX25

DRIVING SPEEDS Without load

3.48 mph

3.48 mph

With rated load

3.11 mph

3.11 mph

Lift without load

7.87 inch/s

7.48 inch/s

Lift with rated load

4,72 inch/s

3.94 inch/s

Lower without load, mechanical valve

7,10 inch/s

6.30 inch/s

Lower with rated load, mechanical valve

9.45 inch/s

9.45 inch/s

Lower without load, electrical valve

7,10 inch/s

6.30 inch/s

Lower with rated load, electrical valve

6.69 inch/s

6.69 inch/s

Driving without load

27 Amp

27 Amp

Driving with rated load

33 Amp

35 Amp

Lifting without load

39 Amp

39 Amp

Lifting with rated load

118 Amp

130 Amp

LIFTING/LOWERING TIME

CURRENT CONSUMPTION

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Ordering Spare Parts • Locate the fault on the truck.

• Find out the machine type and machine number.

• Find the machine type and machine number in the spare part catalogue’s list of contents.

• Look up the page with the exploded diagram and locate the position number for the part you require.

• Look up the position number in the table. Select the column with regard to the actual machine type and machine number.

• Note the article number.

• Call the BT Prime-Mover dealer and state the article number.

If you cannot find the machine type, machine number or the article number call the BT Prime-Mover dealer and they will help you.

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P2.0 Contents, section P

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Contents, section P 1. PREVENTIVE MAINTENANCE P1.0

INTRODUCTION

P2.0

SERVICE SCHEDULE

P3.0

LUBRICATION MAINTENANCE

P4.0

OIL AND GREASE SPECIFICATION

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Introduction, maintenance The schedules of maintenance and lubrication given in this section of the Service Manual covers up to one year’s operation of a truck.

These schedules are based on hourly usage and can be adapted to suit most normal 1 shift patterns. The following hourly usage figures have been used when calculating the schedule: Single shift- 8 am-5 pm, 20 hours per week usage Double shift- 6 am-2 pm, 2 pm-10 pm, 40 hours per week usage Triple shift- 6 am-2 pm, 2 pm-10 pm, 10 pm-6 am, 60 hours per week usage The schedules are intended only as a guide not a rigid structure. Operators of trucks may wish to adapt them to local requirements but it is emphasised that the schedules represents minimum manufacturer requirements and all items should be included in a service programme to ensure minimum downtime and a high safety status of the equipment.

- Use only spare parts approved by BT Products AB. - Always clean the equipment and carry out full safety check after service.

1. SAFE JACKING PROCEDURE Any jacking operation must be carried out on a level, non slip and firm surface. Avoid newly laid tarmac surfaces or any such surface in hot weather.

Select the jacking point carefully. Avoid sloping skirts, choose the point where the jack will be asked to lift the lightest load eg one corner at a time. If the truck has marked lifting point at the lower part of the chassis, these should be used as jacking points to get a well balanced lift.

Use the correct jacking lever bar supplied, too short and it requires too great an effort, with slipping or strains as the possible consequence. Too long and there is a possibility of overloading causing failure even collapsing of the jack.

Block the machine. As the jacking process continues, keep the block(s) as close as possible to the object being raised to lessen the fall if any slip should occur.

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Never block the jack to achieve greater lift height.

Always make sure that the surface upon which the jack stands is clean and not slippery e.g. free from grease or oil.

Make sure that your hands and the jacking lever bar is clean and free from grease or any other slippery agent.

Always apply the parking brake to prevent the truck from moving during the jacking operation. If jacking the braked wheel chock the other wheel to prevent movement.

Do not block under wheels unless a purpose made block is used, i.e. the block has provision to prevent the wheel from rolling off.

NEVER work under a jacked up machine without suitable blocking in place.

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Service schedule Valid from machine number: 270001 -

1. Preventive maintenance schedule ITEM 0000.

0000.1 0000.2 0000.3 0000.4 0000.5 0000.6 0000.7 0640 0640.1 0640.2 0640.3 0840 0840.1 1700.

1700.1 1700.2 1700.3 1700.4 1700.5 1700.6

WORK REQUIRED Interval in hours Interval in Days/Weeks/Months Chassis Check that the truck identification plate is legible Check the battery securing blocks for wear Check for damage and cracks Retighten the truck body fastening bolts (to the chassis) Check the cover lockings Retighten the support arm clamp bolts Check the mounting of the support arm safety catch Operator Controls Check that the travel direction/ speed selector is not binding Check that the horn button is operational Check that the lift/lower button is operational Drivers Protection Check that the red safety switch button is not binding Drive Motor Check for arcing due to poor connections All connections tight Check carbon brushes Clean motor of dirt and dust Check tightening of motor bolts Check for abnormal noise in motor bearings

5 1d

20 1v

80 1m

250 3m

500 6m

1000 12 m

3000 36 m

X X X X X X X

X X X

X

X X X X X X

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ITEM 2550 2550.1 2550.2 2550.3 2550.4 3100.

3100.1 3100.2 3100.3 3500 3500.1 3500.2 3500.3 4100.

4100.1 4100.2 4100.3 4100.4 5110 5110.1 5110.2 5110.3 5110.4 5200 5200.1 5300.

5300.1 5300.2 5300.3

WORK REQUIRED Interval in hours Interval in Days/Weeks/Months Drive Gear Check for oil leakage Check oil level Check for abnormal noise Change the gear oil Brake Cleaning from dust and debris Check brake disc for wear Check correct clearence of brake disc Wheels Remove all string, wrapping and debris Check drive wheel for wear and bolt torque Dismount and grease fork wheel bearings Steering Arm Check fastening Check steering force Check return of steering arm to upper position Lubricate the steering ball bearing Battery Electrolyte level, 10 - 15 mm above cell plates All connections: battery, battery and charger plugs All cell and link covers intact Check of battery specific gravity Instrument Panel Check battery indicator and hour meter for correct operation Electrical Control System Check Ignition keyswitch operational Check ”brake micro switch” (S10) operational Check the function of direction/ speed micro switches

5 1d

20 1v

80 1m

250 3m

Service Manual

1000 12 m

3000 36 m

X X X X X X X

X X X

X X X X

X X X X X

X X X

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ITEM 5300.4 5400 5400.1 5400.2 5400.3 5400.4 5400.5 5710 5710.1 5710.2 5710.3 6000 6000.1 6000.2 6000.3 6000.4 6000.5 7100 7100.1 7100.2 7100.3 7100.4 7100.5 7100.6 7310.

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WORK REQUIRED Interval in hours Interval in Days/Weeks/Months Check control wiring harness for wear Electrical Panel Cleaning and fixation to chassis Tightening of connections Check contactor contacts, clean and unburnt Check contactor contacts for free movements Check all cable insulations for damage Electronic Card Cleaning of electronic card, blow with air and whipe off Check for poor connections in cable connectors Check of LED indications Hydraulic System Check hoses and connections for leakage Check hoses for wear and damage Check oil tank for cracks, leaks and mounting Check correct oil level Change the hydraulic oil Lifting mast Check for damage and crack formation Retighten the mast mounting bolts Check the play of the innersection rollers Check the lateral play of the inner section Check for wear on the lift chains and chain rollers Check the adjustment of the lift chains Lift Cylinder Check for leakage Check mounting

5 1d

20 1v

80 1m

250 3m

500 6m X

1000 12 m

3000 36 m

X X X X X

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

X X

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ITEM

WORK REQUIRED

Interval in hours Interval in Days/Weeks/Months 7400.

Lifting device 7400.1 Check the play of the fork carriage/yoke rollers 7400.2 Check the fork carriage/yoke for damage and crack formation 7400.3 Check the forks for wear and crack formation

5 1d

20 1v

80 1m

250 3m

500 6m X X X

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P3.0 Lubrication chart

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Lubrication chart Valid from machine number: 270001-

Pos no

Service point

Interval/Running hours 500h

1 2 3 4 5 6

Wheel bearings Mast beam Lifting chains Hydraulic system Steering Bearings Drive gear

1000h

3000h

L L L C

O L

C L= Lubrication

O

C = Check

Lubricant A F D B G C

O = Oil change

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Oil and grease specification Valid from machine number: 270001-

1. Approved oil’s and grease for WSX 20/25 Lubricant A

Grease

B C D

Hydraulic oil Transmission oil Grease

F G

Grease Grease

Specification > - 15°C

Application area < - 15°C

BT 26777 (Spray) ISO-L-HM32 SAE 80W/90 BT 26778 (Spray) BT 055-70111 Tex. Ref. C and C #880

BT 26777 (Spray) ISO-L-HV32 SAE 75W BT 26778 (Spray) BT 055-74320 Tex. Ref. C and C #880

Bearings and bushings Hydraulic system Gears Chains and wires Side shift forks Steering bearings

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M Contents, section S

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Contents, section S 1. SERVICE INSTRUCTIONS NO FUNCTION GROUP

C-CODE

0

CHASSIS

0000

1

DRIVE MOTOR

1000

2

DRIVE GEAR/TRANSMISSION

2000

3

BRAKE/WHEEL SYSTEM

3000

4

STEERING SYSTEM

4000

5

ELECTRICAL SYSTEM

5000

6

HYDRAULIC/PNEUMATIC SYSTEM

6000

7

OPERATING FUNCTION-

7000

LIFTING MAST/CYLINDERS 8

PERIPHERAL/INSTALLATION

8000

EQUIPMENT 9

OPTIONS/ATTACHMENTS

9000

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S0.0 0350 Support arm chassis

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Support arm chassis Valid from machine number: 270001-

1. General The support arm chassis is bolted to the drive unit chassis to complete the truck, it also has got the mounting points for the lifting mast and lift cylinders.

The support arms of the straddle chassis are adjustable in width from 32 inches to 51 inches to suit different pallet sizes.

Normally the support arms are only adjusted prior to a truck being delivered to a customer.

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2. Main components 4

5

3 6 2 10

7 1

9

8

Pos no

Description

1

Support arm wheel axle

2

Wheel axle locking circlip

3

Support arm wheel

4

Support arm

5

Mounting bracket to drive unit chassis

6

Support arm safety catch

7

Support arm clamp

8

Support arm locking bolt

9

Lift cylinder mounting bracket

10

Mast mounting bracket

3. Maintenance The support arm clamp bolts need to be checked at the regular 500 hours preventive maintenance service. The torque of the support arm clamp bolts (pos no. 7 in chapter 2) must be checked with a torque wrench set at 88.5 ft-lb.

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4. Adjustment of the support arm width B

A

B

3 2 1

To adjust the measurement A between the support arms proceed as follows: • Jack up the side of the truck.

Warning!

The truck can tip over.

Do not jack up both support arms at the same time. the truck is a three wheeler.

Jack up one side at the time and support it while working.

• Loosen the bolt at the front of the cross beam, pos 1.

• Loosen the clamp bolts,pos 2.

• Pull out (or push in) the support arm. To get the measurement A, measure B = A/2 - 12 inches. Make sure that the measurement B is equal on both sides.

If the support arm is pulled out too much the safety catch, 3, will drop into the hole in the arm to stop it from falling out.

• Tighten bolt 1 and lock it with the locking nut.

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C-code

0350

• Tighten the four clamp bolts, pos 2, with a torque wrench.

Torque value: 88.5 ft-lb.

5. Exchange of support arms When changing a support arm the job is more extensive than adjusting the arm width.

• Lift out the battery.

• Remove the battery box from the chassis. Remove the two bolts at the bottom of the box.

• Remove the safety catch from the support arm clamp.

• Jack up the side of the truck where the support arm is to be changed.

2 1

• Loosen the bolt at the front of the cross beam, 1.

• Loosen the clamp bolts,2.

• Pull out the support arm.

• Fit the new support arm and adjust the arm width according to chapter 4.

• Lower the truck to the floor.

Return 42

Service Manual

1995-07-27

English

F-code

Section

PS

C-code

S0.0 0350 Support arm chassis

Version no

T-code

001

354

• After tightened the clamp bolts, fit the safety catch.

• Install the battery box.

• Install the battery.

Return © BT Products AB

Service Manual

1995-07-27

English

43

F-code

Section

PS S0.0 Support arm chassis Version no

T-code

001

354

C-code

0350

Return 44

Service Manual

1995-07-27

English

F-code

Section

C-code

PS

S2.0

2550 Transmission

Issued by

Approved by

Version no

T-code

TDC

K Hallman

001

204,351,352,353,354

Transmission Valid from machine number: 270001-

1. General technical desciption

1.1. Technical data Data

Description

Type

2-step angular

Upper gear wheels

Angle spur gear

Lower gear wheels

Angle gear 90 degrees

Gear ratio, overall

19.43:1

Return © BT Products AB

Service Manual

1995-07-21

English

45

Section

C-code

PS S2.0 Transmission

F-code

2550

Version no

T-code

001

204,351,352,353,354

Data

Description

Gear ratio, upper gear

4:1

Gear ratio, lower gear

4.86:1

Oil volume

1.0 litre

Oil type, normal temperature SAE 80W/90 Oil type, < -15oC

SAE 75

Oil change

First time: 250 hours Regular change: 3000 hours

Return 46

Service Manual

1995-07-21

English

F-code

Section

PS

S2.0 2550 Transmission

C-code

Version no

T-code

001

204,351,352,353,354

1.2. Gear components

1

2 3 4 5 A

12 11

6

10

9

8

7

Pos No

Component

1

Primary gears

2

Upper pinion bearing

L2

3

Bearing shim

S2

4

Bearing shim

S1

5

Lower pinion bearing

L1

6

Set of pinion and crown gears

7

Inner drive shaft bearing

L3

8

Bearing shim

S3

9

Outer drive shaft bearing

L4

Return © BT Products AB

Service Manual

1995-07-21

English

47

Section

C-code

PS S2.0 Transmission

F-code

2550

Version no

T-code

001

204,351,352,353,354

Pos No

Component

10

Bearing shim

11

Drive shaft

12

Drive shaft seal

A

Measurement, pinion height

S4

Return 48

Service Manual

1995-07-21

English

65 mm

F-code

Section

PS

S2.0 2550 Transmission

C-code

Version no

T-code

001

204,351,352,353,354

1.3. Special tools

Pos No

Tool

1

Bearing withdrawer: part no = 08-13022

2

Dial indicator with magnetic bracket

3

Feeler gauge

4

Micrometer 0-25 mm (0-1 inch)

5

Spring balance 0-10 kg (0-22 lb)

6

Measuring gauge: part no = 06-13020

7

Assembly axle: part no 08-13021

2. Removing the gear from the truck • Lift the machine so the bolts for the driving gear are accessible from beneath.

The truck can also be laid on the side after removal of the battery and sealing off the hydraulic system.

