Master Service Manual

Product family PS
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© BT Industries AB Part number: 147 639-040

Issued: 1995-11-28 SSD
 F-code Section C-code
PS
Contents Master Service Manual (MSM)
IIssued by Approved by Version no T-code
SSD Jessica Forsgard 001 204, 349-353

Contents
Master Service Manual (MSM)
Part number: 147 639-040
Issued 1995-11-28

Valid from serial number:

T-code Model Serial No Notes

204 PPH 1600MX 270001AA-711956
349 PPS 1600MXD 270001AA-437099AA
350 PPS 1200MXF 270001AA-437099AA
351 PPS 1000MX 270001AA-437099AA
352 PPS 1200MX 270001AA-437099AA
353 PPS 1200MXS 270001AA-436503AA

1 Document list
Section C-code T-code Document Issued
Introduction to BT’s Service Manual 1998-11-04
Contents, M 1998-11-04
M1 204, 349-353 Operator’s manual 1999-06-14
M2 349 General product information 1998-08-13
350 General product information 1998-08-13
351-353 General product information 1995-11-30
M4 349, 350 Technical data 1998-01-09
351-353 Technical data 1995-11-30
M6 204, 349-353 Ordering Spare Parts 1998-11-04
M7 204, 349-353 Quality Parts 1999-06-14
M8 204, 349-353 Recommended Spare Parts (RSP) 1999-06-14

© BT Industries AB Service Manual 2002-12-02 English 1 (2)

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Contents, P 1998-11-04
P1 204, 349-353 Introduction, maintenance 1997-12-19
P2 351, 352 Preventive maintenance 1995-12-01
353 Preventive maintenance 1995-12-01
P3 351-353 Oil and grease specification 1995-12-01
Contents, S 1998-11-04
S0 0350 353 Support arm chassis 1995-12-01
S1 1700 204, 349-353 Drive motor 1999-02-03
S2 2550 204, 349-353 Driving gear 1999-01-19
S3 3360 204, 349-353 Mechanical brakes 1999-02-03
S5 5000 204 Electrical system 1994-12-20
5000 349-350 Electrical system 1998-01-09
5000 351-353 Electrical system 1995-12-04
5230 204, 349-353 Battery controller/hourmeter 1999-01-20
5460.1 204, 351-353 Transistor controller 1995-12-07
5460.2 204, 349-353 Transistor controller 1997-03-19
5710 204 Electronic card 1994-12-20
5710 349-350 Electronic card 1997-03-25
5710 351-353 Electronic card 1995-12-07
S6 6000 204 Hydraulic system 1995-01-10
6000.1 351-353 Hydraulic system 1995-12-07
6000.2 351-353 Hydraulic system 1995-12-07
S7 7120 204, 349-353 Main lift chain system 2002-12-02

2 (2) Service Manual 2002-12-02 English

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This Service manual contains product information regarding
the current trucks including the technical data and instructions
for maintenance and service. It includes the operator’s
Instruction Manual, Spare Part Handbook and oil and grease
specifications:
M Machine information
P Preventive maintenance
S Service instructions
O Options
At the top of each page you can find information on which
section the page belongs: 6HFWLRQ M 4 means that it is Tech-
nical Data; )FRGH means it deals with this specific truck fam-
ily; 7FRGH means specific products; 'DWH and 9HUVLRQ
QXPEHU give information on when the page was issued and
which version.
It is our ambition to send modification notifications concerning
improvements to you as soon as possible. It’s stated on the
notifications which section/s in the binder should be replaced.
Notifications should be inserted immediately so that the
binder always contains current service information.
When contacting BT’s technical support always have the
actual Service Manual close at hand. If you have any views
regarding the Service Manual, please contact your training
officer at BT who will forward your views to the technical doc-
umentation department.
This document can be available on different media and will
have different part numbers. Please see the following exam-
ple:
XXXXXX-040= An English document on paper
XXXXXX-04C= The same document but on CD-ROM

© BT Industries AB Service Manual 1998-11-04 English 1 (2)

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2 (2) Service Manual 1998-11-04 English

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IIssued by Approved by Version no T-code
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M1 Operator’s Manual
M2 General product information
M3 Product sheet
M4 Technical data
M5 Product improvements
M6 Spare Part ordering
M7 Quality Parts
M8 Recommended Spare Parts

© BT Industries AB Service Manual 1998-11-04 English 1 (2)

F-code Section C-code
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Version no T-code


2 (2) Service Manual 1998-11-04 English

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IIssued by Approved by Version no T-code
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Valid from serial number:

7FRGH 0RGHO 6HULDO1R 1RWHV

204 PPH 1600MX 270001AA-
349 PPS 1600MXD 296773AA-
350 PPS 1200MXF 296773AA-
351 PPS 1000MX 270001AA-
352 PPS 1200 MX 270001AA-
353 PPS 1200MXS 270001AA-

*HQHUDO
An Operator´s Manual is supplied with every truck. If, for any
reason, the customer does not obtain an Operator´s Manual,
they can be ordered from BT. In the table below, you can see
which Operator´s Manuals are available for this machine
series.

,VVXHGRSHUDWRU¶VPDQXDOV

7FRGH 0RGHO 6HULDOQXPEHU 2UGHUQXPEHU ,VVXHG

204 PPH 1600MX 277161AA-293314AA 147340 1996-04-04
204 PPH 1600MX 293315AA-298799AA 156055 1996-10-17
204 PPH 1600MX 298800AA-306954AA 157361 1997-04-01
204 PPH 1600MX 306955AA-324213AA 161489 1998-02-06
204 PPH 1600MX 324214AA- 166155 1998-08-11
204 PPH 1600MX 324214AA- 169987 1999-02-04

349 PPS 1600MXD 296773AA-309699AA 157175 1997-03-04

349 PPS 1600MXD 309700AA-319480AA 161732 1998-02-09
349 PPS 1600MXD 319481AA-329899AA 163583 1998-05-19
349 PPS 1600MXD 329900AA- 166898 1998-11-23

© BT Industries AB Service Manual 1999-06-14 English 1 (2)

F-code Section C-code
36 0
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Version no T-code
 

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350 PPS 1200MXF 296776AA-309399AA 157174 1997-03-03
350 PPS 1200MXF 309700AA-319480AA 161731 1998-02-09
350 PPS 1200MXF 319481AA-329899AA 163582 1998-05-19
350 PPS 1200MXF 329900AA- 166897 1998-10-12

351 PPS 1000MX 270001AA-277153AA 147346 1995-07-03

351 PPS 1000MX 277154AA-295450AA 150189 1996-07-04
351 PPS 1000MX 295451AA-301299AA 157253 1997-01-15
351 PPS 1000MX 301300AA-309699AA 158718 1997-05-07
351 PPS 1000MX 309700AA-319480AA 161729 1998-02-06
351 PPS 1000MX 319481AA-329899AA 163580 1998-05-19
351 PPS 1000MX 329900AA- 166895 1998-10-12

352 PPS 1200MX 270001AA-277153AA 147347 1995-07-04

352 PPS 1200MX 277154AA-295450AA 150190 1996-07-05
352 PPS 1200MX 295451AA-301299AA 157253 1997-01-15
352 PPS 1200MX 301300AA-309699AA 158718 1997-05-07
352 PPS 1200MX 309700AA-319480AA 161729 1998-02-06
352 PPS 1200MX 319481AA-329899AA 163580 1998-05-19
352 PPS 1200MX 329900AA- 166895 1998-10-12

353 PPS 1200MXS 270001AA-277153AA 147348 1995-07-04

353 PPS 1200MXS 277154AA-295450AA 150191 1996-07-05
353 PPS 1200MXS 295451AA-309699AA 157254 1997-01-15
353 PPS 1200MXS 309700AA-319480AA 161730 1998-02-09
353 PPS 1200MXS 319481AA-329899AA 163581 1998-05-19
353 PPS 1200MXS 329900AA- 166896 1998-11-23

2 (2) Service Manual 1999-06-14 English

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IIssued by Approved by Version no T-code
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349 PPS 1600MXD 296773AA-

3UHVHQWDWLRQRIWKHWUXFN
The truck is a battery-powered support arm truck. In its stand-
ard design the truck is equipped with a tiller arm for control
while walking.
The truck has a maximum lifting capacity of 1600 kg.
The truck is intended for double pallet handling, i.e. for han-
dling two loads simultaneously, one on the forks and one on
the support arms.
The truck has a 24V electrical system and the speed is regu-
lated by means of a transistor controller to provide gentle con-
trol of acceleration and speed while driving.
The forks are raised by means of a powerful hydraulic unit.
The lift is electrically controlled using the buttons on the tiller
arm. Control of the lowering speed and positioning of the
forks when stacking is performed using the truck’s mechanical
hydraulic valves.
The truck can be equipped with different accessories such as
riding platform, integrated charger, load support, electrical
lowering of the forks and running meter/battery status. The
truck can also be fitted with low temperature oil if it is to be
used in cool and humid conditions.

,QWHQGHGDSSOLFDWLRQRIWKHWUXFN
The truck is solely designed and manufactured to handle
goods. The trucks should be fitted with the appropriate acces-
sories relevant to the application.