• Remove the drive wheel (17 mm)

Return © BT Products AB

Service Manual

1995-07-21

English

49

Section

C-code

PS S2.0 Transmission

F-code

2550

Version no

T-code

001

204,351,352,353,354

• Drain the oil by removing the lower gear cover ( 6 mm allen key).

• Remove the nuts (13 mm) holding the gear and motor together.

• Take the driving gear out of the machine.

• Installing the driving gear into the truck is made in the reversed order.

3. Change of seal on the drive shaft • Remove the gear from the truck as shown in chapter 2.

• Remove the upper gear cover (6 mm allen key).

Return 50

Service Manual

1995-07-21

English

F-code

Section

PS

S2.0 2550 Transmission

C-code

Version no

T-code

001

204,351,352,353,354

• Knock out the locking on the drive shaft nut.

• Remove the drive shaft nut (36 mm).

• Knock the drive shaft out with a plastic hammer or press it out.

• Remove the crown wheel and bearing L3.

• Remove the old seal and replace.

Return © BT Products AB

Service Manual

1995-07-21

English

51

Section

C-code

PS S2.0 Transmission

F-code

2550

Version no

T-code

001

204,351,352,353,354

• Put the drive shaft in place and place the inner ring of the bearing L3 in the gear housing.

• Put the crown gear onto the splines of the drive shaft and a new washer and nut.

Tighten the drive shaft nut 300 Nm (217 ft-lb) with a torque wrench.

• Lock the shaft nut with a punch into the groove in the shaft.

• Fit the covers to the gear with new gaskets.

Tightening torque: 26,6 Nm (19,5 ft-lb).

• Fit the driving gear into the truck.

Tightening torque: 26,6 Nm (19,5 ft-lb).

Fill with new oil.

• Fit the drive wheel Tightening torque: 65Nm (47,7 ft-lb).

Return 52

Service Manual

1995-07-21

English

F-code

Section

PS

S2.0 2550 Transmission

C-code

Version no

T-code

001

204,351,352,353,354

4. Reconditioning of the gear • Remove the gear from the truck as shown in chapter 2.

• Remove the gear covers (6 mm allen key).

• Knock out the locking on the drive shaft nut.

• Remove the drive shaft nut (36 mm spanner).

• Knock the drive shaft out with a plastic club or press it out.

• Remove the crown wheel and bearing L3.

• Press or knock out the bearing cups for bearing L3 and L4 and remove the shim-pack S3 from the gear housing.

• Remove the bearing L4 from the drive shaft by using the withdrawer, part no 08-13022. Remove the shim S4 from the shaft.

• Knock out the locking on the pinion nut. Remove the nut (22 mm spanner) and the primary gear wheel.

Return © BT Products AB

Service Manual

1995-07-21

English

53

Section

C-code

PS S2.0 Transmission

F-code

2550

Version no

T-code

001

204,351,352,353,354

• Knock out the pinion with a plastic club or press it out.

Remove the bearing L2 and shim S2.

• Remove the bearing L1 from the pinion with the withdrawer, part no 08-13022.

• Press or knock the cups for the bearingsL1 and L2 out and remove the shim-pack S1 from the housing. Remove the old seal ring.

• Clean the covers, gear housing and drive shaft with a suitable dissolvent.

• Fit new races for the bearings L1 and L2 into the gear housing with 0,5 mm shim S1.

• Fit the new bearing L1 on the new pinion.

• Assemble the pinion, bearing L2 and primary gear wheel.

Assemble with enough thickness of shim S2 so that there is no axial play. Tighten the nut 30 Nm (22,5 ft-lb), using the old nut.

Return 54

Service Manual

1995-07-21

English

F-code

Section

PS

S2.0 2550 Transmission

C-code

Version no

T-code

001

204,351,352,353,354

• Fit the new races for the bearings L3 and L4 into the gear housing without shim S3.

• Fit the assembly axle 08-13021 with the bearing L4 into the gear housing. Place the bearing L3 and the crown wheel onto the axle. Make sure that there is enough shim S4 for the bearing L4 that there is no axial play on tool 08-13021.

Tighten the axle nut 100 Nm (72 ft-lb), using the old nut.

• Measure the pinion height with the measuring gauge, part no 08-13020, between the surface of bearing L1 and the pin on tool 08-13021. Use shims or feeler gauge together with the measuring gauge to get the correct thickness of shim S1. Built-in measure pinion height = 65 mm, measuring gauge length 59 mm + the radius of the pin 5 mm + 1 mm shim or feeler gauge thickness. The difference from 65 mm gives you the thickness of shim S1.

• Fit the measured shim thickness under bearing L1.

Return © BT Products AB

Service Manual

1995-07-21

English

55

Section

C-code

PS S2.0 Transmission

F-code

2550

Version no

T-code

001

204,351,352,353,354

• Assemble the pinion, bearings and primary gear wheel with shim thickness S2 so that there is no axial play on the pinion,Zero-play, when having tightened the pinion nut 70 Nm (50,5 ft-lb). When needed adjust S2 so that the play is zero.

• Fit the assembly axle with bearings, crown wheel and shim as previously. Tighten the nut 300 Nm (217 ft-lb) • Measure the flank clearence with the crowh wheel in three different positions. Carefully point the dial indicator 90 degrees to the gear tooth surface.

• Shim (S3) bearing L3 so that a flank clearence of 0,10-0,15 mm is attained. Remove the same shim thickness from S4 that is fitted on S3, before the tool with bearings and crown wheel is reassembled.

• Check the flank clearence and measure the axial play on the tool 08-13021.

• Adjust the axial play to Zero-play by adjusting shim S4.

Return 56

Service Manual

1995-07-21

English

F-code

Section

PS

S2.0 2550 Transmission

C-code

Version no

T-code

001

204,351,352,353,354

• Check the gear tooth impression with engineer’s blue.

Adjust shim S1 when needed. S2 is to be adjusted, reduced if S1 is increased and increased if S1 is reduced, correspondingly to the change on S1. Check the axial play on the pinion.

• Fit the tool 08-13021 with bearings and crown wheel.

Check the flank clearence. Adjust shim S3 when needed.

S4 is to be adjusted, reduced if S3 is increased and increased if S3 is reduced, correspondingly to the change on S3. Check the axial play on tool 08-13021.

• Check the gear tooth impression. ´When the impression is correct fit a new washer and pinion nut. Tighten the nut 70 Nm (50,5 ft-lb) and lock it with a punch in the keygroove.

• When the gear tooth impression and the axial play is correctly adjusted, remove tool 08-13021. Shim-pack S4 is shifted over to the drive shaft and bearing L4 is placed on the shaft.

• Fit the new seal ring in the gear housing.

• Put the drive shaft into the housing and put bearing L3 in place.

Return © BT Products AB

Service Manual

1995-07-21

English

57

F-code

Section

PS

S2.0 2550 Transmission

C-code

Version no

T-code

001

204,351,352,353,354

• Put the crown wheel onto the splines of the drive shaft and fit a new washer and nut.

Tighten the drive shaft nut 300 Nm (217 ft-lb) with a torque wrench. Check the axial play on the drive shaft, shall be Zero. Lock the nut with a punch in the gtoove on the shaft.

• Check the force needed to rotate the gear with the spring balance.

Maximum value: 6-6,5 kg

• Fit the covers onto the gear with new gaskets.

Tightening torque: 26,6 Nm (19,5 ft-lb).

• Fit the driving gear into the truck.

Tightening torque: 26,6 Nm (19,5 ft-lb).

Fill up with new oil.

• Fit the drive wheel.

Tightening torque: 65 Nm (47,7 ft-lb)

Return © BT Products AB

Service Manual

1995-07-21

English

58

F-code

Section

PS

S5.0 5000 Electrical System

Issued by

Approved by

Version no

T-code

TDC

K Hallman

001

353,354

C-code

Electrical System Valid from machine number: 270001-

1. Electrical panel, components.

RV1 F50

A2

F10

K11 K13 K30

F3 A1

H1

Return © BT Products AB

Service Manual

1995-07-19

English

59

Section

C-code

PS S5.0 Electrical System

F-code

5000

Version no

T-code

001

353,354

2. List of symbols.

Symbol

Description

Function

Remark

A1

Transistor controller

A2

Connection card

BT

Battery

F3

Fuse

Pump motor circuit

160A

F10

Fuse

Drive motor circuit

100A

F50

Fuse

Control circuit

7,5A

H1

Horn

K11

Contactor

Drive direction

Fork direction

K13

Contactor

Drive direction

Steer wheel direction

K30

Contactor

Pump motor

M1

Motor

Drive

M3

Motor

Pump

P1

Indicator

Hour meter

P3

Indicator

Batteryindicator/Hour meter

R1

Potentiometer

Speed

RV1

Potentiometer

Speed reduction

S10

Switch

”Brake”

S15

Switch

Drive direction

Fork direction

S16

Switch

Drive direction

Steer wheel direction

S17

Switch

Key

5 - 0 kOhm

Return 60

Service Manual

1995-07-19

English

Symbol

Description

Function

S18

Switch

Horn

S20

Switch

Reverser

S41

Switch

Fork lower

S52

Switch

Fork lift

Y41

Magnetic valve

Fork lower

F-code

Section

PS

S5.0 5000 Electrical System

Version no

T-code

001

353,354

C-code

Remark

For optional electric lowering.

Always connected

When having optional electric lowering

Return © BT Products AB

Service Manual

1995-07-19

English

61

Section

C-code

PS S5.0 Electrical System

F-code

5000

Version no

T-code

001

353,354

2.1. Circuit diagram 1(3)

Return 62

Service Manual

1995-07-19

English

F-code

Section

PS

S5.0 5000 Electrical System

Version no

T-code

001

353,354

C-code

2.2. Circuit diagram 2(3)

Return © BT Products AB

Service Manual

1995-07-19

English

63

Section

C-code

PS S5.0 Electrical System

F-code

5000

Version no

T-code

001

353,354

2.3. Circuit diagram 3(3)

Return 64

Service Manual

1995-07-19

English

F-code

Section

PS

S5.0 5000 Electrical System

C-code

Version no

T-code

001

353,354

3. DESCRIPTION OF FUNCTION 3.1. General The Transistor controller (A1) regulates the infinitely variable speed control. When starting the truck, does the controller checks the closing sequence of the micro switches in the circuit. The controller is equipped with a light emitting diode (LED) showing system status and potentiometers for adjusting the current limit and acceleration, placed under a sliding cover.

106

111 204

105

110

104 103

207

203 202

206

109 201

205

102

108

101

107 301

409

417

408

416

407

415

406

The electrical system has a connection card (A2) to group all connections of the control circuits for input and output signals to the transistor controller. The connection card is equipped with LED’s for indication of input or output signals and a potentiometer for adjustment of the maximum speed.

414

405 302

404

413

403 402

412 411

3.2. Adjustable settings:

410 401

Setting

Std. value

Min. value

Max. value

Current limit

150 Amp

100 Amp

150 Amp

Acceleration

0.8 s

0.1 s

3s

3.6 mph

1.9 mph

3.6 mph

Maximum speed, without load

3.3. REFERENCES: For more information about: adjustment of the speed potentiometer, the transistor controller and the connection card, see C-code 5330, 5460 resp. 5710.

The description is divided into different phases which correspond to the operational sequense steps. For each sequense step the correct LED-pattern is shown below. A filled circle denotes a LED emitting light.

Return © BT Products AB

Service Manual

1995-07-19

English

65

Section

C-code

PS S5.0 Electrical System

F-code

5000

Version no

T-code

001

353,354

3.4. Key switchS17 in the ON position 106

111 204

105

110

104

207

203 202

206

103

109 201

205

102

108

101

107 301

409

417

408

416

407

415

406

414

405 302

When S17 closes, the transistor controller will check that S10 is not closed. If this is the case, operation is not permitted.

404

413

403 402

412 411 410

401

Battery voltage on A2-terminal 202, LED 202 lights up. A2 (-) return terminal 409. Battery voltage to A1.16 via A2-terminal 410, LED-status starts to flash.

3.5. The operating arm in drive position, S10, brake switch closed 106

111 204

105

110

104

207

203 202

206

103

109 201

205

102

108

101

107 301

409

417

408

416

407

415

406

414

405 302

404

413

403 402

412 411 410

401

When the operating arm is pulled down to the driving position, S10 is activated and closes and at the same time the brake is mechanically released. Voltage obtained via terminal 109 and 408 to A1.15, LED 109 lights up, on the hour meter terminal 206 and the shunt field terminal 301.

The transistor controller now regulates the current through the shunt field, 1.2 A, (-) return via terminal 302, 417 and A1.1.

3.6. Driving, fork direction 106

111 204

105

110

104 103

When the thumb control is activated for driving in the fork direction, S15 will close.

207

203 202

206

109 201

205

102

108

101

107 301

409

417

408

416

407

415

406

414

405 302

404

413

403 402

412 411 410

401

Battery voltage to terminal 101 and 411 to A1.11, LED 101 lights up. Battery voltage to K11 from terminal 403. A1.2 now gives (-) return to K11, (-)input on terminal 401, LED 401 lights up.

Depending on the position of the speed potentiometer(R1) and the adjustment of potentiometer RV1, A1.8 will receive a voltage between 4.8-0.25 V. The motor current now passes through F10, the series field D2-D1, K11, the armature A2-A1 and K11 to battery negative via A1 (M-).

Return 66

Service Manual

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English

F-code

Section

PS

S5.0 5000 Electrical System

Version no

T-code

001

353,354

C-code

3.7. Driving, steer wheel direction

106

111 204

105

110

104 103

When the thumb control is activated for driving in the steer wheel direction, S16 will close. The transistor controller checks that S10 is closed before S16 closes. If not, driving is blocked.

207

203 202

206

109 201

205

102

108

101

107 301

409

417

408

416

407

415

406

414

405 302

404

413

403 402

412 411 410

401

Battery voltage to terminal 102 and 412 to A1.12, LED 102 lights up. Battery voltage to K13 from terminal 403. A1.3 now gives (-) return to K13, (-)input on terminal 402, LED 402 lights up.

Depending on the position of the speed potentiometer(R1) and the adjustment of potentiometer RV1, A1.8 will receive a voltage between 4.8-0.25 V. The motor current now passes through F10, the series field D2-D1, K13, the armature A1-A2 and K13 to battery negative via A1 (M-).

3.8. Reversing/motor brake fork direction to steer wheel direction S15 returns to open position while S16 closes. The current in the series field causing the motor to work as a generator since the drive wheel is rotating in the opposite direction.

The transistor controller detects the generated current at connection A2, and reduces the series field current to 60A. When the drive wheel rotates in the right direction and the potential at connection A2 becomes positive, acceleration is done according to adjusted values of current limit and acceleration.

During the plugging sequence, the armature current passes in the circuit A2-A1, K13, A2 (the brake diode of the transistor controller), M- and K13.

Return © BT Products AB

Service Manual

1995-07-19

English

67

Section

C-code

PS S5.0 Electrical System

F-code

5000

Version no

T-code

001

353,354

3.9. Reversing/motor brake steer wheel direction to fork direction S16 returns to open position while S15 closes. The current in the series field causing the motor to work as a generator since the drive wheel is rotating in the opposie direction.

The transistor controller detects the generated current at connection A2, and reduces the series field current to 60A. When the drive wheel rotates in the right direction and the potential at connection A2 becomes positive, acceleration is done according to adjusted values of current limit and acceleration.

During braking sequence, the armature current passes in the circuit A1-A2, K11, A2 (the brake diode of the transistor controller), M- and K11.

3.10. Reverser switch

106

111 204

105

110

104 103

Possible breaks in the wiring for the reverser switch is continously checked by the transistor controller. It sends a small pulsed current through the circuit from A1.10, terminal 416, 111, wire 32, S20, wire 32, terminal 110, 415 and A1.13.

207

203 202

206

109 201

205

102

108

101

107 301

409

417

408

416

407

415

406

414

405 302

404

413

403 402

412 411 410

401

S20 is activated causing terminal 110, 415 and A1.13 to become positive, A1 now interrupts the (-)return to K13 which opens. At the same time A1 will provide (-) at A1.3 to K11, LED 401 lights up.

The motor will now be connected for motor braking at a maximum current limit 150A, and subsequently accelerate in the fork direction until S20 returns to its neutral position.

When S20 returns to neutral position, (+) disappears from terminal 110, A1 will interrupt the (-)return at A1.3 to K11 and the truck will stop.

In order to be able to start again if S16 is still activated, the transistor controller must be returned to the inactive position by letting the speed potentiometer return to the neutral position, after which a new direction of travel can be chosen.

Return 68

Service Manual

1995-07-19

English

F-code

Section

PS

S5.0 5000 Electrical System

Version no

T-code

001

353,354

C-code

3.11. Lifting the forks 106

111 204

105

110

104

207

203 202

206

103

109 201

205

102

108

101

107 301

409

417

408

416

407

415

406

414

405 302

404

413

403 402

412 411 410

401

106

111 204

105

110

104

207

203 202

206

103

109 201

205

102

108

101

107 301

409

417

408

416

407

415

406

(-)return via wire 40. K30 closes and the pump motor M3 starts.

3.12. Horn

414

405 302

The micro switch S52 closes. K30 receives (+)voltage via terminal 105, 203, battery controller or the jumper, terminal 201 and 405, LED 105 and 405 light up.

404

413

403 402

412 411 410

401

Micro switch S18 is activated. The horn, H1, receives (+)voltage via terminal 107 and 406, LED 107 lights up. (-)return via wire 40.

4. Options 106

111 204

105

110

104

207

203 202

206

103

109 201

205

102

108

101

107 301

409

417

408

416

407

415

406 405 302

404

413

403 402

412 411 410

401

4.1. Electrical lowering of the forks

414

When lowering the forks S41 is activated. The magnetic valve, Y41, receives (+)voltage via terminal 106 and 204, LED 106 lights up. (-)return via wire 40.

Return © BT Products AB

Service Manual

1995-07-19

English

69

Section

C-code

PS S5.0 Electrical System

F-code

5000

Version no

T-code

001

353,354

Return 70

Service Manual

1995-07-19

English

F-code

Section

C-code

PS S-5230 Battery controller/hourmeter Issued by

Approved by

Version no

T-code

TDC

K Hallman

001

351,352,353,354

Battery controller/hourmeter Valid from machine number: 270001-

1. GENERAL This instrument consists of a single, quartz, hourmeter (H), a 10 bar multi color battery discharge controller (BC), and a lockout relay. The lift lockout relay is operating in such a way 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.Meaning that there will be no lockout of the lift during the lift operation. The hourmeter features a liguid crystal dispay (LCD) which has six segment digits with a decimal point before the last digit. This provoides resolution of 0.1 hours or 6 minutes.

kga00004

2. ELECTRICAL 2.1. Voltage The instrument is supplied as a pin selectable dual voltage unit with the voltage of 24/48 VDC.

Return © BT Products AB

Service Manual

1995-07-25

English

71

F-code

Section

C-code

PS S-5230 Battery controller/hourmeter Version no

T-code

001

351,352,353,354

2.1.1. The contact voltage and current ratings for switching resistive loads.

Open Contact Voltage

200

VDC

Max

Closed Contact Current

3

ADC

Max

Volt Ampere Product

50

W

Max

.

2.1.2. Memory Retention The instrument contains an internal battery which allows (BC) memory retention when external power is removed. Typical battery life is 10 years. The hourmeter has a solid state non volatile memory which does not require battery backup.

3. BATTERY CONTROLLER 3.1. GENERAL 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, to show the current discharge level. When the battery is 70% 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% 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 gage . The inital 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% correct lockout for a specific application.

Return 72

Service Manual

1995-07-25

English

F-code

Section

C-code

PS S-5230 Battery controller/hourmeter

Battery Ah 180 210 240

Version no

T-code

001

351,352,353,354

WSX 20/25 L-M M-N N-O

L-M means that you should adjust on the line between L and M. N-O means that you should adjust on the line between N and O. A 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 then 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.

Return © BT Products AB

Service Manual

1995-07-25

English

73

F-code

Section

C-code

PS S-5230 Battery controller/hourmeter Version no

T-code

001

351,352,353,354

.

SETTING

VPC

K

1.57

L

1.63

M

1.68

N

1.73

O

1.78

P

1.82

Q

1.84

R

1.86

S

1.91

T

1.93

PIN NO:

FUNCTION

1

Hour meter (-)

2

Keyswitch (+)

3

Relay arm (+)

4

Relay NC (-)

5

Battery (-)

6

Hour meter (+)

7

24 Volt (+)

8

48 Volt (+)

kga00005

NOTE: The instrument can be connected differently in different trucks, please see diagrams in the electrical descriptions C-code 5000.

Return 74

Service Manual

1995-07-25

English

F-code

Section

C-code

PS S-5230 Battery controller/hourmeter Version no

T-code

001

351,352,353,354

NOTE: The discharge adjustments can be made at any time during a working cycle before lift lockout. However, discharge pot. adjustments made lately in a working cycle have little or no effect in delaying the lift lockout in that particular working cycle. Normally discharge pot. adjustments are made before or at the beginning of a working cycle to effectively change the discharge profile of that working cycle. Once lift lockout does occur, the gauge must be reset before discharge pot. 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 conected to the machine.

3.3. Keyswitch 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 of by the keyswitch.

The keyswitch also enables timing function of the hourmeter.

With the keyswitch ”on”, the hourmeter can be activated by the connection No 1 at the rear of the BC. With the keyswitch ”off” the hourmeter will not respond to the connection No 1 and the LCD of the hourmeter will be off.

3.4. HOURMETER Hourmeter operation is indicated by flashing of the hourglass icon on the face of the LCD. The flash rate is 15 times a minute with a duty cycle of 3 seconds on and 1 second off.

When the hourmeter is not in operation the icon is visible but does not flash.

Return © BT Products AB

Service Manual

1995-07-25

English

75

F-code

Section

C-code

PS S-5230 Battery controller/hourmeter Version no

T-code

001

351,352,353,354

4. Trouble shooting This section is separated into two parts: battery discharge indicator and hour meter.

4.1. Battery Discharge Indicator 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 tha 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. Always resets 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 connected to a fully charged battery and allowed to track its discharge without break in power.

NOTE: New instruments are shipped from the factory with a full reading in their memory. The first time the instrument is connected to the truck’s battery it will always show a full charge. 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.

Return 76

Service Manual

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English

F-code

Section

C-code

PS S-5230 Battery controller/hourmeter Version no

T-code

001

351,352,353,354

4.1.3. No discharge, gauge does not run down The instrument monitors loaded battery voltages. If connected to a partially discharged battery, it will not run down until it observes the loaded voltages of that battery. 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 tha gauge indication downwards from a full reading.

4.1.4. No lockout The LED display must be alternately flashing the two left-most 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 remove the wire leading to pin 3 when at lockout. 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. 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 above lockout and should read 0 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. To check for voltage drops use a voltmeter with its positive lead on the bettery’s positive terminal and the meter’s negative lead on pin 7 or 8 (wichever pin B+ is connected to). Load the battery and record this measurement. Repeat this procedure with the voltmeter’s positive lead on pin 5 and its negative lead on the battery’s negative terminal and record the voltage measured. Add the two voltage readings. This total should be less than 1% of the nominal battery voltage. Voltages higher than this will cause the instrument to calculate battery stateof-charge from incorrect readings.

Return © BT Products AB

Service Manual

1995-07-25

English

77

F-code

Section

C-code

PS S-5230 Battery controller/hourmeter Version no

T-code

001

351,352,353,354

4.1.7. LEDs don’t light The battery discharge indicator LEDs are illuminated by the keyswitch, pin 2.

Verify that B+ is present across pin 2 and pin 5.

If voltage is present and the LEDs do not light the instrument is defective.

4.2. Hour meter 4.2.1. No display Lte LCD of the hour meter will illuminate when power is applied at pin 7 or 8 and pin 5. If voltage is measured across these pins and the LCD does not turn on the instrument is defective.

4.2.2. Hour glass icon does not flash If the icon does not flash the hour meter is not accumulating time. The keyswitch pin 2 must be on (at B+), pin 7 or 8 must be connected to B+, and one or both of the hour meter lines must be active. If both the keyswitch is on and one or both inputs are correct and the hour meter icon does not flash the instrument is defective.

4.2.3. Hour meter glass icon always flashes When the icon is flashing the hour meter is accumulating time. Turn the truck’s keyswitch off. This should remove voltage from pin 2 of the instrument. Should voltage be present at pin 2 and the hour meter’s icon is continues to flash the instrument is defective.

Return 78

Service Manual

1995-07-25

English

F-code

Section

PS

C-code

S5.0 5460 Transistor Controller

Issued by

Approved by

Version no

T-code

TDC

K. Hallman

001

351,352,353,354

Transistor Controller Valid from machine number: 270001-

1. Motor circuit The transistor controller have four terminals for the high current circuits according to the table below.

Terminal

Connecting

M-

Output to motor armature

B-

Negative connection to battery

B+

Positive connection to battery/series field

A2

Plug diode to motor armature

Return © BT Products AB

Service Manual

1995-07-17

English

79

F-code

Section

PS S5.0 Transistor Controller

C-code

5460

Version no

T-code

001

351,352,353,354

2. Control circuit The transistor controller have an integrated 16-pin connector to provide the low power logic control connections. The designation of the pins are according to table below.

Pin No

Connecting

CONTACTOR DRIVERS P1

Shunt field driver output

P2

Fork direction contactor driver output

P3

Steer wheel direction contactor driver output

P4

Not connected

THROTTLE CONNECTIONS P5

Not connected

P6

Not connected

P7

Throttle: pot low

P8

Throttle: 2-wire 5 kOhm-0 input

BASIC CONTROL SIGNALS P9

Not connected

P10

Emergency reverse check output

P11

Drive fork direction input

P12

Drive steer wheel direction input

P13

Emergency reverse input

P14

Speed range selection input

P15

Brake switch input

P16

Key switch input (KSI)

Return 80

Service Manual

1995-07-17

English

F-code

Section

PS

C-code

S5.0 5460 Transistor Controller

Version no

T-code

001

351,352,353,354

3. Technical specification The technical specification for the BT-version of the Curtis 1207 transistor controller is according to table below.

PARAMETER

RANGE

STD SETTING

UNITS

Operating voltage

24

24

Volt

Maximum voltage

45

Volt

Overvoltage point

Minimum operating voltage

16

Volt

Undervoltage point

Electrical isolation to heatsink

500

Volt ac

Minimum

Frequency

15

kHz

Contactor voltage

24

Volt

Contactor current

1

Amp

Shunt driver current

2

KSI input current

80

mA

Logic input current

10

mA

Logic input threshold

8

Volt

Ambient operating temperature

-40 - +50

o

1.2

DESCRIPTION

Maximum(current limit at 2 amp)

Amp

At 24 Volt

C

Return © BT Products AB

Service Manual

1995-07-17

English

81

F-code

Section

C-code

PS S5.0 Transistor Controller

5460

Version no

T-code

001

351,352,353,354

PARAMETER

RANGE

STD SETTING

UNITS

DESCRIPTION

Heatsink overtemperature cutback

85

oC

Heatsink undertemperature cutback

-25

oC

Plug Braking

Variable

Variable

Current Limit, Main

100-150

150

Amp

Current Limit, Low Speed, Main

100

Amp

Maximum current in low speed mode

Current Limit, Plug

60

Amp

Maximum plug current in the series field

Current Limit, Low Speed, Plug

60

Amp

Maximum plug current in the series field in low speed mode

Current Limit, Emergency Reverse

150

Amp

Maximum field current in emergency reverse

Current Limit, Low speed, Emr. Reverse

150

Amp

Max. field current when in low speed for emergency reverse

Throttle Type

5k-0

Ohm

Plug current dependant upon throttle position

Return 82

Service Manual

1995-07-17

English

F-code

Section

PS

PARAMETER

Version no

T-code

001

351,352,353,354

STD SETTING

UNITS

DESCRIPTION

Min. Duty Cycle

0

%

Speed (duty factor) at minimum throttle setting

Low Speed

70

%

Maximum speed (duty factor) in low speed mode

Emergency Reverse Speed

50

%

Speed during emergency reverse

0.8

Sec

Time to reach full output from zero output

Acceleration Rate

RANGE

C-code

S5.0 5460 Transistor Controller

0.1 - 3

4. Adjustment panel

The adjustment panel is located on top of the controller, under a sliding protective cover. The panel provides access to a set of adjustable potentiometers, a connector for a handheld terminal and the STATUS LED.

4.1. Adjustable Potentiometers: MAIN and ACCEL potentiometers can be adjusted with a screwdriver within the range given in the technical specification.

NOTE: In the BT-version of the Curtis 1207 only two of the potentiometers are used, MAIN and ACCEL. The other three potentiometers are disabled from factory.

4.2. Connection of handheld terminal: To adjust the parameters with the handheld terminal the corresponding potentiometer must be set to ”off”.