© BT Industries AB Service Manual 1998-08-13 English 1 (12)

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The truck is designed for handling goods indoors. It is not per-
mitted to use the truck for other purposes including the follow-
ing:
- In areas that contain dust or gases which can cause
fires or explosions.
- As a tow-truck for trailers.
- To tow other trucks.
- To transport/lift passengers.
- To drive on gravel or grass.

7UXFNGDWD
The table provides information regarding some technical
data, which is of value with daily use of the truck.

7UXFNW\SH 3360;'
Rated capacity, double pal- 1600
let handling, kg *
Lift height, mm 1700 1900 2100
Fork lift, rated load, kg 1200 1200 1000
Travel speed without load, 1,6
m/s
Travel speed with rated 1,4
load, m/s
Gradient with rated load,% 10
Weight without batteries,
with platform, kg
240 Ah 675 685 695
320 Ah 685 695 705
Weight with batteries, with
platform, kg
240 Ah 875 885 895
320 Ah 885 895 905
Turning radius (Wa), mm 1776
(fork length 1150 mm)

2 (12) Service Manual 1998-08-13 English

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7UXFNW\SH 3360;'
Continuous noise level, <70
according to
CE prEN 12053, dB A
Continuous noise level, 65
according to ASME B56,
11, 5_1992, dB A
Permitted drive wheel, rubber
material siped rubber
non-mark rubber
tractothan

* Deviations may occur on trucks adapted to specific applica-

tion; the correct value can be found on the truck’s identifica-
tion plate. In such cases the truck is also fitted with a
modification plate.
The truck’s lifting capacity, lift height and weight can be found
on the truck’s identification plate.

© BT Industries AB Service Manual 1998-08-13 English 3 (12)

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7UXFNGLPHQVLRQV
The illustration shows external dimensions for the truck in its
standard design.

4 (12) Service Manual 1998-08-13 English

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A - without platform 1355
A - with platform 1290
B 620
C 1820-2144
D 90
E 1000-1150
F - without platform 1966
(fork length = 1150 mm)
G - with folded platform 2054
(fork length = 1150 mm)
H 770
I - without platform 1676
J - with folded platform 1768
K 380
L 570
M - with lowered platform 2439
(fork length= 1150 mm)
N - with lowered platform 2152

© BT Industries AB Service Manual 1998-08-13 English 5 (12)

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,GHQWLILFDWLRQSODWH
The illustration shows the identification plate for the truck in
CE-design.

,WHP 7H[W 8QLW

A MODEL
B SERIAL NO
C RATED CAPACITY kg
D WEIGHT WITHOUT BATTERY kg
E BATTERY WEIGHT MAX kg
MIN kg
F BATTERY VOLTAGE V

The illustration shows the identification plate for the truck in

ASME-design.

A
B ,WHP 7H[W 8QLW
C A TYPE
D B SERIAL NO.
E
C RATED CAPACITY kg
E
F D WEIGHT WITHOUT BATTERY kg
E BATTERY WEIGHT MAX kg
G MIN kg
F BATTERY VOLTAGE V
G BATTERY TYPE

6 (12) Service Manual 1998-08-13 English

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&DSDFLW\SODWH
The illustration shows the capacity plate used on the truck.

,WHP 7H[W 8QLW

H SERIAL NO
I LIFT HEIGHT mm
J ACTUAL CAPACITY kg
K LOAD CENTRE mm
L THE TRUCK MUST ALWAYS BE
DRIVEN WITH LOWERED FORKS
EXCEPT WHEN PLACING OR
REMOVING LOAD
L5 ACTUAL CAPACITY ON THE SUP- kg
PORT ARMS

/RDGGLVWULEXWLRQSODWH
The diagram shows the truck’s load distribution plate.

,WHP 7H[W 8QLW

LD LOAD DISTRIBUTION DIAGRAM
M* MAXIMUM PERMITTED LOAD FOR kg
FORK LIFT IN COMBINATION WITH
SUPPORT ARM LIFT (See load dis-
tribution diagram for other combina-
tions)

© BT Industries AB Service Manual 1998-08-13 English 7 (12)

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K2 MAXIMUM PERMITTED LOAD FOR kg
SUPPORT ARM LIFT IN COMBINA-
TION WITH FORK LIFT (See load
distribution diagram for other combi-
nations)
L1* MAXIMUM PERMITTED LOAD kg
WHEN LIFTING WITH THE FORKS
WITH UNLOADED SUPPORT ARMS
K1 MAXIMUM PERMITTED LOAD FOR kg
SUPPORT ARM LIFT WITH
UNLOADED FORKS

*With 600 mm load centre spacing.

0RGLILFDWLRQSODWH
The illustration shows the modification plate which is found on
the truck if it is supplied as non-standard or if it has been
modified after leaving the manufacturer. The plate includes
information according to the table below.

,WHP 7H[W
A Modification plate
B Type
C Serial number
D Place of manufacture
E Place of manufacture
F Modification number
G Date

8 (12) Service Manual 1998-08-13 English

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 7LOOHUDUP
The truck is manoeuvred by the driver while walking.
204 degree steering area.
The brakes are applied in the tiller arm’s upper and lower
positions.
 ,GHQWLILFDWLRQSODWH
With model designation, serial number, year of manufac-
ture, weight without battery, battery weight, rated capacity,
battery voltage and manufacturer.
 &RYHUV
Removable which provides good accessibility when serv-
icing.
 ,QVWUXPHQW$FFHVVRULHV
Combined hour meter/battery controller or hour meter
only.
 +\GUDXOLFFRQWURO
For controlling lifting and lowering functions.
 +\GUDXOLFXQLW
Pump motor, pump and oil tank are integrated in a com-
pact unit.
 +\GUDXOLFYDOYHV
The valves are located to provide easy access.
 (PHUJHQF\GLVFRQQHFWRUDQGEDWWHU\FRQQHFWRU
The battery is charged via the permanently fitted charging
connector.
 'ULYHXQLWZLWKEUDNH
Suspended drive unit with spring-loaded mechanical
brake, travel motor, gears and drive wheel combined into
a compact unit. Steering bearings between motor and
gears.
 6HULDOQXPEHU
The serial number plate fitted to the chassis.
 (OHFWULFSDQHO
Removable, which provides good access when servicing.
24 volt electrical supply. The speed is variably controlled
by means of a transistor.
 6XSSRUWFDVWRUZKHHOV
Two support castor wheels to ensure stability.
 %DWWHU\
24V with different Ah values. The battery is automatically
locked in the battery compartment.

© BT Industries AB Service Manual 1998-08-13 English 9 (12)

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 0DVW
Fitted with a finger guard to cover the driver’s normal
reach.
 3XPSPRWRUIXVH
160 A BT part no. 29223.
 'ULYHPRWRUIXVH
100 A, BT part no. 29228.
 &RQWUROFLUFXLWIXVH
7,5 A BT part no.122308-075.

10 (12) Service Manual 1998-08-13 English

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© BT Industries AB Service Manual 1998-08-13 English 11 (12)

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V\PEROV
The figure shows the position and significance of the plates
and symbols located on the truck.
1. Hydraulic lever: Lifting/lowering of the support arms.
2. Travel direction.
3. Hydraulic lever: Lifting/lowering of the forks.
4. Signal/Horn.
5. Capacity plate.
6. Identification plate, A: CE, B: ASME, depending on mar-
ket.
7. Hydraulic control: Lower.
8. Serial number.
9. Hydraulic oil filling.
10. Modification plate.
11. Do not walk under an elevated load.
12. Load distribution plate.
13. Lifting points.

A
B
C
D
$ E
E
%
F

12 (12) Service Manual 1998-08-13 English

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Valid from serial number:

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350 PPS1200 MXF 296773AA-

3UHVHQWDWLRQRIWKHWUXFN
The truck is a battery powered support arm truck. In its basic
design the truck is equipped with a tiller arm for walking oper-
ation.
The truck has a maximum lifting capacity of 1200 kg.
The truck has a 24 V electrical system and the speed is con-
trolled by means of a transistor regulator to provide smooth
control over acceleration and the speed while driving.
The truck is equipped with raisable support arms that simplify
the truck’s driving characteristics on uneven surfaces and
over thresholds. When the forks are completely lowered on
the support arms it is possible to use support arms when lift-
ing loads of maximum 1600 kg.
The forks are lifted by means of a powerful hydraulic unit. The
lift is controlled electrically by means of buttons on the tiller
arm. Control of the lowering speed and positioning of the
forks while stacking is performed by using the truck’s
mechanical hydraulic valve.
The truck can be equipped with different accessories includ-
ing a ride-on platform, integrated charger, load support and
electrical lowering of the forks, running meter/battery guard.
The truck can also be fitted with low temperature oil with use
in cold and damp environments.

,QWHQGHGXVHRIWKHWUXFN
The truck is designed and manufactured solely for the han-
dling of goods. The truck should be equipped with the appro-
priate accessories relevant to its working situation.

© BT Industries AB Service Manual 1998-08-13 English 1 (10)

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As the truck is designed for indoor handling of goods it is for-
bidden, among others, to use the truck for the following:
- For driving in areas containing dust or gases that can
cause fire or explosions.
- As a tow truck for trailers.
- For towing other trucks.
- For the transport/lift of passengers.
- For driving on surfaces other than hard surfaces, e.g.
grass or gravel surfaces.