Return © BT Products AB

Service Manual

1995-07-17

English

83

F-code

Section

PS S5.0 Transistor Controller

C-code

5460

Version no

T-code

001

351,352,353,354

4.3. Status LED: The LED displays flashing codes to indicate controller status.

The codes are listed with explanations in section 6.

5. Maintenance There are no servicable parts inside the transistor controller.

No attempt should be made to open the controller. OPENING THE CONTROLLER WILL VOID THE WARRANTY! It is however recommended that the controller exterior be cleaned periodically. When cleaning the controller gives a good opportunity to check the controller’s diagnostic history file with the handheld terminal, if available.

5.1. Safety The controller is inherently a high power device. When working around any battery powered vehicle, proper safety precautions should be taken. These include, but are not limited to: proper training, wearing eye protection, avoiding loose clothing, removing watches and jewelry, and using insulated wrenches.

WARNING Risk of short circuits.

Remove all watches and jewelry and always use insulated tools.

5.2. Cleaning Although the controller requires virtually no maintenance if properly installed, the following minor maintenance is recommended on a regular 250 hours basis.

1. Remove power by disconnecting the battery.

2. Discharge the capacitors in the controller, by connecting a load (such as a contactor coil or the horn) across the controller’s B+ and B- terminals, before doing any work on the controller.

3. Remove all dirt or corrosion from the bus bar area. The controller should be wiped clean with a moist rag. Allow it to dry before reconnecting the battery.

Return 84

4. Make sure the connections to the bus bars are tight.

Service Manual

1995-07-17

English

F-code

Section

PS

C-code

S5.0 5460 Transistor Controller

Version no

T-code

001

351,352,353,354

Use two well insulated wrenches for this task in order to avoid stressing the bus bars.

6. Diagnostics and troubleshooting

During normal operation, with no faults present, the Status LED flashes a single flash at approximately 1 flash/second. If the controller detects a fault, a 2-digit code is flashed continously until the fault is corrected, see table below.

If using a handheld terminal for the diagnostics, switched over to diagnostic mode, the diagnostic information can be read in the terminal display, see table below.

LED CODE

TERMINAL LCD DISPLAY

EXPLANATION

POSSIBLE CAUSE

1,2

¤ ¤¤

HW FAILSAFE

hardware fail-safe error

1. Controller defective

1,3

¤ ¤¤¤

M- FAULT

M- output shorted

1. M- output shorted to ground.

2. Direction contactor not closing.

3. Direction contactor not closing fast enough.

4. Internal motor short to ground.

1,4

¤ ¤¤¤¤

SRO

SRO fault

1. Improper sequence of KSI, brake and direction inputs.

2. Brake or direction switch circuit open.

2,1

¤¤ ¤

THROTTLE FAULT 1

5kOhm-0 or wiper fault

1. Throttle input wire open.

2. Throttle input wire shorted to ground or B+.

3. Throttle pot defective.

4. Wrong throttle type.

2,2

¤¤ ¤¤

BB WIRING CHECK

emerg. reverse wiring fault

1. BB wire open.

2. BB check wire open.

Return © BT Products AB

Service Manual

1995-07-17

English

85

F-code

Section

PS S5.0 Transistor Controller

C-code

5460

Version no

T-code

001

351,352,353,354

LED CODE

TERMINAL LCD DISPLAY

EXPLANATION

POSSIBLE CAUSE

2,3

¤¤ ¤¤¤

HPD

HPD sequencing fault

1. Improper sequence of KSI, brake, throttle inputs.

2. Misadjusted throttle.

2,4

¤¤ ¤¤¤¤

THROTTLE FAULT 2

Pot Low broken or shorted

1. Pot low wire open.

2. Pot low wire shorted.

3. Wrong throttle type.

3,1

¤¤¤ ¤

CONT DRVR OC

driver output overcurrent

1. Direction contactor coil shorted.

2. Shunt field shorted.

3,2

¤¤¤ ¤¤

DIR CONT WELDED

welded direction contactor

1. Direction contactor stuck closed.

3,4

¤¤¤ ¤¤¤¤

MISSING CONTACTOR

missing contactor or shunt

1. Direction contactor open coil.

2. Direction contactor missing.

3. Shunt field open.

4. Wire to shunt or direction contactor open.

4,1

¤¤¤¤ ¤

LOW BATTERY VOLTAGE

low battery voltage

1. Battery voltage <16 volts.

2. Corroded battery terminal.

3. Loose battery or controller terminal.

4,2

¤¤¤¤ ¤¤

OVERVOLTAGE

overvoltage

1. Battery voltage > 45 volts.

2. Vehicle operating with charger attached.

4,3

¤¤¤¤ ¤¤¤

THERMAL CUTBACK

over-/under-temperature cutback

1. Temperature >85oC or < 25 oC. 2. Excessive load on vehicle.

3. Improper mounting of controller.

4. Operation in extreme environments.

Return 86

Service Manual

1995-07-17

English

F-code

Section

C-code

PS

S5.0

5710 PCB Card

Issued by

Approved by

Version no

T-code

TDC

K Hallman

001

351,352,353,354

PCB Card Valid from machine number: 270001-

1. The PCB The PCB is a card to create a common connection point in the electrical system for the different wiring harnesses. The card is equipped with green LED’s on the inputs from micro switches and red LED’s on the outputs to the contactors. This will simplyfy the tracing of faults in the wiring or the switches.

The card is also equipped with a potentiometer for adjustment of the maximum speed.

Return © BT Products AB

Service Manual

1995-07-19

English

87

F-code

Section

C-code

PS PCB Card

S5.0

5710

Version no

T-code

001

351,352,353,354

2. Connectors and adjustments 1

5

106

111 204

105

110

104

207

203

202

206

103

109 201

205

102

108

101

107 301

417

408

416

407

415

406

414

405 302

4

404

413

403 402

412

401

411 410

Position

Connection/Adjustment

1

Key switch(S17), battery -, instrument, magnetic valve (Y41)

2

Battery +, armature voltage, contactors, horn

3

Shunt field

4

RV1, adjustment of maximum speed

5

Micro switches

Return 88

409

Service Manual

1995-07-19

English

F-code

Section

C-code

PS

S5.0

5710 PCB Card

Version no

T-code

001

351,352,353,354

3. Terminals and LED’s

106

111 204

105

110

104

207

203 202

206

103

109 201

205

102

108

101

107 301

409

417

408

416

407

415

406

414

405 302

404

413

403 402

412 411 410

401

Terminal No

LED No

Connection

Function

101

101

I

Driving, fork direction

102

102

I

Driving, steer wheel direction

103

O

Speed control

104

I

Reference value, speed

105

105

I

Fork lift

106

106

I

Fork lower, always connected even if the option electrical lowering is fitted

107

107

I

Horn

O

24 V (+)

I

Brake

110

I

Reverser (S20)

111

I

Reverser (S20)

201

I

Battery controller/ Lift interupt

I

24 V (+)

O

Battery controller/ Lift interupt

108 109

202 203

109

202

Return © BT Products AB

Service Manual

1995-07-19

English

89

F-code

Section

C-code

PS PCB Card

S5.0

5710

Version no

T-code

001

351,352,353,354

Terminal No

LED No

Connection

Function

204

O

To magnetic valve, when having the option electrical lowering of the forks

205

O

24 V (+)

206

O

Hour meter

301

O

Shunt field(+)

302

O

Shunt field(-)

401

401

I

Contactor (-), fork direction

402

402

I

Contactor (-), steer wheel direction

O

Contactor drive direction, common (+)

403 404 405

Not connected 405

O

Contactor, pump motor

406

O

Horn

407

I

24 V (+)

408

O

Output signal, brake released

409

I

(-)

410

O

24 V (+), to transistor controller

411

O

Driving, fork direction

412

O

Driving, steer wheel direction

413

I

Speed control

414

O

Reference value, speed

415

O

Reverser, (S20)

416

O

Reverser, (S20)

417

I

Shunt field(-)

I = Input, green LED O = Output, red LED

Return 90

Service Manual

1995-07-19

English

F-code

Section

PS

S-6000 Hydraulic system

Issued by

Approved by

Version no

T-code

TDC

K. Hallman

001

354

C-code

Hydraulic system Valid from machine number: 270001-

1. General The hydraulic system consists of a compact hydraulic unit, including a mechanical lowering valve, pressure relief valve and the cylinders for the lift of the forks.

2. Description of function 2.1. Hydraulic diagram and components

1

A

M

B

A C

2

Return © BT Products AB

Service Manual

1995-07-26

English

91

Section

C-code

PS S-Hydraulic system

F-code

6000

Version no

T-code

001

354

2.2. Main components Pos No

Description

Remark

1

Lift Cylinders

Fork lift

2

Hydraulic Unit

A = Check valve B = Lowering valve C = Relief valve M = Pump motor

2.3. Description 2.3.1. Lift When the pump motor starts, the oil flows through the pump and check valve to the lift cylinders.

2.3.2. Lower When the lowering valve is affected by the lower lever on the chassis, it opens to let the oil in the pressure lines return to the oil tank. The lowering speed is regulated by the movement of the lever.

2.3.3. Operating pressure The operating pressures at rated load are: 1. WSX20: 2090 psi 2. WSX25: 2610 psi 2.3.4. Relief valve The relief valve opens at the following pressures: 1. WSX20: 2300 psi 2. WSX25: 2870 psi

Return 92

Service Manual

1995-07-26

English

F-code

Section

PS

S-6000 Hydraulic system

Issued by

Approved by

Version no

T-code

TDC

K. Hallman

002

354

C-code

Hydraulic system Valid from machine number: 270001-

1. General The hydraulic system consists of a compact hydraulic unit, including a mechanical lowering valve, an electromagnetic lowering valve, pressure relief valve and the cylinders for the lift of the forks.

2. Description of function 2.1. Hydraulic diagram and components

1

A

M

D B

A

C

2

Return © BT Products AB

Service Manual

1995-07-26

English

93

Section

C-code

PS S-Hydraulic system

F-code

6000

Version no

T-code

002

354

2.2. Main components Pos No

Description

Remark

1

Lift Cylinders

Fork lift

2

Hydraulic Unit

A = Check valve B = Lowering valve C = Relief valve D = Electro-magnetic lowering valve M = Pump motor

2.3. Description 2.3.1. Lift When the pump motor starts, the oil flows through the pump and check valve to the lift cylinders.

2.3.2. Lower When the lowering valve is affected by the lower lever on the chassis, it opens to let the oil in the pressure lines return to the oil tank. The lowering speed is regulated by the movement of the lever.

2.3.3. Lower, electrical When the electro-magnetic valve is energized electrically from the push button on the handle, it opens fully to let the oil in the pressure lines return to the oil tank. The lowering speed is regulated by a restriction in the hydraulic unit.

2.3.4. Operating pressure The operating pressures at rated load are: 1. WSX20: 2090 psi 2. WSX25: 2610 psi 2.3.5. Relief valve The relief valve opens at the following pressures: 1. WSX20: 2300 psi 2. WSX25: 2870 psi

Return 94

Service Manual

1995-07-26

English

Return

Section

C-code

PS S-Hydraulic system

F-code

6000

Version no

T-code

002

354

Return 96

Service Manual

1995-07-26

English

THE PRIME-MOVER CO. 3000 NORTH US HIGHWAY 61 MUSCATINE, IOWA 52761-5810

Return

Service Manual WSX-20/25 Electric Walkie Adjustable Straddle Stacker Effective Serial Number 295451AA000

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: 304944-000 Return

Date: July 15, 1997

Return

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

Return

C-Code

0

Chassis

0000

1

Drive Motor

1000

2

Drive Gear / Transmission

2000

3

Brake / Wheel System

3000

4

Steering System

4000

5

Electrical System

5000

6

Hydraulic / Pneumatic System

6000

7

Operating Function-lifting Mast / Cylinders

7000

8

Peripheral / Installation Equipment

8000

9

Optionals / Attachments

9000

Service Manual

1997-07-15

1

F-code

Section

C-code

BT Standard Codes Version no

T-code

000

2

Return

Service Manual

1997-07-15

Table of Contents

BT Standard Codes ............................................................................. 1 Warning Symbols ................................................................................ 5 Prohibitory Symbols ........................................................................... 6 Introduction, service manual ............................................................. 7 Contents, Section M ........................................................................... 9 General product information ........................................................... 11 Technical service data ...................................................................... 29 Ordering Spare Parts ........................................................................ 33 Contents, Section P .......................................................................... 35 Introduction, Maintenance ............................................................... 37 Service schedule ............................................................................... 39 Lubrication chart ............................................................................... 45 Oil and grease specification ............................................................ 47 Contents, Section S .......................................................................... 49 Support arm chassis ........................................................................ 51 Transmission ..................................................................................... 57 Electrical System .............................................................................. 71 Battery Controller/Hourmeter .......................................................... 83 Transistor Controller ........................................................................ 91 PCB Card ........................................................................................... 99 Hydraulic system, mechanical lowering ....................................... 105 Hydraulic system, electrical lowering ........................................... 107

© BT Products

3

Return

Table of Contents

© BT Products

4

Return

F-code

Section

C-code

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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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.

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354

Introduction, service manual The information in this Service Manual covers the truck types BT WSX20 and WSX25.

Federal and State laws require that operators be completely trained in the safe operation of lift trucks.

An Operator’s Manual is attached to every BT lift truck when it is manufactured. If the Operator’s Manual is missing from the truck, a new manual may be obtained by contacting: BT Prime-Mover, Inc. 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

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SUBJECT

M

MACHINE INFORMATION

P

PLANNED MAINTENANCE

S

SERVICE INSTRUCTIONS

O

OPTIONS

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M Contents, Section M Version no

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Contents, Section M 1. Machine Information

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M1.0

GENERAL PRODUCT INFORMATION

M2.0

TECHNICAL SERVICE DATA

M3.0

ORDERING SPARE PARTS

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General product information Valid from machine number: 270001-

2. Presentation of the WSX20/25 The trucks BT WSX20 and WSX25 are battery powered straddle arm trucks solely to be operated by pedestrian operators when handling pallets or similar load carriers indoors. In its standard design the truck is equipped with a steering arm with all the controls for operating the truck within easy access.

The trucks have a maximum lifting capacity of 2000 lbs. and 2500 lbs.

These trucks are equipped with a 24V electrical system and the speed is regulated by means of a transistor controller to provide infinite control of acceleration and speed while driving.

The forks are raised by means of a powerful hydraulic unit.

The control of the lift is done electrically with the push button on the steering arm. Control of the lowering speed and the positioning of the forks when stacking is done with the mechanical valve lever of the truck.

The truck can be fitted with different accessories including a battery-pack, electrical lowering of the forks and hour meter/ battery indicator. The truck can also be fitted with stainless steel axles and low temperature oil if it is to be used in cool conditions.