7UXFNGDWD
The table provides information on specific technical data,
which is of value with the daily use of the truck.

7UXFNW\SH 3360;)
Lifting capacity, classified load, kg * 1200

Lifting capacity support arm lift with 1600

fully lowered forks, kg

Lifting height, mm 2700-3300

Operating speed without load, m/s 1.65

Operating speed with classified load, 1.4

m/s

Max. gradient with classified load, % 10

Weight without battery, kg 730-755

Weight with battery, kg (Ah) 930-955 (240)

Turning radius (Wa), mm 1676

(fork length 1150 mm)

Continuous sound pressure level <70

value according to CE prEN 12053,
dB A

Continuous sound pressure level 61

value according to ASME
B56,11,5_1992, dB A

2 (10) Service Manual 1998-08-13 English

 F-code Section C-code
36 0
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Version no T-code
 

7UXFNW\SH 3360;)
Permitted drive wheel, material rubber
rubber siped
rubber non-mark
tractothane

* Deviations may occur on application tailored trucks, correct

values are evident from the truck’s type plate. In these cases
the truck is fitted with a modification plate.
The lifting capacity, lifting height and weight of the truck can
be found on the truck’s type plates.

© BT Industries AB Service Manual 1998-08-13 English 3 (10)

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7UXFNGLPHQVLRQV
The diagram shows the outside dimensions of the truck in its
standard design.

4 (10) Service Manual 1998-08-13 English

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A - without platform 1380
A - with platform 1290
B 620
C 1820-2144
D 90
E 1000-1150
F - without platform
(fork length = 1150 mm) 1966
G - with raised platform
(fork length = 1150 mm) 2054
H 800
I - without platform 1676
J - with raised platform 1768
K 380
L 570
M - with raised platform
(fork length = 1150 mm) 2439
N - with raised platform 2152

© BT Industries AB Service Manual 1998-08-13 English 5 (10)

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7\SHSODWH
The diagram shows the truck’s type plate in its CE-design.

&KDU 7H[W 8QLW

DFWHU
A TYPE
B No.
C CLASSIFIED LIFTING CAPACITY kg
D WEIGHT WITHOUT BATTERY kg
E BATTERY WEIGHT MAX kg
MIN kg
F BATTERY VOLTAGE V

The diagram shows the truck’s type plate in its ASME-design.

A &KDU 7H[W 8QLW

DFWHU
B
C A TYPE
D B No.
E
C CLASSIFIED LIFTING CAPACITY kg
E
F D WEIGHT WITHOUT BATTERY kg
E BATTERY WEIGHT MAX kg
G MIN kg
F BATTERY VOLTAGE V
G BATTERY TYPE

6 (10) Service Manual 1998-08-13 English

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&DSDFLW\SODWH
The diagram shows the truck’s capacity plate.

&KDUDF 7H[W 8QLW

WHU
H No.
I LIFTING HEIGHT mm
J PERMITTED LOAD kg
K LOAD CENTRE DISTANCE mm
L THE TRUCK SHOULD ALWAYS BE
DRIVEN WITH LOWERED FORKS
EXCEPT WHEN STACKING
L5 PERMITTED LOAD ON SUPPORT kg
ARMS

0RGLILFDWLRQSODWH
The diagram shows the modification plate that should be fit-
ted to the truck if supplied as non-standard or if it has been
modified after delivery by the manufacturer. The sign gives
information as set out in the table below.

&KDUDFWHU 7H[W
A Modification plate
B Type
C Serial number
D Place of manufacture
E Place of manufacture
F Modification number
G Date

© BT Industries AB Service Manual 1998-08-13 English 7 (10)

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0DLQFRPSRQHQWV
 7LOOHUDUP
The truck is operated by the driver when walking.
Steering range 204 degrees.
The brakes are applied in the tiller’s upper and lower posi-
tions.
 7\SHSODWH
With type designation, machine number, year of manufac-
turer, weight without battery, battery weight, classified lift-
ing capacity, battery voltage and manufacturer.
 +RRGV
Easily removable, providing good accessibility when serv-
icing.
 ,QVWUXPHQW$FFHVVRU\
Combined running meter/battery guard or just running
meter.
 +\GUDXOLFFRQWURO
For control of the lifting and lowering functions.
 +\GUDXOLFXQLW
Pump motor, pump and oil tank are integrated into a com-
pact unit.
 +\GUDXOLFYDOYHV
The valves are located in an easily accessible position.
 %DWWHU\VZLWFKDQG&KDUJLQJSOXJ
The battery is charged via the fixed charging plug.
 'ULYHXQLWZLWKEUDNHV
Fixed drive unit with spring loaded mechanical brakes,
travel motor, drive gear, and drive wheel integrated into a
compact unit. Steering bearing between the motor and
drive gear.
 0DFKLQHQXPEHU
Punched plate on the chassis.
 (OHFWULFDOSDQHO
Removable, providing good accessibility for servicing.
24 volt electrical system. The speed is regulated variably
by means of a transistor regulator.
 6XSSRUWFDVWRUZKHHO
2 support castors to ensure stability.
 %DWWHU\
24 V with different Ah-rates. The battery is automatically
locked in the battery compartment.
 0DVW
Fitted with finger guard to cover the driver’s normal reach.

8 (10) Service Manual 1998-08-13 English

 F-code Section C-code
36 0
*HQHUDOSURGXFWLQIRUPDWLRQ
Version no T-code
 

 3XPSPRWRUIXVH
160 A BT item no. 29223.
 'ULYHPRWRUIXVH
100 A, BT item no.29228.
 &RQWUROIXVH
7.5 A, BT item no. 122308-075.

© BT Industries AB Service Manual 1998-08-13 English 9 (10)

F-code Section C-code
36 0
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Version no T-code
 

:DUQLQJDQGLQIRUPDWLRQSODWHV
The diagram shows the placement and significance of the
plates on the truck.
1. Hydraulic control: Lifting/lowering of the support arms.
2. Travel direction.
3. Hydraulic control: Lifting/lowering of the forks.
4. Horn.
5. Lifting capacity.
6. Type plate, A: CE, B: ASME, depending on the market.
7. Hydraulic control: Lowering.
8. Machine number.
9. Hydraulic oil refilling point.
10. Modification plate.
11. Max. height for classified lifting capacity.
12. Do not walk under a suspended load.
13. Lifting points.

A
B
C

%
D

$ E
E
F

10 (10) Service Manual 1998-08-13 English

 F-code Section C-code
36 0
*HQHUDOSURGXFWLQIRUPDWLRQ
IIssued by Approved by Version no T-code
66' .+DOOPDQ  

*HQHUDOSURGXFWLQIRUPDWLRQ
Valid from serial number:

7FRGH 0RGHO 6HULDO1R 1RWHV

351 PPS 1000MX 270001AA-
352 PPS 1200MX 270001AA-
353 PPS 1200MXS 270001AA-

3UHVHQWDWLRQRIWKH%7SHGHVWULDQ
VWDFNHUV
The BT pedastrian stackers are battery powered support arm
trucks solely to be operated by pedestrian operators when
handling pallets or similar load carriers in-doors. In its stand-
ard design the truck is equipped with a tiller arm with all the
controls for operating the truck within easy access.
The stackers are produced in both a fork over version and a
straddle [Link] fork over versions are five wheel trucks
(including castor wheels) having a maximum lifting capacities
of 1000 kg or 1200 kg. The straddle version is a three wheeler
without castor wheels having a maximum lifting capacity of
1200 kg.
These trucks are equipped with 24 V electrical system and
the speed is regulated by means of a transistor controller to
provide gentle 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 tiller arm. Control of the lowering speed and the posi-
tioning of the forks when stacking is done with the mechanical
valve lever.
The truck can be fitted with different accessories including a
battery-pack, electrical lowering of the forks and hour meter/
battery guard. The truck can also be fitted with stainless steel
axles and low temperature oil if it is to be used in cool and
humid conditions.

,QWHQGHGDSSOLFDWLRQRIWKHWUXFN
The truck is solely designed and manufactured to handle
goods. The truck should be fitted with the appropriate acces-
sories relevant to the application.
© BT Industries AB Service Manual 1995-11-30 English 1 (10)
F-code Section C-code
36 0
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Version no T-code
 

)RUELGGHQDSSOLFDWLRQRIWKHWUXFN
The truck is designed for handling goods indoors. It is not per-
mitted to use the truck for other purposes including the follow-
ing:

- 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.

7UXFNGDWD
The table provides information regarding some technical
data, which is of value with daily use of the truck.

7UXFNW\SH 3360; 3360; 3360;6

Lifting capacity rated load, kg 1000 1200 1200
Lift height, mm 1400–3300 1400–3700 2650–3650
Operating speed without load, m/s 1,6 1,6 1,6
Operating speed with rated load, m/s 1,4 1,4 1,4
Max. operating gradient with load, % 8 8 8
Service weight without battery, kg 570–590 640–685 682–726
Service weight including battery, kg 720–740 (180) 840–885 (240) 882–926 (240)
(Ah)
Turning radius (Wa), mm (fork length 1476 1516 1506
1150 mm)
Continuous noise level, dB A < 70 < 70 < 70
Vibration levelm/s2 < 2,5 < 2,5 < 2,5

The truck’s lifting capacity, lifting height and weight can be

found on the truck’s type plate.