2.1. Intended application of the truck The truck is solely designed and manufactured to handle goods. The trucks should be fitted with the appropriate accessories relevant to the application.

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2.2. Forbidden application of the truck The truck is designed for handling goods indoors. It is not permitted to use the truck for other purposes including the following: - In areas that contain gases which can cause fires or explosions - As a towing truck for trailers - To tow other trucks - To transport/lift passengers - To drive on gravel or grass

2.3. Truck data The table provides information regarding some technical data which is of value with daily use of the truck.

Truck type

WSX20/25

Lifting capacity rated load, lbs.

2000/2500

Lift height, inches

104 - 144

Operating speed without load, mph

3.6

Operating speed with rated load, mph

3.1

Max. operating gradient with load, %

8

Service weight without battery, lbs.

1502-1599

Service weight including battery, lbs. (Ah)

1943 2040(240)

Turning radius (Wa), inches (fork length 45.3 inches)

59.3

Continuous noise level, dB A

< 70

The truck’s lifting capacity, lifting height, and weight can be found on the truck’s type plate.

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2.4. Truck dimensions The diagram shows external dimensions for the truck in its standard design.

71.3"91.1" 53"

4"

2"

45.3"

MIN 32.1" MAX 51.2"

28.5" 17.8"

59.3" 4"

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2.5. Truck data plate The diagram shows the type plate used on the truck.

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3. Main components 1. Tiller arm: The truck is to be controlled by the operator walking. 204 degrees steering angle.

The brake is applied in the upper and lower position of the tiller arm.

2. Type plate: With type designation, manufacturing number, year of manufacture, service weight, battery weight, classified lifting capacity, battery voltage and manufacturer.

3. Hoods: Removable which provides good accessibility when servicing.

4. Instrument: (accessory) Combined hour meter/battery guard or hour meter only.

5. Hydraulic control: For controlling lifting and lowering functions.

6. Hydraulic unit: Pump motor, pump, valves, and oil tank integrated in a compact unit.

7. Hydraulic valves: The valves are located to provide easy access.

8. Drive unit with brake: Fixed drive unit with a spring loaded brake, drive motor, gear, and drive wheel combined into a compact unit.

Steering bearings between motor and gear.

9. Machine number: The manufacturing number plate fitted to the chassis.

10. Electric panel: Removable, which provides good access when servicing.

24 volt electrical system. The speed is variably controlled by means of a transistor.

11. Battery: 24V with different Ah values. The truck can also be equipped with a battery pack (4x6V) with an integrated charger (accessory).

12. Battery isolator/Recharging connector: The battery is recharged through the removable charging connector. If the truck is equipped with a battery pack the

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batteries are charged by connecting the removable charging connector to the integrated charger.

13. Mast: Covered by a finger protection which covers the operator’s normal range of reach from the operating position.

5

13 1 12 1/2

0

1

3 +

5 81 101_

4 2 5 81 11_0

11

5

6

12 10 7 9 16

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4. Warning and information signs The figure shows the position and significance of the signs located on the truck.

1. Hydraulic control: Lifting 2. Signal/Horn 3. Direction: Forward/Rearward 4. General warning /informations sign 5. Hydraulic control: Lowering 6. Hydraulic oil level 7. Machine data plate 8. No Riding decal 9. Machine signs 10. Do not stand on the forks/Do not walk under lifted load 11. Lifting points 12. Pinch point

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1

3

12

2 10

11

11

5

4

9

6

8 7

18

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Inch (SAE) and Metric Fasteners

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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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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A = THREAD SIZE B = PITCH C = LENGTH

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3. Strength Identification The most common property classes for metric fasteners are 8.8 and 10.9. The property class is marked with a number on the head of the cap screw or on a nut. Property classes less then 8.8 are often not marked. Grades for inch bolts go from 2 to 8. Grade 2 fasteners normally do not have marks. The following tables show 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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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

5.2

7

8

Hex Head Bolts & Cap Screws 5

4.6*

4.8*

5.8*

8.8

4.6

4.8

5.8

8.8

9.8

10.9

12.9

9.8

10.9

12.9

Markings for size M5 and Larger

8

Hex Head Flange Screws

Same As Above 5

8

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

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Table 2. Stud and Nut Designations

Types of Fasteners

Inch Fasteners

Metric Fasteners

Strength Levels: SAE Grades

Strength Levels: Property Classes

* Markings Not Required

* Markings Not Required

5.2*

5*

4.6*

4.8* 5.8*

8.8

4.6

4.8

8.8

9.8 9.8

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.

2

Hex Nuts

Hex Slotted Nuts

Hex Flange Nuts

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5

5

8

9

5

8

9

5

8

9

10

12

10

12

10

12

8 or

or

Markings Not Required

5

8

9

10

12

5

8

9

10

12

5

8

9

10

12

5

8

9

10

12

Markings Not Required

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Table 3. Torque Nut Designations

Types of Fasteners

Inch Fasteners Strength Levels: SAE Grades

A

Metric Fasteners Strength Levels: Property Classes

B

C

5

9

10

B

C

5

9

10

or All Metal Prevailing Torque Nuts

F

G 9

10

9

10

or All Metal Prevailing Torque Flange Nuts or

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Table 4. Torque Nut with Nylon Insert Designations

Types of Fasteners

Metric Fasteners

Inch Fasteners

Strength Levels: Property Classes

Strength Levels: SAE Grades

5

9

10

5

9

10

or Nylon Insert Prevailing Torque Nuts

Markings Not Required

or or

Markings Not Required

9

10

9

10

or

Nylon Insert Prevailing Torque Flange Nuts

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Table 5. Fastener Torque Values

Size and Pitch

Property, Class 8.8*

Property, Class 10.9**

Property, Class 12.9***

N•m

in.-lb

N•m

in.-lb

N•m

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 -----------

N•m

ft-lb

N•m

ft-lb

N•m

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

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4. Conversion of Metric and English Units AREA Multiply

By

To Get

Multiply

By

To Get

inches²

6.451

centimeters² (cm²)

centimeters²

0.155

inches² (in²)

feet²

0.093

meters² (m²)

meters²

10.764

feet² (ft²)

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/in²

6.895

kilopascal (kPa)

kilopascals

0.145

pounds/in² (psi)

pounds/in²

0.007

megapascal (MPa)

megapascals

145.04

pounds/in² (psi)

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TEMPERATURE Multiply

By

To Get

Multiply

By

To Get

(Fahrenheit -32)

0.56

Celsius (C)

(Celsius x 1.8)

+32

Fahrenheit (F)

By

To Get

TORQUE Multiply

By

To Get

Multiply

inch pound

0.113

Newton meter (N•m) Newton meter

8.851

inch pounds in.-lb

feet pound

1.356

Newton meter (N•m) 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

inches³

16.387

centimeters³ (cm³)

centimeters³

0.061

inches³ (in³)

inches³

0.016

liters

liters

61.024

inches³ (in³)

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)

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Section

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M1.2 Technical service data

Version no

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002

354

Technical service data Valid from machine number: 270001 MODEL WSX20

WSX25

Type

TTL 1403-M2

TTL 1403-M2

Power

1.2 kW

1.2 kW

Duty factor

60%

60%

Min carbon brush length

0.5 inch

0.5 inch

Min commutator diameter 1.85 inch

1.85 inch

Part no

134397

134397

Type

2-step angular

2-step angular

Gear ratio

19.43:1

19.43:1

Oil volume

1 quart

1 quart

Oil type

Hypoid oil

Hypoid oil

Normal temperature

SAE 80W/90

SAE 80W/90

< -15oC

SAE 75W

SAE 75W

Drive wheel

Dia215x70 mm

Dia215x70 mm

Wheel pressure without load

1342 lb

1342 lb

Wheel pressure with rated load

1420 lb

1542 lb

Torque wheel bolts

47 ft-lb

47 ft-lb

Fork wheel

Dia 100x75 mm

Dia 100x75 mm

Axle pressure with rated load

2412 lbs

3110 lbs

Service Manual

1997-07-15

DRIVE MOTOR

TRANSMISSION/GEAR

WHEELS

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MODEL WSX20

WSX25

HYDRAULIC UNIT Power

2.0 kW

2.0 kW

Revolutions/min at work pressure

2600

2400

Duty factor

9%

9%

Min carbon brush length

0.5 inch

0.5 inch

Min commutator thickness/diameter

1.7 inch

1.7 inch

Pressure at rated load

2090 psi

2610 psi

Relief pressure

2300 psi

2870 psi

Pump flow

6.4 litre/min at 2090 psi

5.9 litre/min at 2610psi

Tank volume

0.92 gallons

0.92 gallons

Oil type

Hydraulic oil

Hydraulic oil

Normal temperature

ISO-L-HM32

ISO-L-HM32

< -15oC

ISO-L-HV32

ISO-L-HV32

Drive motor circuit

29228

29228

Amperage

100 A

100 A

Pump motor circuit

29223

29223

Amperage

160 A

160 A

Control circuit

122308-075

122308-075

Amperage

7.5 A

7.5 A

Dimension WxLxH

196x645x570 mm

196x645x570 mm

Capacity

240 Ah

240 Ah

Weight

440 lb

440 lb

FUSES

BATTERIES

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Version no

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354

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.

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PS Version no

Section

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M3.0 Ordering Spare Parts T-code

000

Ordering Spare Parts 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.

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000

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PS Version no

Section

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P Contents, Section P T-code

000

Contents, Section P 5. Planned Maintenance

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P1.0

INTRODUCTION

P2.0

SERVICE SCHEDULE

P3.0

LUBRICATION MAINTENANCE

P4.0

OIL AND GREASE SPECIFICATION

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PS

Section

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P1.0 Introduction, Maintenance

Version no

T-code

000

Introduction, Maintenance The schedules of maintenance and lubrication given in this section of the Service Manual cover up to one year’s 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.

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C-code

PS P1.0 Introduction, Maintenance Version no

T-code

000

46

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Service Manual

1997-07-15

F-code

Section

PS

P2.0 Service schedule

Version no

T-code

002

354

C-code

Service schedule Valid from machine number: 270001 -

1. Preventive maintenance schedule ITEM

0000.

0000.1 0000.2 0000.3 0000.4 0000.5 0000.6 0000.7 0640 0640.1 0640.2 0640.3 0840 0840.1 1700.

1700.1 1700.2 1700.3 1700.4 1700.5 1700.6

© BT Products

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WORK REQUIRED Interval in hours Interval in Days/Weeks/Months Chassis Check that the truck identification plate is legible Check the battery securing blocks for wear Check for damage and cracks Retighten the truck body fastening bolts (to the chassis) Check the cover lockings Retighten the support arm clamp bolts Check the mounting of the support arm safety catch Operator Controls Check that the travel direction/ speed selector is not binding Check that the horn button is operational Check that the lift/lower button is operational Drivers Protection Check that the red safety switch button is not binding Drive Motor Check for arcing due to poor connections Check all connections are tight Check carbon brushes Clean motor of dirt and dust Check tightening of motor bolts Check for abnormal noise in motor bearings Service Manual

5 1d

20 1w

80 1m

250 3m

500 6m

1000 12 m

X X X X X X X

X X X

X

X X X X X X

1997-07-15

39

3000 36 m

F-code

Section

C-code

PS P2.0 Service schedule Version no

T-code

002

354

ITEM

2550 2550.1 2550.2 2550.3 2550.4 3100.

3100.1 3100.2 3100.3 3500 3500.1 3500.2 3500.3 4100.

4100.1 4100.2 4100.3 4100.4 5110 5110.1 5110.2 5110.3 5110.4 5200 5200.1 5300.

5300.1 5300.2

40

Return

WORK REQUIRED Interval in hours Interval in Days/Weeks/Months Drive Gear Check for oil leakage Check oil level Check for abnormal noise Change the gear oil Brake Clean dust and debris Check brake disc for wear Check correct clearance of brake disc Wheels Remove all string, wrapping and debris Check drive wheel for wear and bolt torque Dismount and grease fork wheel bearings Steering Arm Check fastening Check steering force Check return of steering arm to upper position Lubricate the steering ball bearing Battery Electrolyte level, 10 - 15 mm above cell plates All connections: battery, battery and charger plugs All cell and link covers intact Check of battery specific gravity Instrument Panel Check battery indicator and hour meter for correct operation Electrical Control System Check key switch operationl Check ”brake micro switch” (S10) operational

5 1d

20 1w

80 1m

250 3m

500 6m

1000 12 m

3000 36 m

X X X X X X X

X X X

X X X X

X X X X X

X X

Service Manual

1997-07-15

ITEM

5300.3 5300.4 5400 5400.1 5400.2 5400.3 5400.4 5400.5 5710 5710.1 5710.2 5710.3 6000 6000.1 6000.2 6000.3 6000.4 6000.5 7100 7100.1 7100.2 7100.3 7100.4

© BT Products

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WORK REQUIRED Interval in hours Interval in Days/Weeks/Months Check the function of direction/ speed micro switches Check control wiring harness for wear Electrical Panel Cleaning and fixation to chassis Tightening of connections Check contactor contacts, clean and unburned Check contactor contacts for free movements Check all cable insulations for damage Electronic Card Cleaning of electronic card, blow with air and wipe off Check for poor connections in cable connectors Check of LED indications Hydraulic System Check hoses and connections for leakage Check hoses for wear and damage Check oil tank for cracks, leaks, and mounting Check correct oil level Change the hydraulic oil Lifting Mast Check for damage and crack formation Retighten the mast mounting bolts Check the play of the inner section rollers Check the lateral play of the inner section

Service Manual

5 1d X

20 1w

F-code

Section

PS

P2.0 Service schedule

Version no

T-code

002

354

80 1m

250 3m

500 6m

C-code

1000 12 m

X

X X X X X

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

1997-07-15

41

3000 36 m

F-code

Section

C-code

PS P2.0 Service schedule Version no

T-code

002

354

ITEM

7100.5 7100.6 7310.

7310.1 7310.2 7400.