2 (10) Service Manual 1995-11-30 English

 F-code Section C-code
36 0
*HQHUDOSURGXFWLQIRUPDWLRQ
Version no T-code
 

7UXFNGLPHQVLRQV3360;
The diagram shows external dimensions for the truck in its
standard design.

© BT Industries AB Service Manual 1995-11-30 English 3 (10)

F-code Section C-code
36 0
*HQHUDOSURGXFWLQIRUPDWLRQ
Version no T-code
 

7UXFNGLPHQVLRQV3360;
The diagram shows external dimensions for the truck in its
standard design.

4 (10) Service Manual 1995-11-30 English

 F-code Section C-code
36 0
*HQHUDOSURGXFWLQIRUPDWLRQ
Version no T-code
 

7UXFNGLPHQVLRQV3360;6
The diagram shows external dimensions for the truck in its
standard design.

© BT Industries AB Service Manual 1995-11-30 English 5 (10)

F-code Section C-code
36 0
*HQHUDOSURGXFWLQIRUPDWLRQ
Version no T-code
 

7\SHSODWH
The diagram shows the type plate used on the truck.

,WHP 7H[W 8QLW

A MODEL
B NO
C RATED CAPACITY kg
D WEIGHT WITHOUT BATTERY kg
E BATTERY WEIGHT Max kg
Min kg
F BATTERY VOLTAGE V

&DSDFLW\SODWH
H
The diagram shows the capacity plate used on the truck.
I J

,WHP 7H[W 8QLW

H NO
I LIFT HEIGHT mm
K J ACTUAL CAPACITY kg
K LOAD CENTRE mm
L L THE TRUCK MUST ALWAYS BE
DRIVEN WITH LOWERED FORKS
EXCEPT WHEN PLACING OR
REMOVING LOAD

6 (10) Service Manual 1995-11-30 English

 F-code Section C-code
36 0
*HQHUDOSURGXFWLQIRUPDWLRQ
Version no T-code
 

0RGLILFDWLRQSODWH
The diagram shows the modification plate that should be fit-
ted to the truck if supplied as non-standard or if it has been
modified after delivery by the manufacturer. The sign gives
information as set out in the table below.

,WHP 7H[W
A Modification plate
B Type
C Serial number
D Place of manufacture
E Place of manufacture
F Modification number
G Date

© BT Industries AB Service Manual 1995-11-30 English 7 (10)

F-code Section C-code
36 0
*HQHUDOSURGXFWLQIRUPDWLRQ
Version no T-code
 

0DLQFRPSRQHQWV
 7LOOHUDUP
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.
 7\SHSODWH
With type designation,manufacturing number, year of
manufacture, service weight, battery weight, classified lift-
ing capacity, battery voltage and manufacturer.
 +RRGV
Removable which provides good accessibility when serv-
icing.
 ,QVWUXPHQWDFFHVVRU\
Combined hour meter/battery guard or hour meter only.
 +\GUDXOLFFRQWURO
For controlling lifting and lowering functions.
 +\GUDXOLFXQLW
Pump motor, pump, valves and oil tank integrated in a
compact unit.
 +\GUDXOLFYDOYHV
The valves are located to provide easy access.
 %DWWHU\LVRODWRU5HFKDUJLQJFRQQHFWRU
The battery is recharged via the fixed mounted charging
connector.
 'ULYHXQLWZLWKEUDNH
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.
 0DFKLQHQXPEHU
The manufacturing number plate fitted to the chassis.
 (OHFWULFSDQHO
Removable, which provides good access when servicing.
24 volt electrical system. The speed is variably controlled
by means of a transistor.
 6XSSRUW&DVWRUZKHHOV
Two support castor wheels to ensure stability.
127( On PPS 1000/1200MX only.
 %DWWHU\
24V with different Ah values.
 0DVW
Fitted with a finger protection which covers the operators
normal range of reach from the operating position.

8 (10) Service Manual 1995-11-30 English

 F-code Section C-code
36 0
*HQHUDOSURGXFWLQIRUPDWLRQ
Version no T-code
 

© BT Industries AB Service Manual 1995-11-30 English 9 (10)

F-code Section C-code
36 0
*HQHUDOSURGXFWLQIRUPDWLRQ
Version no T-code
 

:DUQLQJDQGLQIRUPDWLRQVLJQV
The figure shows the position and significance of the signs
located on the truck.

1. Hydraulic control: Lifting.

2. Travel direction.
3. Signal/Horn.
4. Lifting capacity.
5. Machine signs.
6. Hydraulic control: Lowering.
7. Machine number.
8. Hydraulic oil, filling point.
9. Maximum lift height for rated capacity.
10. Do not walk under lifted load.
11. Lifting points.
12. Modification plate.

10 (10) Service Manual 1995-11-30 English

 F-code Section C-code
36 0
7HFKQLFDOGDWD
Issued by Approved by Version no T-code
66' /*$QGHUVVRQ  

7HFKQLFDOGDWD
Valid from serial number:

7FRGH 0RGHO 6HULDOQXPEHU 1RWHV

349 PPS 1600 MXD 296773AA-
350 PPS 1200 MXF 296773AA-

0RGHO 3360;) 3360;'

'ULYHPRWRU
Type TTL 140S-M2 TTL 140S-M2
Output 1.2 kW 1.2 kW
Duty cycle 60% 60%
Min carbon brush length 12 mm 12 mm
Min commutator diameter 47 mm 47 mm
7UDQVPLVVLRQGULYHJHDU
Type 2-stage angle trans- 2-stage angle trans-
mission mission
Gear ratio 19.14:1 19.14:1
Oil volume 1.0 litre 1.0 litre
Oil Hypoid oil Hypoid oil
Normal temperature SAE 80W/90 SAE 80W/90
< -15oC SAE 75W SAE 75W
:KHHOV
Drive wheel Dia 215x70 mm Dia 215x70 mm
Axle pressure without load 325 kg 325 kg
Axle pressure at rated load 325 kg 325 kg
Tightening torque for wheel bolts 65 Nm 65 Nm
Support arm wheels Dia 80x75 mm Dia 80x75 mm
Max. axle pressure without load, medium 241 kg 225 kg
battery

© BT Industries AB Service Manual 1998-01-09 English 1 (4)

F-code Section C-code
36 0
7HFKQLFDOGDWD
Version no T-code
 

0RGHO 3360;) 3360;'

Max. axle pressure with rated load, medium 1240/1585 kg 1222/1565 kg
battery/1600 kg on support arms
Support castors Dia 125x50 mm 125x50 mm
Max. axle pressure without load, medium 364 kg 325 kg
battery
Max axle pressure with rated load, medium 565/620 kg 528/585 kg
battery/ 1600 kg on support arms
+\GUDXOLFV\VWHP
Output 2.0 kW 2.0 kW
Speed/min at working pressure 2500 2500
Duty cycle 6% 6%
Min. carbon brush length, mm 12 mm 12 mm
Min. commutator diameter 43 mm 43 mm
Pressure at rated load 180 bar 180 bar
Relief pressure 200 bar 200 bar
Pump flow 6 litre/min at 180 bar 6 litre/min at 180 bar
Tank volume 3.5 litre 3.5 litre
Oil Hydraulic oil Hydraulic oil
Normal temperature ISO-L-HM32 ISO-L-HM32
< -15oC ISO-L-HV32 ISO-L-HV32
)XVHV
Drive motor circuits 100 A 100 A
Pump motor circuits 160 A 160 A
Control circuirts 7.5 A 7.5 A
%DWWHULHV $OOPRGHOV
Dimension WxLxH 196x645x570 mm 244x645x570 mm
Capacity max 240 Ah 320 Ah
Weight min/max 150/200 kg 200/250 kg

2 (4) Service Manual 1998-01-09 English

 F-code Section C-code
36 0
7HFKQLFDOGDWD
Version no T-code
 

0RGHO 3360;) 3360;'

'ULYLQJVSHHGV
Without load, 5.4 km/h 5.4 km/h
without platform 1.5 m/s 1.5 m/s
Without load, 5.9 km/h 5.9 km/h
with platform 1.65 m/s 1.65 m/s
With rated load, 5.0 km/h 5.0 km/h
without platform 1.4 m/s 1.4 m/s
With rated load, 5.5 km/h 5.5 km/h
with platform 1.55 m/s 1.55 m/s
/LIWLQJORZHULQJWLPHV
Lifting without load 0.19 m/s 0.19 m/s
Lifting with rated load 0.10 m/s 0.10 m/s
Lowering without load, mechanical valve 0.18 m/s (tele) 0.18 m/s (tele)
0.16 m/s (hi-lo) 0.16 m/s (hi-lo)
Lowering with rated load, mechanical valve 0.24 m/s 0.24 m/s
Lowering without load, electric valve 0.18 m/s (tele) 0.18 m/s (tele)
0.16 m/s (hi-lo) 0.16 m/s (hi-lo)
Lowering with rated load, electric valve 0.17 m/s 0.17 m/s
3RZHUFRQVXPSWLRQ
Driving without load 28 A 28 A
Driving with rated load 35 A 35 A
Lift without load 60 A 60 A
Lift with rated load 160 A 160 A