7400.1 7400.2 7400.3

42

Return

WORK REQUIRED Interval in hours Interval in Days/Weeks/Months Check for wear on the lift chains and chain rollers Check the adjustment of the lift chains Lift Cylinder Check for leakage Check mounting Lifting Device Check the play of the fork carriage/yoke rollers Check the fork carriage/yoke for damage and crack formation Check the forks for wear and crack formation

5 1d

Service Manual

20 1w

80 1m

250 3m

500 6m X

1000 12 m

3000 36 m

X

X X X X X

1997-07-15

F-code

Section

PS

P2.0 Service schedule

Version no

T-code

002

354

C-code

0840

0640

7310 5330 7100

4100

0000

7400

5200

1 /2

0

1

+

58 1 1_10

5300

5710

3550

6000 5110 3550 2550

5400

© BT Products

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Service Manual

1997-07-15

3100

1700

43

F-code

Section

C-code

PS P2.0 Service schedule Version no

T-code

002

354

44

Return

Service Manual

1997-07-15

F-code

Section

PS

P3.0 Lubrication chart

Version no

T-code

002

354

C-code

Lubrication chart Valid from machine number: 270001Pos no

Service point

1 2 3 4 5 6

Wheel bearings Mast beam Lifting chains Hydraulic system Steering bearings Drive gear

Interval/Running hours 500h 1000h 3000h L L L C O L C O

Lubricant A F D B G C

L= Lubrication C = Check O = Oil change

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Service Manual

1997-07-15

45

F-code

Section

C-code

PS P3.0 Lubrication chart Version no

T-code

002

354

3 2

1 6

4

5

46

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Service Manual

1997-07-15

F-code

Section

C-code

PS P4.0 Oil and grease specification Version no

T-code

002

354

Oil and grease specification Valid from machine number: 270001-

2. Approved oils and grease

© BT Products

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Lubricant

Specification > - 15°C < - 15°C

Application area

A

Grease

Bearings and bushings

B C D

Hydraulic oil Transmission oil Grease

F G

Grease Grease

BT 26777 (Spray) ISO-L-HM32 SAE 80W/90 BT 26778 (Spray) BT 055-70111 Tex. Ref. C and C #880

Service Manual

BT 26777 (Spray) ISO-L-HV32 SAE 75W BT 26778 (Spray) BT 055-74320 Tex. Ref. C and C #880

1997-07-15

Hydraulic system Gears Chains and wires Side shift forks Steering bearings

47

F-code

Section

C-code

PS P4.0 Oil and grease specification Version no

T-code

002

354

48

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Service Manual

1997-07-15

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

0

CHASSIS

0000

1

DRIVE MOTOR

1000

2

DRIVE GEAR / TRANSMISSION

2000

3

BRAKE / WHEEL SYSTEM

3000

4

STEERING SYSTEM

4000

5

ELECTRICAL / PNEUMATIC SYSTEM

5000

6

HYDRAULIC SYSTEM

6000

7

LIFTING MAST / CYLINDERS

7000

8

PERIPHERAL / INSTALLATION

8000

EQUIPMENT 9

© BT Products

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OPTIONS / ATTACHMENTS

Service Manual

1997-04-15

9000

61

F-code

Section

C-code

PS S Contents, Section S Version no

T-code

000

62

Return

Service Manual

1997-04-15

F-code

PS

Section

C-code

S 0350 Support arm chassis

Version no

T-code

002

354

Support arm chassis Valid from machine number: 270001-

2. General The support arm chassis is bolted to the drive unit chassis to complete the truck. It also has the mounting points for the lifting mast and lift cylinders.

The support arms of the straddle chassis are adjustable in width from 32 inches to 51 inches to suit different pallet sizes.

Normally the support arms are only adjusted prior to a truck being delivered to a customer.

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Service Manual

1997-04-15

51

F-code

Section

PS S Support arm chassis Version no

T-code

002

354

C-code

0350

3. Main components 4

5

3 6 2 10

7 1

9

8

Pos no

Description

1

Support arm wheel axle

2

Wheel axle locking circlip

3

Support arm wheel

4

Support arm

5

Mounting bracket to drive unit chassis

6

Support arm safety catch

7

Support arm clamp

8

Support arm locking bolt

9

Lift cylinder mounting bracket

10

Mast mounting bracket

4. Maintenance The support arm clamp bolts need to be checked at the regular 500 hours preventive maintenance service. The torque of the support arm clamp bolts (pos no. 7 in chapter 2) must be checked with a torque wrench set at 88.5 ft-lb.

52

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Service Manual

1997-04-15

F-code

PS

Section

C-code

S 0350 Support arm chassis

Version no

T-code

002

354

5. Adjustment of the support arm width B

A

B

3 2 1

To adjust measurement A between the support arms proceed as follows: • Park the truck on a level surface.

• Disconnect and remove the battery from truck to prevent accidental operation.

• Block truck with one side about 1 in. off floor.

Warning!

The truck can tip over.

Do not jack up both support arms at the same time. The truck is a three wheeler.

Jack up one side at the time and support it while working.

• Loosen the bolt at the front of the cross beam (1).

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Service Manual

1997-04-15

53

F-code

Section

PS S Support arm chassis Version no

T-code

002

354

C-code

0350

• Loosen the clamp bolts (2).

• Pull out (or push in) the support arm. To get measurement A, measure B = A/2 - 12 inches. Make sure that measurement B is equal on both sides.

If the support arm is pulled out too much the safety catch, 3, will drop into the hole in the arm to stop it from falling out.

• Tighten bolt 1 and lock it with the locking nut.

• Tighten the four clamp bolts, pos 2, with a torque wrench.

Torque value: 88.5 ft/lbs.

6. Exchange of support arms When changing a support arm the job is more extensive than adjusting the arm width.

• Lift out the battery.

• Remove the battery box from the chassis. Remove the two bolts at the bottom of the box.

1

2 • Remove the safety catch from the support arm clamp.

• Jack up the side of the truck where the support arm is to be changed.

• Loosen the bolt at the front of the cross beam, 1.

• Loosen the clamp bolts, 2.

54

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1997-04-15

F-code

PS

Section

C-code

S 0350 Support arm chassis

Version no

T-code

002

354

• Pull out the support arm.

• Install the new support arm and adjust the arm width according to chapter 4.

• Lower the truck to the floor.

• After tightening the clamp bolts, fit the safety catch.

• Install the battery box.

• Install the battery.

© BT Products

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Service Manual

1997-04-15

55

F-code

Section

PS S Support arm chassis Version no

T-code

002

354

56

Return

C-code

0350

Service Manual

1997-04-15

F-code

Section

PS

S2.0 2550 Transmission

Version no

002

C-code

T-code

204, 351, 352, 353, 354

Transmission Valid from machine number: 270001-

1. General technical description

© BT Products

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Service Manual

1997-09-24

57

F-code

Section

C-code

PS S2.0 Transmission

2550

Version no

T-code

002

204, 351, 352, 353, 354

1.1. Technical data Data

Description

Type

2-step angular

Upper gear wheels

Angle spur gear

Lower gear wheels

Angle gear 90 degrees

Gear ratio, overall

19.43:1

Gear ratio, upper gear

4:1

Gear ratio, lower gear

4.86:1

Oil volume

1.0 litre

Oil type, normal temperature SAE 80W/90

58

Return

Oil type, < -15oC

SAE 75

Oil change

First time: 250 hours Regular change: 3000 hours

Service Manual

1997-09-24

F-code

Section

PS

S2.0 2550 Transmission

Version no

C-code

T-code

002

204, 351, 352, 353, 354

1.2. Gear components

1

2 3 4 5 A

12 11

6

10

9

© BT Products

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8

7

Pos No

Component

1

Primary gears

2

Upper pinion bearing

L2

3

Bearing shim

S2

4

Bearing shim

S1

5

Lower pinion bearing

L1

6

Set of pinion and crown gears

7

Inner drive shaft bearing

Service Manual

1997-09-24

L3 59

F-code

Section

C-code

PS S2.0 Transmission

2550

Version no

T-code

002

204, 351, 352, 353, 354

60

Return

Pos No

Component

8

Bearing shim

S3

9

Outer drive shaft bearing

L4

10

Bearing shim

S4

11

Drive shaft

12

Drive shaft seal

A

Measurement, pinion height

Service Manual

65 mm

1997-09-24

F-code

Section

PS

S2.0 2550 Transmission

Version no

002

C-code

T-code

204, 351, 352, 353, 354

1.3. Special tools

Pos No

Tool

1

Bearing with drawer: part no = 08-13022

2

Dial indicator with magnetic bracket

3

Feeler gauge

4

Micrometer 0-25 mm (0-1 inch)

5

Spring balance 0-10 kg (0-22 lbs.)

6

Measuring gauge: part no = 06-13020

7

Assembly axle: part no. = 08-13021

2. Removing the gear from the truck • Lift the machine so the bolts for the driving gear are accessible from beneath.

The truck can also be laid on the side after removal of the battery and sealing off the hydraulic system.

• Remove the drive wheel (17 mm) © BT Products

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Service Manual

1997-09-24

61

F-code

Section

C-code

PS S2.0 Transmission

2550

Version no

T-code

002

204, 351, 352, 353, 354

• Drain the oil by removing the lower gear cover ( 6 mm allen key).

• Remove the nuts (13 mm) holding the gear and motor together.

• Take the driving gear out of the machine.

• Installing the driving gear into the truck is made in the reversed order.

62

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1997-09-24

F-code

Section

PS

S2.0 2550 Transmission

Version no

002

C-code

T-code

204, 351, 352, 353, 354

3. Change of seal on the drive shaft • Remove the gear from the truck as shown in chapter 2.

• Remove the upper gear cover (6 mm allen key).

• Knock out the locking on the drive shaft nut.

• Remove the drive shaft nut (36 mm).

• Knock the drive shaft out with a plastic hammer or press it out.

• Remove the crown wheel and bearing L3.

• Remove the old seal and replace. © BT Products

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Service Manual

1997-09-24

63

F-code

Section

C-code

PS S2.0 Transmission

2550

Version no

T-code

002

204, 351, 352, 353, 354

64

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Service Manual

1997-09-24

F-code

Section

PS

S2.0 2550 Transmission

Version no

002

C-code

T-code

204, 351, 352, 353, 354

• Put the drive shaft in place and place the inner ring of the bearing L3 in the gear housing.

• Put the crown gear onto the splines of the drive shaft and a new washer and nut.

Tighten the drive shaft nut to 300 Nm (217 ft-lb) with a torque wrench.

• Lock the shaft nut with a punch into the groove in the shaft.

• Install the covers to the gear with new gaskets.

Tightening torque: 26.6 Nm (19.5 ft-lb) • Install the driving gear into the truck.

Tightening torque: 26.6 Nm (19.5 ft-lb) Fill with new oil.

• Install the drive wheel Tightening torque: 65Nm (47.7 ft-lb)

© BT Products

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Service Manual

1997-09-24

65

F-code

Section

C-code

PS S2.0 Transmission

2550

Version no

T-code

002

204, 351, 352, 353, 354

4. Reconditioning of the gear • Remove the gear from the truck as shown in chapter 2.

• Remove the gear covers (6 mm allen key).

• Knock out the locking on the drive shaft nut.

• Remove the drive shaft nut (36 mm spanner).

• Knock the drive shaft out with a plastic hammer or press it out.

• Remove the crown wheel and bearing L3.

• Press or knock out the bearing cups for bearing L3 and L4 and remove the shim-pack S3 from the gear housing.

• Remove the bearing L4 from the drive shaft by using the puller, part no. 08-13022. Remove the shim S4 from the shaft.

• Knock out the locking on the pinion nut. Remove the nut (22 mm spanner) and the primary gear wheel.

66

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F-code

Section

PS

S2.0 2550 Transmission

Version no

002

C-code

T-code

204, 351, 352, 353, 354

• Knock out the pinion with a plastic hammer or press it out.

Remove the bearing L2 and shim S2.

• Remove the bearing L1 from the pinion with the puller, part no. 08-13022.

• Press or knock the cups for the bearings L1 and L2 out and remove the shim-pack S1 from the housing. Remove the old seal ring.

• Clean the covers, gear housing and drive shaft with a suitable solvent.

• Install new races for the bearings L1 and L2 into the gear housing with 0.5 mm shim S1.

• Install the new bearing L1 on the new pinion.

• To determine shim needed assemble the pinion, bearing L2 and primary gear with the old nut and shim. Till there is no axial play enough thickness of shim S2 so that there is no axial play. Tighten the nut to 30 Nm (22.5 ft/lbs.) using the old nut.

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Service Manual

1997-09-24

67

F-code

Section

C-code

PS S2.0 Transmission

2550

Version no

T-code

002

204, 351, 352, 353, 354

• Install the new races for the bearings L3 and L4 into the gear housing WITHOUT shim S3.

• Install the assembly axle part no. 08-13021 with the bearing L4 into the gear housing. Place the bearing L3 and the crown wheel onto the axle. Make sure that there is enough shim S4 for the bearing L4 so that there is no axial play on tool 08-13021. Tighten the axle nut to 100 Nm (72 ft/lb) using the old nut.

• Measure the pinion height with the measuring gauge, part no. 08-13020, between the surface of bearing L1 and the pin on tool 08-13021. Use shims or feeler gauge together with the measuring gauge to get the correct thickness of shim S1. Built-in measure pinion height = 65 mm, measuring gauge length 59 mm + the radius of the pin 5 mm + 1 mm shim or feeler gauge thickness. The difference from 65 mm gives you the thickness of shim S1.

• Install the measured shim thickness under bearing L1 race.

68

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1997-09-24

F-code

Section

PS

S2.0 2550 Transmission

Version no

002

C-code

T-code

204, 351, 352, 353, 354

• Assemble the pinion, bearings, and primary gear wheel with shim thickness S2 so that there is no axial play on the pinion. Zero-play, when having tightened the pinion nut 70 Nm (50.5 ft-lb). When needed, adjust S2 so that the play is zero.

• Install the assembly axle with bearings, crown wheel, and shim as previously. Tighten the nut 300 Nm (217 ft/lbs.)

• Measure the flank clearance with the crown wheel in three different positions. Carefully point the dial indicator 90° to the gear tooth surface.

• Shim (S3) bearing L3 so that a flank clearance of 0.10-0.15 mm is attained. Remove the same shim thickness from S4 that is fitted on S3 before the tool with bearings and crown wheel is reassembled.

• Check the flank clearance and measure the axial play on the tool 08-13021.

• Adjust the drive shaft axial play to zero-play by adjusting shim S4.

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Service Manual

1997-09-24

69

F-code

Section

C-code

PS S2.0 Transmission

2550

Version no

T-code

002

204, 351, 352, 353, 354

• Check the gear tooth impression with engineer’s blue.

Adjust shim S1 when needed. S2 is to be adjusted, and reduced if S1 is increased, and increased if S1 is reduced, correspondingly to the change on S1. Check the axial play on the pinion.

• Install the tool 08-13021 with bearings and crown wheel.

Check the flank clearance. Adjust shim S3 when needed.

S4 is to be adjusted, and reduced if S3 is increased, and increased if S3 is reduced, correspondingly to the change on S3. Check the axial play on tool part no. 08-13021.

• Check the gear tooth impression. When the impression is correct install a new washer and pinion nut. Tighten the nut 70 Nm (50 ft-lb) and lock it with a punch in the key groove.