© BT Industries AB Service Manual 1998-01-09 English 3 (4)

F-code Section C-code
36 0
7HFKQLFDOGDWD
Version no T-code
 

4 (4) Service Manual 1998-01-09 English

 F-code Section C-code
36 0
7HFKQLFDOGDWD
IIssued by Approved by Version no T-code
66' .+DOOPDQ  

7HFKQLFDOGDWD
Valid from serial number:

7FRGH 0RGHO 6HULDO1R 1RWHV

351 PPS 1000MX 270001AA-
352 PPS 1200MX 270001AA-
353 PPS 1200MXS 270001AA-

0RGHO 3360; 3360; 3360;6

'ULYH0RWRU
Type TTL 1403-M2 TTL 1403-M2 TTL 1403-M2
Power 1.2 kW 1.2 kW 1.2 kW
Intermittens 60% 60% 60%
Min carbon brush 12 mm 12 mm 12 mm
length
Min commutator 47 mm 47 mm 47 mm
diameter
Part no 134397 134397 134397
7UDQVPLVVLRQJHDU
Type 2-step angular 2-step angular 2-step angular
Gear ratio 19.43:1 19.43:1 19.43:1
Oil volume 1.0 litre 1.0 litre 1.0 litre
Oil type Hypoid oil Hypoid oil Hypoid oil
Normal temperature SAE 80W/90 SAE 80W/90 SAE 80W/90
< -15oC SAE 75W SAE 75W SAE 75W
:KHHOV
Drive wheel Dia 215x70 mm Dia 215x70 mm Dia215x70 mm
Wheel pressure with- 310 kg 310 kg 609 kg
out load
Wheel pressure with 310 kg 310 kg 700 kg
rated load
Torque wheel bolts 65 Nm 65 Nm 65 Nm

© BT Industries AB Service Manual 1995-11-30 English 1 (4)

F-code Section C-code
36 0
7HFKQLFDOGDWD
Version no T-code
 

0RGHO 3360; 3360; 3360;6

Fork wheel Dia 80x95 mm Dia 80x95 mm Dia100x75 mm
Axle pressure with 1095 kg 1290 kg 1412 kg
rated load
Support wheel Dia 125x40 mm 125x40 mm -------------
Axle pressure with-out 228 kg 313 kg -------------
load
Axle pressure with 335 kg 465 kg -------------
rated capacity
+\GUDXOLFXQLW
Power 2.0 kW 2.0 kW 2.0 kW
Revolutions/min at 2600 2500 2400
work pressure
Intermittens 13% 10% 9%
Min carbon brush 12 mm 12 mm 12 mm
length
Min commutator thick- 43 mm 43 mm 43 mm
ness/diameter
Pressure at rated load 150 bar 180 bar 190 bar
Relief pressure 170 bar 200 bar 210 bar
Pump flow 6,4 litre/min at 6 litre/min at 5,9 litre/min at
150 bar 180 bar 190 bar
Tank volume 3,5 litre 3,5 litre 3,5 litre
Oil type Hydraulic oil Hydraulic oil Hydraulic oil
Normal temperature ISO-L-HM32 ISO-L-HM32 ISO-L-HM32
< -15oC ISO-L-HV32 ISO-L-HV32 ISO-L-HV32
)XVHV
Drive motor circuit 29228 29228 29228
Amperage 100 A 100 A 100 A
Pump motor circuit 29223 29223 29223
Amperage 160 A 160 A 160 A
Control circuit 122308-075 122308-075 122308-075
Amperage 7,5 A 7,5 A 7,5 A

2 (4) Service Manual 1995-11-30 English

 F-code Section C-code
36 0
7HFKQLFDOGDWD
Version no T-code
 

0RGHO 3360; 3360; 3360;6

%DWWHULHV
Dimension WxLxH 196x645x450 mm 196x645x510 mm 196x645x570 mm
Capacity 180 Ah 210 Ah 240 Ah
Weight 150 kg 175 kg 200 kg
Part No 134364 133991 134365
'ULYLQJVSHHGV
Without load 5.6 km/h 5.6 km/h 5.6 km/h
1.56 m/s 1.56 m/s 1.56 m/s
With rated load 5.1 km/h 5.0 km/h 5.0 km/h
1.41 m/s 1.39 m/s 1.39 m/s
/LIWLQJORZHULQJWLPH
Lift without load 0.2 m/s 0.19 m/s 0.19 m/s
Lift with rated load 0.12 m/s 0.10 m/s 0.10 m/s
Lower without load, 0.18 m/s 0.16 m/s 0.16 m/s
mechanical valve
Lower with rated load, 0.24 m/s 0.24 m/s 0.24 m/s
mechanical valve
Lower without load, 0.18 m/s 0.16 m/s 0.16 m/s
electrical valve
Lower with rated load, 0.17 m/s 0.17 m/s 0.17 m/s
electrical valve
&XUUHQW&RQVXPSWLRQ
Driving without load 27 A 27 A 27 A
Driving with rated load 33 A 35 A 35 A
Lifting without load 39 A 39 A 39 A
Lifting with rated load 118 A 130 A 130 A

© BT Industries AB Service Manual 1995-11-30 English 3 (4)

F-code Section C-code
36 0
7HFKQLFDOGDWD
Version no T-code
 

4 (4) Service Manual 1995-11-30 English

 F-code Section C-code
36 0
2UGHULQJ6SDUH3DUWV
IIssued by Approved by Version no T-code
66'  

2UGHULQJ6SDUH3DUWV
• Localise 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 Truck Centre and state the article number.
The Truck Centre will now order the actual article via compu-
ter from BT Parts. The article is delivered by DDD during the
night and the next day you will have the part (If you place the
order after 4.30 pm the delivery will be delayed).
If you cannot find the machine type, machine number or the
article number call the Truck Centre and they will help you.

© BT Industries AB Service Manual 1998-11-04 English 1 (2)

F-code Section C-code
36 0
2UGHULQJ6SDUH3DUWV
Version no T-code


2 (2) Service Manual 1998-11-04 English

 F-code Section C-code
36 0
4XDOLW\3DUWV
IIssued by Approved by Version no T-code
66' -HVVLFD)RUVJDUG  

4XDOLW\3DUWV
Valid from serial number:

7FRGH 0RGHO 6HULDO1R 1RWHV

204 PPH 1600MX 270001AA-
349 PPS 1600MXD 296773AA-
350 PPS 1200MXF 296773AA-
351 PPS 1000MX 270001AA-
352 PPS 1200 MX 270001AA-
353 PPS 1200MXS 270001AA-

,VVXHG4XDOLW\3DUWV
7FRGH 0RGHO 6HULDO1R 2UGHUQXPEHU ,VVXHG
204 PPH 1600MX 268677AA-275359AA 148187 1995/05
204 PPH 1600MX 275360AA-284058AA 150197 1995/10
204 PPH 1600MX 284059AA-293314AA 152383 1996/05
204 PPH 1600MX 293315AA-298799AA 156769 1996/12
204 PPH 1600MX 298800AA-306954AA 157360 1997-04-09
204 PPH 1600MX 306955AA-324213AA 161287 1997-11-05
204 PPH 1600MX 324214AA-329899AA 166148 1998-09-04
204 PPH 1600MX 329900AA- 169015 1998-11-23
204 PPH 1600MX 335439AA- 169996 1999-03-15

349 PPS 1600MXD 296773AA-309699AA 157170 1997-05-02

349 PPS 1600MXD 309700AA-319480AA 161980 1997-11-14
349 PPS 1600MXD 319481AA-329899AA 163531 1998-05-18
349 PPS 1600MXD 329900AA- 165675 1998-11-27

350 PPS 1200MXF 296776AA-309699AA 157169 1997-05-02

350 PPS 1200MXF 309700AA-319480AA 161979 1997-11-13

© BT Industries AB Service Manual 1999-06-14 English 1 (2)

F-code Section C-code
36 0
4XDOLW\3DUWV
Version no T-code
 

7FRGH 0RGHO 6HULDO1R 2UGHUQXPEHU ,VVXHG

350 PPS 1200MXF 319481AA-329899AA 163530 1998-05-18
350 PPS 1200MXF 329900AA- 165674 1998-11-26

351, 352 PPS 1000MX/ 270001AA-284058AA 147696 1995/12

1200MX
351, 352 PPS 1000MX/ 284059AA-295606AA 152509 1996/09
1200MX
351, 352 PPS 1000MX/ 295607AA-301305AA 156759 1997-01-28
1200MX
351, 352 PPS 1000MX/ 301306AA-309699AA 158723 1997-05-28
1200MX
351, 352 PPS 1000MX/ 309700AA-319480AA 161977 1997-11-13
1200MX
351, 352 PPS 1000MX/ 319481AA-329899AA 163528 1998-05-18
1200MX
351, 352 PPS 1000MX/ 329900AA- 166907 1998-11-25
1200MX

353 PPS 1200MXS 270001AA-284058AA 147697 1995/12

353 PPS 1200MXS 284059AA-309699AA 152510 1996/09
353 PPS 1200MXS 309700AA-319480AA 161978 1997-11-13
353 PPS 1200MXS 319481AA-329899AA 163529 1998-05-18
353 PPS 1200MXS 329900AA- 166908 1998-11-26

2 (2) Service Manual 1999-06-14 English

 F-code Section C-code
36 0
5HFRPPHQGHG6SDUH3DUWV563
IIssued by Approved by Version no T-code
66' -HVVLFD)RUVJDUG  

5HFRPPHQGHG6SDUH3DUWV563
Valid from serial number:

7FRGH 0RGHO 6HULDO1R 1RWHV

204 PPH 1600MX 270001AA-
349 PPS 1600MXD 296773AA-
350 PPS 1200MXF 296773AA-
351 PPS 1000MX 270001AA-
352 PPS 1200 MX 270001AA-
353 PPS 1200MXS 270001AA-

,VVXHG563
7FRGH 0RGHO 6HULDO1R ,VVXHG
204 PPH 1600MX 251000AA-275359AA 1995-11-06
204 PPH 1600MX 275360AA-293314AA 1996-12-17
204 PPH 1600MX 293315AA-324213AA 1996-12-17
204 PPH 1600MX 324214AA-335438AA 1998-11-04
204 PPH 1600MX 335439AA- 1999-05-21

349 PPS 1600MXD 296773AA-319480AA 1997-04-24

349 PPS 1600 MXD 319481AA- 1997-07-22

350 PPS 1200MXF 296776AA-309699AA 1997-04-24

350 PPS 1200MXF 309700AA-319480AA 1997-08-30
350 PPS 1200MXF 319481AA- 1997-08-30

351 PPS 1000/1200MX, MXS 270001AA-284058AA 1996-10-11

351 PPS 1000/1200MX, MXS 284059AA-309699AA 1998-02-13
351 PPS 1000/1200MX, MXS 309700AA-319480AA 1998-02-13
351 PPS 1000/1200MX, MXS 319481AA- 1998-07-21

© BT Industries AB Service Manual 1999-06-14 English 1 (2)

F-code Section C-code
36 0
5HFRPPHQGHG6SDUH3DUWV563
Version no T-code
 

2 (2) Service Manual 1999-06-14 English

 F-code Section C-code
36 3
&RQWHQWV3
IIssued by Approved by Version no T-code
66'  

&RQWHQWV3

3UHYHQWLYH0DLQWHQDQFH
P1 Introduction
P2 Preventive Maintenance
P3 Oil and grease specification
P4 Tools

© BT Industries AB Service Manual 1998-11-04 English 1 (2)

F-code Section C-code
36 3
&RQWHQWV3
Version no T-code


2 (2) Service Manual 1998-11-04 English

 F-code Section C-code
36 3
,QWURGXFWLRQPDLQWHQDQFH
IIssued by Approved by Version no T-code
66' /*$QGHUVVRQ  

,QWURGXFWLRQPDLQWHQDQFH
All points in the service program should be carried out to
attain the highest safety and the least possible downtime. The
service intervals are only a guide and do not need to be fol-
lowed to the letter. The operator may adapt them to local con-
ditions, but it is important that the intervals comply with BT’s
minimum requirements.
The service intervals are based on the running times and can
be adapted to most normal 8 hour shifts. The service interval
may be shortened if the truck is used more frequently or in
more demanding situations, e.g cold store, dusty or corrosive
situations. The following running times have been used when
calculating the intervals:
- Day time: 08.00-17.00 (20 hr./week)
- 2-shifts: 06.00-14.00, 14.00-22.00 (40 hr./week)
- 3-shifts: 06.00-14.00, 14.00-22.00,22.00-06.00
(60 hr./week)
Ensure the truck is given a regular maintenance service after
every 500 driving hours. The truck’s safety, efficiency and
service life is dependent on the service and maintenance it is
given.
Only use BT approved spare parts when service and repair
work are carried out.

6DIHW\UHJXODWLRQVZLWKPDLQWH
QDQFHZRUN
Only personnel that have been trained in the service and
repair of this type of truck are authorised to carry out service
and repair work.
• Do not carry out any maintenance work on the truck unless
you have the correct training and knowledge to do so
• Keep the area where you carry out the service clean. Oil or
water makes the floor slippery
• Never wear loose objects or jewellery when working on the
truck

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© BT Industries AB Service Manual 1997-12-19 English 1 (4)
F-code Section C-code
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• Always disconnect the battery by pulling out the battery

isolator when carrying out maintenance work on the truck
unless otherwise stated in this Service Manual
• Always switch off the truck’s power supply before opening
the covers on the drive unit or electrical system
• Relieve the system pressure slowly before starting work on
the truck’s hydraulic system
• Use paper or a rigid sheet of cardboard when checking for
oil leakage. 1HYHU use your hand
• Bear in mind that the oil in the transmission or the hydraulic
system can be hot

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• Only fill the hydraulic system with new and clean oil

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• Store and dispose of changed oil in accordance with local
directives
• Do not release solvents and the like, which are used for
cleaning/washing, into drains that are not intended for this
purpose. Follow the local directives that apply for disposal
• Disconnect the battery when welding on the truck
127(
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• Remove at least 100 mm of paint around the welding/
grinding area through sand-blasting or the use of a paint
stripper when welding or grinding on painted surfaces

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2 (4) Service Manual 1997-12-19 English

 F-code Section C-code
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Cleaning and washing of the truck is important to ensure the
truck’s reliability.
• Carry out general cleaning and washing weekly
127(
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• Remove rubbish, etc. from the wheels daily
• Use a well-known degreasing agent, diluted to a suitable
concentration
• Rinse off loose grime using tepid water
127(
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• Cover the electric motors, connections and valves before
washing
127(
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• Clean the motor compartment using a well-known
degreasing agent, diluted to a suitable concentration
• Rinse off loose grime using tepid water

© BT Industries AB Service Manual 1997-12-19 English 3 (4)

F-code Section C-code
36 3
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Version no T-code
 

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• Blow electric motors down using compressed air
• Clean the electrical panels, electronic boards, contactors,
connections, solenoid valves, etc. using a damp cloth and
a cleaning agent
127(
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All lifting must be carried out on a flat, non-slip and firm sur-
face. Avoid new laid asphalt or asphalt on a hot summer’s
day.
• Activate the parking brake to prevent the truck from moving
during the lift. If the lift applies to the brake wheel, chock
the other wheels so that the truck stands still
• Select a lifting point so that the lift is as easy as possible
(one corner at a time). If the truck has marked lifting points
on the under side of the chassis these can be used to
obtain a well balanced lift
• Ensure that the surface under the jack is clean and free
from oil and grease
• Ensure that your hands and the jack’s lever are free from
oil and grease
• Use the lever that belongs to the jack. A lever that is too
short requires more force than is necessary. If the lever is
too long there is a risk of the jack being overloaded
• Support the truck:
- as close as possible to the part of the chassis that is to
be lifted. This reduces the risk of the truck tipping over
- so that the truck cannot roll
• 1HYHU lift up the jack in order to lift higher
• 1HYHU work under a lifted truck unless it is well supported

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4 (4) Service Manual 1997-12-19 English

 F-code Section C-code
36 3
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351 PPS 1000MX 270001AA-
352 PPS 1200MX 270001AA-

0DLQWHQDQFHVFKHGXOH

,WHP :RUNUHTXLUHG
,QWHUYDOLQKRXUV       
,QWHUYDOLQ'D\V:HHNV0RQWKV G Z P P P P P
 &KDVVLV
0000.1 Check that the truck identification X
plate is legible
0000.2 Check the battery securing X
blocks for wear
0000.3 Check for damage and crack for- X
mation
0000.4 Retighten the truck body fasten- X
ing bolts (to the chassis)
0000.5 Check the cover lockings X
 2SHUDWRU&RQWUROV
0640.1 Check that the travel direction/ X
speed control is not binding
0640.2 Check that the horn button is X
operational
0640.3 Check the the lift/lower button is X
operational
 'ULYHUV3URWHFWLRQ
0840.1 Check that the red safety switch X
button is not binding

© BT Industries AB Service Manual 1995-12-01 English 1 (8)

F-code Section C-code
36 3
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Version no T-code
 

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,QWHUYDOLQKRXUV       
,QWHUYDOLQ'D\V:HHNV0RQWKV G Z P P P P P
 'ULYH0RWHU
1700.1 Check for arcing due to poor con- X
nections
1700.2 All connections tight X
1700.3 Check of carbon brushes X
1700.4 Clean moteo of dirt and dust X
1700.5 Check tightening of motor bolts X
1700.6 Check for abnormal noise in X
motor bearings
 'ULYH*HDU
2550.1 Check for oil leakage X
2550.2 Check oil level X
2550.3 Check for abnormal noise X
2550.4 Change the gear oil X
 %UDNH
3100.1 Cleaning from dust and debris X
3100.2 Check brake disc for wear X
3100.3 Check correct clearence of brake X
disc
 :KHHOV
3500.1 Remove strings, wrapping and X
debris
3500.2 Check drive wheel for wear and X
bolt torque
3500.3 Check castor wheeel free to X
rotate and swivel
3500.4 Dismount and grease fork wheel X
bearings