• When the gear tooth impression and the axial play is correctly adjusted remove tool part no. 08-13021. Shimpack S4 is shifted over to the drive shaft and bearing L4 is placed on the shaft.

• Install the new seal ring in the gear housing.

• Put the drive shaft into the housing and put bearing L3 in place.

70

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1997-09-24

F-code

Section

PS

S2.0 2550 Transmission

Version no

002

C-code

T-code

204, 351, 352, 353, 354

• Put the crown wheel onto the splines of the drive shaft and install a new washer and nut.

Tighten the drive shaft nut 300 Nm (217 ft-lb) with a torque wrench. Check the axial play on the drive shaft. It shall be zero. Lock the nut with a punch in the groove on the shaft.

• Check the force needed to rotate the gear with the spring balance.

Maximum value: 6-6.5 kg

• Install the covers onto the gear with new gaskets.

Tightening torque: 26.6 Nm (19.5 ft-lb) • Install the driving gear into the truck.

Tightening torque: 26.6 Nm (19.5 ft-lb) Fill up with new oil.

• Install the drive wheel.

Tightening torque: 65 Nm (47.7 ft-lb)

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Service Manual

1997-09-24

71

F-code

Section

C-code

PS S2.0 Transmission

2550

Version no

T-code

002

204, 351, 352, 353, 354

72

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Service Manual

1997-09-24

F-code

Section

PS

S5.0 5000 Electrical System

Version no

003

C-code

T-code

353, 354

Electrical System Valid from machine number: 270001-

1. Electrical panel, components.

RV1 F50

A2

F10

K11 K13 K30

F3 A1

H1

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Service Manual

1997-07-17

71

F-code

Section

C-code

PS S5.0 Electrical System Version no

T-code

003

353, 354

5000

2. List of symbols.

72

Return

Symbol

Description

Function

Remark

A1

Transistor controller

A2

Connection card

BT

Battery

F3

Fuse

Pump motor circuit

160A

F10

Fuse

Drive motor circuit

100A

F50

Fuse

Control circuit

7.5A

H1

Horn

K11

Contactor

Drive direction

Fork direction

K13

Contactor

Drive direction

Steer wheel direction

K30

Contactor

Pump motor

M1

Motor

Drive

M3

Motor

Pump

P1

Indicator

Hour meter

P3

Indicator

Battery indicator/Hour meter

R1

Potentiometer

Speed

RV1

Potentiometer

Speed reduction

S10

Switch

Brake

Service Manual

5 - 0 kOhm

1997-07-17

F-code

Section

PS

S5.0 5000 Electrical System

Version no

003

© BT Products

Return

C-code

T-code

353, 354

Symbol

Description

Function

Remark

S15

Switch

Drive direction

Fork direction

S16

Switch

Drive direction

Steer wheel direction

S17

Switch

Key

S18

Switch

Horn

S20

Switch

Reverser

S41

Switch

Fork lower

S52

Switch

Fork lift

Y41

Magnetic valve

Fork lower

Service Manual

1997-07-17

For optional electric lowering.

Always connected

When having optional electric lowering

73

F-code

Section

PS S5.0 Electrical System Version no

T-code

003

353, 354

C-code

5000

2.1. Circuit diagram 1(3)

74

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Service Manual

1997-07-17

F-code

Section

PS

S5.0 5000 Electrical System

Version no

003

C-code

T-code

353, 354

2.2. Circuit diagram 2(3)

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Service Manual

1997-07-17

75

F-code

Section

PS S5.0 Electrical System Version no

T-code

003

353, 354

C-code

5000

2.3. Circuit diagram 3(3)

76

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Service Manual

1997-07-17

F-code

Section

PS

S5.0 5000 Electrical System

Version no

003

C-code

T-code

353, 354

3. DESCRIPTION OF FUNCTION 3.1. General The transistor controller (A1) regulates the infinitely variable speed control. When starting the truck, the controller checks the closing sequence of the micro switches in the circuit. The controller is equipped with a light emitting diode (LED) showing system status and potentiometers for adjusting the current limit and acceleration, placed under a sliding cover.

106

111 204

105

110

104 103

207

203 202

206

109 201

205

102

108

101

107

409

417

408

416

407

415

406

The electrical system has a connection card (A2) to group all connections of the control circuits for input and output signals to the transistor controller. The connection card is equipped with LED’s for indication of input or output signals and a potentiometer for adjustment of the maximum speed.

414

405 301

302

404

413

403 402

412 411

3.2. Adjustable settings:

410 401

Setting

Std. value

Min. value

Max. value

Current limit

150 Amp

100 Amp

150 Amp

Acceleration

0.8 s

0.1 s

3s

3.6 mph

1.9 mph

3.6 mph

Maximum speed, without load

3.3. References: For more information about adjustment of the speed potentiometer, the transistor controller, and the connection card, see C-code 5330, 5460 resp. 5710.

The description is divided into different phases which correspond to the operational sequence steps. For each sequence step the correct LED pattern is shown below. A filled circle denotes LED is emitting light.

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Service Manual

1997-07-17

77

F-code

Section

C-code

PS S5.0 Electrical System Version no

T-code

003

353, 354

5000

3.4. Key switch S17 in the ON position 106

111 204

105

110

104

207

203 202

206

103

109 201

205

102

108

101

107

409

417

408

416

407

415

406

414

405 301

302

When S17 closes, the transistor controller will check that S10 is not closed. If this is the case, operation is not permitted.

404

413

403 402

412 411 410

401

Battery voltage on A2-terminal 202, LED 202 lights up. A2 (-) return terminal 409. Battery voltage to A1.16 through A2terminal 410, LED-status starts to flash.

3.5. The operating arm in drive position, S10, brake switch closed 106

111 204

105

110

104

207

203 202

206

103

109 201

205

102

108

101

107

409

417

408

416

407

415

406

414

405 301

302

404

413

403 402

412 411 410

401

When the operating arm is pulled down to the driving position, S10 is activated and closes, and at the same time the brake is mechanically released. Voltage obtained through terminal 109 and 408 to A1.15. LED 109 lights up on the hour meter terminal 206 and the shunt field terminal 301.

The transistor controller now regulates the current through the shunt field, 1.2 A, (-) return through terminal 302, 417 and A1.1.

3.6. Driving, fork direction 106

111 204

105

110

104

207

203 202

206

103

109 201

205

102

108

101

107

409

417

408

416

407

415

406

414

405 301

302

404

413

403 402

412 411 410

401

When the thumb control is activated for driving in the fork direction, S15 will close.

Battery voltage to terminal 101 and 411 to A1.11, LED 101 lights up. Battery voltage to K11 from terminal 403 A1.2 now gives (-) return to K11, (-)input on terminal 401, LED 401 lights up.

Depending on the position of the speed potentiometer (R1) and the adjustment of potentiometer RV1, A1.8 will receive a voltage between 4.8-0.25 V. The motor current now passes through F10, the series field D2-D1, K11, the armature A2-A1 and K11 to battery negative through A1 (M-).

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Section

PS

S5.0 5000 Electrical System

Version no

003

C-code

T-code

353, 354

3.7. Driving, steer wheel direction

106

111 204

105

110

104

207

203 202

206

103

109 201

205

102

108

101

107

409

417

408

416

407

415

406

414

405 301

302

404

413

403 402

412 411 410

401

When the thumb control is activated for driving in the steer wheel direction, S16 will close. The transistor controller checks that S10 is closed before S16 closes. If not, driving is blocked.

Battery voltage to terminal 102 and 412 to A1.12, LED 102 lights up. Battery voltage to K13 from terminal 403, A1.3 now gives (-) return to K13, (-)input on terminal 402, LED 402 lights up.

Depending on the position of the speed potentiometer (R1) and the adjustment of potentiometer RV1, A1.8 will receive a voltage between 4.8-0.25 V. The motor current now passes through F10, the series field D2-D1, K13, the armature A1-A2 and K13 to battery negative through A1 (M-).

3.8. Reversing/motor brake fork direction to steer wheel direction S15 returns to open position while S16 closes. The current in the series field causes the motor to work as a generator since the drive wheel is rotating in the opposite direction.

The transistor controller detects the generated current at connection A2, and reduces the series field current to 60A. When the drive wheel rotates in the right direction and the potential at connection A2 becomes positive, acceleration is done according to adjusted values of current limit and acceleration.

During the plugging sequence, the armature current passes in the circuit A2-A1, K13, A2 (the brake diode of the transistor controller), M- and K13.

3.9. Reversing/motor brake steer wheel direction to fork direction S16 returns to open position while S15 closes. The current in the series field causes the motor to work as a generator since the drive wheel is rotating in the opposite direction. © BT Products

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PS S5.0 Electrical System Version no

T-code

003

353, 354

5000

The transistor controller detects the generated current at connection A2 and reduces the series field current to 60A. When the drive wheel rotates in the right direction and the potential at connection A2 becomes positive, acceleration is done according to adjusted values of current limit and acceleration.

During braking sequence, the armature current passes in the circuit A1-A2, K11, A2 (the brake diode of the transistor controller), M- and K11.

3.10. Reverser switch

106

111 204

105

110

104

207

203 202

206

103

109 201

205

102

108

101

107

409

417

408

416

407

415

406

414

405 301

302

404

413

403 402

412 411 410

401

Possible breaks in the wiring for the reverser switch is continuously checked by the transistor controller. It sends a small pulsed current through the circuit from A1.10, terminal 416, 111, wire 32, S20, wire 32, terminal 110, 415 and A1.13.

S20 is activated causing terminal 110, 415 and A1.13 to become positive. A1 now interrupts the (-)return to K13 which opens. At the same time A1 will provide (-) at A1.3 to K11, LED 401 lights up.

The motor will now be connected for motor braking at a maximum current limit 150A, and subsequently accelerate in the fork direction until S20 returns to its neutral position.

When S20 returns to its neutral position, (+) disappears from terminal 110, A1 will interrupt the (-)return at A1.3 to K11, and the truck will stop.

In order to be able to start again if S16 is still activated, the transistor controller must be returned to the inactive position by letting the speed potentiometer return to the neutral position, after which a new direction of travel can be chosen.

106

111 204

105

110

104 103

207

203 202

206

109 201

205

102

108

101

107

409

417

408

416

407

415

406

414

3.11. Lifting the forks

405 301

302

404

413

403 402

412 411 410

401

The micro switch S52 closes. K30 receives (+)voltage through terminal 105, 203, battery controller or the jumper, terminal 201 and 405, LED 105 and 405 light up.

(-)return through wire 40. K30 closes and the pump motor M3 starts.

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PS

S5.0 5000 Electrical System

Version no

003

C-code

T-code

353, 354

3.12. Horn 106

111 204

105

110

104

207

203 202

206

103

109 201

205

102

108

101

107

409

417

408

416

407

415

406

414

405 301

302

404

413

403 402

412

The horn switch S18 is activated. The horn, H1, receives (+) voltage through terminal 107 and 406, LED 107 lights up. (-) return through wire 40.

411 410

401

4. Options 106

111 204

105

110

104 103

207

203 202

206

109 201

205

102

108

101

107

409

417

408

416

407

415

406

414

4.1. Electrical lowering of the fork

405 301

302

404

413

403 402

412 411 410

401

When lowering the forks S41 is activated. The magnetic valve, Y41, receives (+) voltage through terminal 106 and 204, LED 106 lights up. (-) return through wire 40.

5. Wire Coupler Not used on all trucks.

5.1. Electrical wire coupler Trucks using tiller control handle shown on the left has a wire coupler between handle/frame and head harnesses. Below are the pin and wire locations of the coupler and handle/ frame.

Pin # Truck Wire # 1 22-1 2 34 3 33 4 38 5 37 6 22-4 7 -8 39 9 36 10 22-3 11 132-1 12 31 13 35 14 -15 -16 --

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Handle Wire # 6 2 3 4 5 Unmarked -8 Unmarked Unmarked 11 6 Unmarked ----

1997-07-17

Description Horn Power Fork direction Steer wheel direction Lower Raise Raise Power --Horn Potentiometer Wiper Lower Power Emerg. Reverse N/O Emerg. Reverse Com. Potentiometer -------

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5000

Service Manual

1997-07-17

F-code

Section

C-code

PS S5.3 5230 Battery Controller / Hourmeter / Lift Interrupt Version no

T-code

001

Battery Controller / Hourmeter / Lift Interrupt 1. General Information 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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PS S5.3 5230 Battery Controller / Hourmeter / Lift Interrupt Version no

T-code

001

2.1.1. The Contact Voltage and Current Ratings for Switching Resistive Loads.

Open Contact Voltage

200

VDC

Max

Closed Contact Current

3

ADC

Max

Volt Ampere Product

50

W

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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PS S5.3 5230 Battery Controller / Hourmeter / Lift Interrupt Version no

T-code

001

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 .

8

7

6

5

4

3

2

1

SETTING

VPC

SETTING

VPC

K

1.57

P

1.82

L

1.63

Q

1.84

M

1.68

R

1.86

N

1.73

S

1.91

O

1.78

T

1.93

O P Q R S K DISCHARGE T

N M L

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PIN NO:

FUNCTION

1

Hourmeter (-)

2

Key switch (+)

3

Relay arm (+)

4

Relay NC (-)

5

Battery (-)

6

Hourmeter (+)

7

24 Volt (+)

8

48 Volt (+)

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PS S5.3 5230 Battery Controller / Hourmeter / Lift Interrupt Version no

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001

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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PS S5.3 5230 Battery Controller / Hourmeter / Lift Interrupt Version no

T-code

001

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 © BT Products

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PS S5.3 5230 Battery Controller / Hourmeter / Lift Interrupt Version no

T-code

001

connected to a fully charged battery and allowed to track its discharge without break in power.

NOTE! New instruments are shipped from the factory with a full reading in their memory. The first time the instrument is connected to the truck’s battery it will always show a full charge. 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 168

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PS S5.3 5230 Battery Controller / Hourmeter / Lift Interrupt 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 battery’s positive terminal and the meter’s 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 voltmeter’s positive lead on pin 5 and its negative lead on the battery’s 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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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 truck’s key switch off. This should remove voltage from pin 2 of the instrument. Should voltage be present at pin 2 and the hourmeter’s icon continues to flash, the instrument is defective.

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PS

Section

C-code

S5.0 5460 Transistor Controller

Version no

002

T-code

351, 352, 353, 354

Transistor Controller Valid from machine number: 270001-

1. Motor circuit The transistor controller has four terminals for the high current circuits according to the table below.