2 (8) Service Manual 1995-12-01 English

 F-code Section C-code
36 3
3UHYHQWLYHPDLQWHQDQFH
Version no T-code
 

,WHP :RUNUHTXLUHG
,QWHUYDOLQKRXUV       
,QWHUYDOLQ'D\V:HHNV0RQWKV G Z P P P P P
 7LOOHU$UP
4100.1 Check fastening X
4100.2 Check steering force X
4100.3 Check return of tiller arm to upper X
position
4100.4 Lubricate the steering ball bear- X
ing
 %DWWHU\
5110.1 Electrolyte level, 10–15 mm X
above cell plates
5110.2 All connections: battery, battery X
and charger plugs
5110.3 All cell and link covers intact X
5110.4 Check of battery specific gravity X
and battery temperature
 ,QVWUXPHQW3DQHO
5200.1 Check battery indicator and hour X
meter for correct operation
 (OHFWULFDO&RQWURO6\VWHP
5300.1 Check Ignition key switch opera- X
tional
5300.2 Check “brake micro switch” oper- X
ational
5300.3 Check the function of direction/ X
speed micro switches
5300.4 Check control wiring harness for X
wear
 (OHFWULFDO3DQHO
5400.1 Cleaning and fixation to chassis X
5400.2 Tightening of connections X

© BT Industries AB Service Manual 1995-12-01 English 3 (8)

F-code Section C-code
36 3
3UHYHQWLYHPDLQWHQDQFH
Version no T-code
 

,WHP :RUNUHTXLUHG
,QWHUYDOLQKRXUV       
,QWHUYDOLQ'D\V:HHNV0RQWKV G Z P P P P P
5400.3 Check contactor contacts, clean X
and unburnt
5400.4 Check contactor contacts for free X
movement
5400.5 Check all cable insulations for X
damage
 (OHFWURQLF&DUG
5710.1 Cleaning of electronic card, blow X
with air and whipe off
5710.2 Check for poor connections in X
cable connectors
5710.3 Check of LED indications X
 +\GUDXOLF6\VWHP
6000.1 Check hoses and connections for X
leakage
6000.2 Check hoses for wear and dam- X
age
6000.3 Check oil tank for cracks, leaks X
and mounting
6000.4 Check correct oil level X
6000.5 Change the hydraulic oil X
 /LIWLQJ0DVW
7100.1 Check for damage and crack for- X
mation
7100.2 Retighten tha mast mounting X
bolts
7100.3 Check the play of the inner sec- X
tion rollers
7100.4 Check the lateral play of the inner X
section

4 (8) Service Manual 1995-12-01 English

 F-code Section C-code
36 3
3UHYHQWLYHPDLQWHQDQFH
Version no T-code
 

,WHP :RUNUHTXLUHG
,QWHUYDOLQKRXUV       
,QWHUYDOLQ'D\V:HHNV0RQWKV G Z P P P P P
7100.5 Check for wear on the lifting X
chains and chain rollers
7100.6 Check the adjustment of the lift- X
ing chains
 /LIW&\OLQGHU
7310.1 Check for leakage X
7310.2 Check mounting X
 /LIWLQJ'HYLFH
7400.1 Check the play of the fork car- X
riage rollers
7400.2 Check the fork carriage for dam- X
age and crack formations
7400.3 Check the forks for wear and X
crack formations

© BT Industries AB Service Manual 1995-12-01 English 5 (8)

F-code Section C-code
36 3
3UHYHQWLYHPDLQWHQDQFH
Version no T-code
 

0840

0640 5300
7100

7310

4100
7400

0000

2550

3500
5200 5300

5710
6000

5110

5400 3100 1700

6 (8) Service Manual 1995-12-01 English

 F-code Section C-code
36 3
3UHYHQWLYHPDLQWHQDQFH
Version no T-code
 

/XEULFDWLRQFKDUW

3RVQR 6HUYLFHSRLQW ,QWHUYDO5XQQLQJKRXUV /XEULFDQW

K K K
1 Wheel bearings L A
2 Mast beam L F
3 Lifting chains L D
4 Hydraulic system C O B
5 Steering Bearings L G
6 Drive gear C O C

L= Lubrication C = Check O = Oil change

© BT Industries AB Service Manual 1995-12-01 English 7 (8)

F-code Section C-code
36 3
3UHYHQWLYHPDLQWHQDQFH
Version no T-code
 

8 (8) Service Manual 1995-12-01 English

 F-code Section C-code
36 3
3UHYHQWLYHPDLQWHQDQFH
IIssued by Approved by Version no T-code
66' .+DOOPDQ  

3UHYHQWLYHPDLQWHQDQFH
Valid from serial number:

7FRGH 0RGHO 6HULDO1R 1RWHV

353 PPS 1200MXS 270001AA-

0DLQWHQDQFHVFKHGXOH

,7(0 :25.5(48,5('
,QWHUYDOLQKRXUV       
,QWHUYDOLQ'D\V:HHNV0RQWKV G Z P P P P P
 &KDVVLV
0000.1 Check that the truck identification X
plate is legible
0000.2 Check the battery securing X
blocks for wear
0000.3 Check for damage and crack for- X
mation
0000.4 Retighten the truck body fasten- X
ing bolts (to the chassis)
0000.5 Check the cover lockings X
0000.6 Retighten the support arm clamp X
bolts
0000.7 Check the mounting of the sup- X
port arm safety catch
 2SHUDWRU&RQWUROV
0640.1 Check that the travel direction/ X
speed selector is not binding
0640.2 Check that the horn button is X
operational
0640.3 Check that the lift/lower button is X
operational

© BT Industries AB Service Manual 1995-12-01 English 1 (8)

F-code Section C-code
36 3
3UHYHQWLYHPDLQWHQDQFH
Version no T-code
 

,7(0 :25.5(48,5('
,QWHUYDOLQKRXUV       
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0840.1 Check that the red safety switch X
button is not binding
 'ULYH0RWRU
1700.1 Check for arcing due to poor con- X
nections
1700.2 All connections tight X
1700.3 Check of carbon brushes X
1700.4 Clean motor of dirt and dust X
1700.5 Check tightening of motor bolts X
1700.6 Check for abnormal noise in X
motor bearings
 'ULYH*HDU
2550.1 Check for oil leakage X
2550.2 Check oil level X
2550.3 Check for abnormal noise X
2550.4 Change the gear oil X
 %UDNH
3100.1 Cleaning from dust and debris X
3100.2 Check brake disc for wear X
3100.3 Check correct clearence of brake X
disc
 :KHHOV
3500.1 Remove all string, wrapping and X
debris
3500.2 Check drive wheel for wear and X
bolt torque
3500.3 Remove and grease fork wheel X
bearings

2 (8) Service Manual 1995-12-01 English

 F-code Section C-code
36 3
3UHYHQWLYHPDLQWHQDQFH
Version no T-code
 

,7(0 :25.5(48,5('
,QWHUYDOLQKRXUV       
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 7LOOHU$UP
4100.1 Check fastening X
4100.2 Check steering force X
4100.3 Check return of tiller arm to upper X
position
4100.4 Lubricate the steering ball bear- X
ing
 %DWWHU\
5110.1 Electrolyte level, 10 - 15 mm X
above cell plates when fully
charged
5110.2 All connections: battery, battery X
and charger plugs
5110.3 All cell and link covers intact X
5110.4 Check of battery specific gravity X
and battery temperature
 ,QVWUXPHQW3DQHO
5200.1 Check battery indicator and hour X
meter for correct operation
 (OHFWULFDO&RQWURO6\VWHP
5300.1 Check Ignition keyswitch is oper- X
ational
5300.2 Check ”brake micro switch” (S10) X
is operational
5300.3 Check the function of direction/ X
speed micro switches
5300.4 Check control wiring harness for X
wear
 (OHFWULFDO3DQHO
5400.1 Cleaning and fixation to chassis X
5400.2 Tightening of connections X

© BT Industries AB Service Manual 1995-12-01 English 3 (8)

F-code Section C-code
36 3
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Version no T-code
 

,7(0 :25.5(48,5('
,QWHUYDOLQKRXUV       
,QWHUYDOLQ'D\V:HHNV0RQWKV G Z P P P P P
5400.3 Check contactor contacts, clean X
and are not burnt
5400.4 Check contactor contacts for free X
movements
5400.5 Check all cable insulations for X
damage
 (OHFWURQLF&DUG
5710.1 Cleaning of electronic card, blow X
with air and whipe off
5710.2 Check for poor connections in X
cable connectors
5710.3 Check of LED indications X
 +\GUDXOLF6\VWHP
6000.1 Check hoses and connections for X
leakage
6000.2 Check hoses for wear and dam- X
age
6000.3 Check oil tank for cracks, leaks X
and mounting
6000.4 Check correct oil level X
6000.5 Change the hydraulic oil X
 /LIWLQJPDVW
7100.1 Check for damage and crack for- X
mation
7100.2 Retighten the mast mounting X
bolts
7100.3 Check the play of the innersec- X
tion rollers
7100.4 Check the lateral play of the inner X
section