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Terminal

Connecting

M-

Output to motor armature

B-

Negative connection to battery

B+

Positive connection to battery/series field

A2

Plug diode to motor armature

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C-code

5460

Version no

T-code

002

351, 352, 353, 354

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

Pin No

Connecting

CONTACTOR DRIVERS P1

Shunt field driver output

P2

Fork direction contactor driver output

P3

Steer wheel direction contactor driver output

P4

Not connected

THROTTLE CONNECTIONS P5

Not connected

P6

Not connected

P7

Throttle: pot low

P8

Throttle: 2-wire 5 kOhm-0 input

BASIC CONTROL SIGNALS

92

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P9

Not connected

P10

Emergency reverse check output

P11

Drive fork direction input

P12

Drive steer wheel direction input

P13

Emergency reverse input

P14

Speed range selection input

P15

Brake switch input

P16

Key switch input (KSI) Service Manual

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PS Version no

002

Section

C-code

S5.0 5460 Transistor Controller T-code

351, 352, 353, 354

3. Technical specification The technical specification for the BT version of the Curtis 1207 transistor controller is according to the table below.

PARAMETER

RANGE

STD SETTING

UNITS

Operating voltage

24

24

Volt

Maximum voltage

45

Volt

Overvoltage point

Minimum operating voltage

16

Volt

Undervoltage point

Electrical isolation to heatsink

500

Volt ac

Minimum

Frequency

15

kHz

Contactor voltage

24

Volt

Contactor current

1

Amp

Shunt driver current

2

KSI input current

80

mA

Logic input current

10

mA

Logic input threshold

8

Volt

Ambient operating temperature

-40 - +50

oC

Heatsink over temperature cutback

85

oC

Heatsink under temperature cutback

-25

oC

1.2

Variable

Variable

Current limit, Main

100-150

150

Amp

100

Amp

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Maximum (current limit at 2 amp)

Amp

Plug braking

Current limit, Low speed, Main

DESCRIPTION

1997-07-11

At 24 Volt

Plug current dependant upon throttle position

Maximum current in low speed mode

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C-code

5460

Version no

T-code

002

351, 352, 353, 354

PARAMETER

STD SETTING

UNITS

DESCRIPTION

Current limit, Plug

60

Amp

Maximum plug current in the series field

Current limit, Low speed, Plug

60

Amp

Maximum plug current in the series field in low speed mode

Current limit, Emergency reverse

150

Amp

Maximum field current in emergency reverse

Current limit, Low speed, Emergency reverse

150

Amp

Maximum field current when in low speed for emergency reverse

Throttle type

5k-0

Ohm

Minimum duty cycle

0

%

Speed (duty factor) at minimum throttle setting

Low speed

70

%

Maximum speed (duty factor) in low speed mode

Emergency reverse speed

50

%

Speed during emergency reverse

0.8

Sec

Time to reach full output from zero output

Acceleration rate

RANGE

0.1 - 3

4. Adjustment panel

The adjustment panel is located on top of the controller under a sliding protective cover. The panel provides access to a set of adjustable potentiometers, a connector for a hand held terminal, and the STATUS LED.

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S5.0 5460 Transistor Controller T-code

351, 352, 353, 354

4.1. Adjustable Potentiometers: MAIN and ACCEL potentiometers can be adjusted with a screwdriver within the range given in the technical specification.

NOTE! In the BT version of the Curtis 1207 only two of the potentiometers are used, MAIN and ACCEL. The other three potentiometers are disabled from factory.

4.2. Connection of hand held terminal: To adjust the parameters with the hand held terminal the corresponding potentiometer must be set to ”off”.

4.3. Status LED: The LED displays flashing codes to indicate controller status.

The codes are listed with explanations in section 6.

5. Maintenance There are no serviceable parts inside the transistor controller.

No attempt should be made to open the controller.

OPENING THE CONTROLLER WILL VOID THE WARRANTY! It is, however, recommended that the controller exterior be cleaned periodically. Cleaning the controller gives a good opportunity to check the controller’s diagnostic history file with the hand held terminal, if available.

5.1. Safety The controller is inherently a high power device. When working around any battery powered vehicle proper safety precautions should be taken. These include, but are not limited to, proper training, wearing eye protection, avoiding loose clothing, removing watches and jewelry, and using insulated wrenches. © BT Products

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95

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PS S5.0 Transistor Controller

C-code

5460

Version no

T-code

002

351, 352, 353, 354

WARNING Risk of short circuits.

Remove all watches and jewelry, and always use insulated tools.

5.2. Cleaning Although the controller requires virtually no maintenance if properly installed, the following minor maintenance is recommended on a regular 250 hour basis.

1.Remove power by disconnecting the battery.

2. Discharge the capacitors in the controller, by connecting a load (such as a contactor coil or the horn) across the controller’s B+ and B- terminals, before doing any work on the controller.

3. Remove all dirt or corrosion from the bus bar area. The controller should be wiped clean with a moist rag. Allow it to dry before reconnecting the battery.

4. Make sure the connections to the bus bars are tight.

Use two well insulated wrenches for this task in order to avoid stressing the bus bars.

6. Diagnostics and troubleshooting

During normal operation, with no faults present, the Status LED flashes a single flash at approximately 1 flash/second. If the controller detects a fault, a 2-digit code is flashed continuously until the fault is corrected. See table below.

If using a hand held terminal for the diagnostics, switched over to diagnostic mode, the diagnostic information can be read in the terminal display. See table below.

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S5.0 5460 Transistor Controller T-code

351, 352, 353, 354

LED CODE

TERMINAL LCD DISPLAY

EXPLANATION

POSSIBLE CAUSE

1,2

¤ ¤¤

HW FAIL-SAFE

hardware fail-safe error

1. Controller defective

1,3

¤ ¤¤¤

M- FAULT

M- output shorted

1. M- output shorted to ground.

2. Direction contactor not closing.

3. Direction contactor not closing fast enough.

4. Internal motor short to ground.

1,4

¤ ¤¤¤¤

SRO

SRO fault

1. Improper sequence of KSI, brake and direction inputs.

2. Brake or direction switch circuit open.

2,1

¤¤ ¤

THROTTLE FAULT 1 5kOhm-0 or wiper fault

1. Throttle input wire open.

2. Throttle input wire shorted to ground or B+.

3. Throttle pot defective.

4. Wrong throttle type.

2,2

¤¤ ¤¤

BB WIRING CHECK

emerg. reverse wiring fault

1. BB wire open.

2. BB check wire open.

2,3

¤¤ ¤¤¤

HPD

HPD sequencing fault

1. Improper sequence of KSI, brake, throttle inputs.

2. Misadjusted throttle.

2,4

¤¤ ¤¤¤¤

THROTTLE FAULT 2 pot low, broken or shorted

1. Pot low wire open.

2. Pot low wire shorted.

3. Wrong throttle type.

3,1

¤¤¤ ¤

CONT DRVR OC

driver output overcurrent

1. Direction contactor coil shorted.

2. Shunt field shorted.

3,2

¤¤¤ ¤¤

DIR CONT WELDED

welded direction contactor

1. Direction contactor stuck closed.

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97

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Section

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PS S5.0 Transistor Controller

5460

Version no

T-code

002

351, 352, 353, 354

LED CODE

TERMINAL LCD DISPLAY

EXPLANATION

POSSIBLE CAUSE

3,4

¤¤¤ ¤¤¤¤

MISSING CONTACTOR

missing contactor or shunt

1. Direction contactor open coil.

2. Direction contactor missing.

3. Shunt field open.

4. Wire to shunt or direction contactor open.

4,1

¤¤¤¤ ¤

LOW BATTERY VOLTAGE

low battery voltage

1. Battery voltage <16 volts.

2. Corroded battery terminal.

3. Loose battery or controller terminal.

4,2

¤¤¤¤ ¤¤

OVERVOLTAGE

overvoltage

1. Battery voltage > 45 volts.

2. Vehicle operating with charger attached.

4,3

¤¤¤¤ ¤¤¤

THERMAL CUTBACK

over-/undertemperature cutback

1. Temperature >85oC or < 25 oC. 2. Excessive load on vehicle.

3. Improper mounting of controller.

4. Operation in extreme environments.

98

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Service Manual

1997-07-11

F-code

Section

C-code

PS

S5.0

5710 PCB Card

Version no

002

T-code

351,352,353,354

PCB Card Valid from machine number: 270001-

7. The PCB The PCB is a card to create a common connection point in the electrical system for the different wiring harnesses. The card is equipped with green LED’s on the inputs from micro switches and red LED’s on the outputs to the contactors. This will simplify the tracing of faults in the wiring or the switches.

The card is also equipped with a potentiometer for adjustment of the maximum speed.

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Service Manual

1997-07-11

99

F-code

Section

C-code

PS PCB Card

S5.0

5710

Version no

T-code

002

351,352,353,354

8. Connectors and adjustments 1

5

4

2

3

100

Return

Position

Connection/Adjustment

1

Key switch (S17), battery -, instrument, magnetic valve (Y41)

2

Battery +, armature voltage, contactors, horn

3

Shunt field

4

RV1, adjustment of maximum speed

5

Micro switches

Service Manual

1997-07-11

F-code

Section

C-code

PS

S5.0

5710 PCB Card

Version no

T-code

002

351,352,353,354

9. Terminals and LED’s

106

111 204

105

110

104

207

203 202

206

103

109 201

205

102

108

101

107

409

417

408

416

407

415

406

414

405 301

302

404

413

403 402

412 411 410

401

Terminal No

LED No

Connection

Function

101

101

I

Driving, fork direction

102

102

I

Driving, steer wheel direction

103

O

Speed control

104

I

Reference value, speed

105

105

I

Fork lift

106

106

I

Fork lower, always connected even if the option electrical lowering is fitted

107

107

I

Horn

O

24 V (+)

I

Brake

110

I

Reverser (S20)

111

I

Reverser (S20)

201

I

Battery controller/ Lift interrupt

108 109

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109

Service Manual

1997-07-11

101

F-code

Section

C-code

PS PCB Card

S5.0

5710

Version no

T-code

002

351,352,353,354

Terminal No

LED No

Connection

Function

202

202

I

24 V (+)

203

O

Battery controller/ Lift interrupt

204

O

To magnetic valve, when having the option electrical lowering of the forks

205

O

24 V (+)

206

O

Hour meter

301

O

Shunt field(+)

302

O

Shunt field(-)

401

401

I

Contactor (-), fork direction

402

402

I

Contactor (-), steer wheel direction

O

Contactor drive direction, common (+)

403 404 405

102

Return

Not connected 405

O

Contactor, pump motor

406

O

Horn

407

I

24 V (+)

408

O

Output signal, brake released

409

I

(-)

410

O

24 V (+), to transistor controller

411

O

Driving, fork direction

412

O

Driving, steer wheel direction

413

I

Speed control

414

O

Reference value, speed

415

O

Reverser, (S20)

416

O

Reverser, (S20)

Service Manual

1997-07-11

F-code

Section

C-code

PS

S5.0

5710 PCB Card

Version no

002

Terminal No 417

LED No

Connection

Function

I

Shunt field(-)

T-code

351,352,353,354

I = Input, green LED O = Output, red LED

© BT Products

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Service Manual

1997-07-11

103

F-code

Section

C-code

PS PCB Card

S5.0

5710

Version no

T-code

002

351,352,353,354

104

Return

Service Manual

1997-07-11

F-code

Section

C-code

PS S6.0 6000 Hydraulic system, mechanical lowering Version no

T-code

003

354

Hydraulic system, mechanical lowering Valid from machine number: 270001-

1. General The hydraulic system consists of a compact hydraulic unit, including a mechanical lowering valve, pressure relief valve, and the cylinders for the lift of the forks.

2. Description of function 2.1. Hydraulic diagram and components

1

A

M

B

A C

2

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Service Manual

1997-07-11

105

F-code

Section

C-code

PS S6.0 6000 Hydraulic system, mechanical lowering Version no

T-code

003

354

2.2. Main components Pos No

Description

Remark

1

Lift Cylinders

Fork lift

2

Hydraulic Unit

A = Check valve B = Lowering valve C = Relief valve M = Pump motor

2.3. Description 2.3.1. Lift When the pump motor starts, the oil flows through the pump and check valve to the lift cylinders.

2.3.2. Lower When the lowering valve is affected by the lower lever on the chassis, it opens to let the oil in the pressure lines return to the oil tank. The lowering speed is regulated by the movement of the lever.

2.3.3. Operating pressure The operating pressures at rated load are: 1. WSX20: 2090 psi 2. WSX25: 2610 psi 2.3.4. Relief valve The relief valve opens at the following pressures: 1. WSX20: 2300 psi 2. WSX25: 2870 psi

106

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Service Manual

1997-07-11

F-code

Section

C-code

PS S6.1 6000 Hydraulic system, electrical lowering Version no

T-code

004

354

Hydraulic system, electrical lowering Valid from machine number: 270001-

1. General The hydraulic system consists of a compact hydraulic unit, including a mechanical lowering valve, an electromagnetic lowering valve, pressure relief valve, and the cylinders for the lift of the forks.

2. Description of function 2.1. Hydraulic diagram and components

1

A

M

D B

A

C

2

© BT Products

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Service Manual

1997-07-11

107

F-code

Section

C-code

PS S6.1 6000 Hydraulic system, electrical lowering Version no

T-code

004

354

2.2. Main components Pos No

Description

Remark

1

Lift Cylinders

Fork lift

2

Hydraulic Unit

A = Check valve B = Lowering valve C = Relief valve D = Electro-magnetic lowering valve M = Pump motor

2.3. Description 2.3.1. Lift When the pump motor starts, the oil flows through the pump and check valve to the lift cylinders.

2.3.2. Lower When the lowering valve is affected by the lower lever on the chassis, it opens to let the oil in the pressure lines return to the oil tank. The lowering speed is regulated by the movement of the lever.

2.3.3. Lower, electrical When the electro-magnetic valve is energized electrically from the push button on the handle, it opens fully to let the oil in the pressure lines return to the oil tank. The lowering speed is regulated by a restriction in the hydraulic unit.

2.3.4. Operating pressure The operating pressures at rated load are: 1. WSX20: 2090 psi 2. WSX25: 2610 psi 2.3.5. Relief valve The relief valve opens at the following pressures: 1. WSX20: 2300 psi 2. WSX25: 2870 psi

108

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Service Manual

1997-07-11

F-code

Section

C-code

PS S6.1 6000 Hydraulic system, electrical lowering

© BT Products

Return

Service Manual

1997-07-11

Version no

T-code

004

354

109

BT Prime-Mover, Inc., 3305 N. Highway 38, Muscatine, Iowa 52761-8800 U.S.A Tel (319) 262-7700 • Fax (319) 262-7600 Return