4 (8) Service Manual 1995-12-01 English

 F-code Section C-code
36 3
3UHYHQWLYHPDLQWHQDQFH
Version no T-code
 

,7(0 :25.5(48,5('
,QWHUYDOLQKRXUV       
,QWHUYDOLQ'D\V:HHNV0RQWKV G Z P P P P P
7100.5 Check for wear on the lift chains X
and chain rollers
7100.6 Check the adjustment of the lift X
chains
 /LIW&\OLQGHU
7310.1 Check for leakage X
7310.2 Check mounting X
 /LIWLQJGHYLFH
7400.1 Check the play of the fork car- X
riage/yoke rollers
7400.2 Check the fork carriage/yoke for X
damage and crack formation
7400.3 Check the forks for wear and X
crack formation

© BT Industries AB Service Manual 1995-12-01 English 5 (8)

F-code Section C-code
36 3
3UHYHQWLYHPDLQWHQDQFH
Version no T-code
 

0840

0640 5300

7100

7310
4100

7400

0000

2550

3550 5300
5200

5710
6000
5110

5400 3100 1700

6 (8) Service Manual 1995-12-01 English
 F-code Section C-code
36 3
3UHYHQWLYHPDLQWHQDQFH
Version no T-code
 

/XEULFDWLRQFKDUW

3RV 6HUYLFHSRLQW ,QWHUYDO5XQQLQJKRXUV /XEUL

QR FDQW
K K K
1 Wheel bearings L A
2 Mast beam L F
3 Lifting chains L D
4 Hydraulic system C O B
5 Steering Bearings L G
6 Drive gear C O C

L= Lubrication C = Check O = Oil change

© BT Industries AB Service Manual 1995-12-01 English 7 (8)

F-code Section C-code
36 3
3UHYHQWLYHPDLQWHQDQFH
Version no T-code
 

8 (8) Service Manual 1995-12-01 English

 F-code Section C-code
36 3
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IIssued by Approved by Version no T-code
66' .+DOOPDQ  

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Valid from serial number:

7FRGH 0RGHO 6HULDO1R 1RWHV

351 PPS 1000MX 270001AA-
352 PPS 1200MX 270001AA-
353 PPS 1200MXS 270001AA-

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3360;DQG3360;6

/XEWLFDQW 6SHFLILFDWLRQ $SSOLFDWLRQDUHD

!ƒ& ƒ&
A Grease BT 26777 BT 26777 Bearings and bushings
(Spray) (Spray)
B Hydraulic oil ISO-L-HM32 ISO-L-HV32 Hydraulic system
C Transmission oil Hypoidolja Hypoidolja Gears
SAE 80W/90 SAE 75W
D Grease BT 26778 BT 26778 Chains and wires
(Spray) (Spray)
F Grease BT 055-70111 BT 055-74320 Side shift forks
G Grease Staburags Staburags Steering bearings
NBU 8EP NBU 8EP

© BT Industries AB Service Manual 1995-12-01 English 1 (2)

F-code Section C-code
36 3
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Version no T-code
 

2 (2) Service Manual 1995-12-01 English

 F-code Section C-code
36 6
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IIssued by Approved by Version no T-code
66'  

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6HUYLFHLQVWUXFWLRQV
&FRGH
S0 Chassis 0000
S1 Primary motor 1000
S2 Transmission/Drive gear 2000
S3 Brake/Wheel/Caterpillar system 3000
S4 Steering system 4000
S5 Electrical system 5000
S6 Hydraulic/pneumatic system 6000
S7 Working functions, lift mast/cylinders 7000
S8 Peripheral/installation equipment 8000
S9 Options, attatchments 9000

© BT Industries AB Service Manual 1998-11-04 English 1 (2)

F-code Section C-code
36 6
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Version no T-code


2 (2) Service Manual 1998-11-04 English

 F-code Section C-code
36 6 
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IIssued by Approved by Version no T-code
66' .+DOOPDQ  

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Valid from serial number:

7FRGH 0RGHO 6HULDO1R 1RWHV

353 PPS 1200MXS 270001AA-

*HQHUDO
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 900 mm to 1300 mm to suit different pallet sizes.
Normally the support arms are only adjusted prior to a truck
being delivered to a customer.

© BT Industries AB Service Manual 1995-12-01 English 1 (4)

F-code Section C-code
36 6 
6XSSRUWDUPFKDVVLV
Version no T-code
 

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4 5
3
6
2
10
7
1
9

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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

0DLQWHQDQFH
The fastening of the support arms needs to be checked at the
regular 500 hours preventive maintenance service. The
torque setting of the support arm clamp bolts (pos no. 7 in
chapter “Main components”) must be checked with a torque
wrench set at 120 Nm.

2 (4) Service Manual 1995-12-01 English

 F-code Section C-code
36 6 
6XSSRUWDUPFKDVVLV
Version no T-code
 

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ZLGWK

3
2
1

To adjust the measurement A between the support arms pro-

ceed as follows:
• Jack up the side of the truck.
:DUQLQJ
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WUXFNLVDWKUHHZKHHOHU
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• Loosen the bolt at the front of the cross beam.
• Loosen the clamp bolts,2.
• Pull out (or push in) the support arm. To get the measure-
ment A, measure B = A/2 - 305 mm. 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.
• Tighten the four clamp bolts, 2, with a torque wrench.
Torque value: 120 Nm.
© BT Industries AB Service Manual 1995-12-01 English 3 (4)
F-code Section C-code
36 6 
6XSSRUWDUPFKDVVLV
Version no T-code
 

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

2
1

• Loosen the clamp bolts, 2.

• Pull out the support arm.
• Fit the new support arm and adjust the arm width accord-
ing to chapter 4.
• Lower the truck to the floor.
• After tightened the clamp bolts, fit the safety catch.

• Remount the battery box.

• Fit the battery.

4 (4) Service Manual 1995-12-01 English

 F-code Section C-code
36 6 
'ULYHPRWRU
IIssued by Approved by Version no T-code
66' -DQ3HWWHUVVRQ  

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Valid from serial number:

7FRGH 0RGHO 6HULDOQXPEHU 1RWHV

204 PPH 1600 MX 270001AA-
349 PPS 1600 MXD 270001AA-
350 PPS 1200 MXF 270001AA-
351 PPS 1000 MX 270001AA-
352 PPS 1200 MX 270001AA-
353 PPS 1200 MXS 270001AA-

*HQHUDO
The driving motor, drive gearbox and brake are combined as a
complete drive unit.
The driving motor is a compound type direct current motor, i.e.
it is comprised of an stator winding connected in series with the
armature and a stator winding, called a shunt field, which is
connected in parallel with the armature.
The armature current is fed by four traditional type carbon
brushes which lie against the armature commutator.
The rotation direction of the motor is changed by changing the
armature current flow direction with relation to the stator wind-
ings.
In the illustration below, A1 and A2 are the armature connec-
tions, D1 and D2 are the series field connections and E1 and
E2 are the shunt field connections. The motor rotation direction
is changed by reversing armature connections A1 and A2.

( (

' ' $ $

( (

' ' $ $

© BT Industries AB Service Manual 1999-02-03 English 1 (12)

F-code Section C-code
36 6 
'ULYHPRWRU
Version no T-code
 

0HFKDQLFDOFRQVWUXFWLRQ
The motor is comprised of a yoke into which the stator wind-
ings are mounted. At each end of the yoke there is a bearing
end bracket in which the armature bearings are mounted.
A brush bridge assembly with four spring loaded carbon
brushes is mounted on the bearing box at the motor commu-
tator end. The carbon brushes sit against the armature com-
mutator and transfer the armature current to armature
windings.
Each of the motor windings is accessible via external connec-
tions.

11

15

03

02

10

26

25

09

24

02 Carbon brush 15 Ball Bearing

03 Brush bridge 24 Ball Bearing
09 Armature 25 Bearing shield
10 Yoke with stator 26 Sealing
11 Bearing shield

2 (12) Service Manual 1999-02-03 English

 F-code Section C-code
36 6 
'ULYHPRWRU
Version no T-code
 

6SHFLDOWRROV
7RRO
Torque wrench >30 Nm
Undercut cleaner 60°, R=0.2 mm, D=0.6 mm
Cradle for drive unit Part number: 08-12432

5HPRYDO5HILWWLQJ
5HPRYLQJWKHPRWRUIURPWKHWUXFN
• Open the motor compartment covers and remove the bat-
tery cable shoe.
• Remove the motor cables (armature winding, series field
winding and shunt field winding) and the tiller arm cable
from the electrical panel. Remove any cable ties.

• Remove the electrical panel and hydraulic assembly. The

hydraulic unit is placed next to the truck for the time being.

© BT Industries AB Service Manual 1999-02-03 English 3 (12)

F-code Section C-code
36 6 
'ULYHPRWRU
Version no T-code
 

• Remove the cover over the tiller arm. Disconnect the tiller
arm cable from the tiller arm and remove the tiller arm from
the bracket.

:$51,1*
3LQFKULVN
$OLIWHGWUXFNWKDWLVQRWVHFXUHGFDQRYHUWXUQ7KHWUXFN
PD\RQO\EHOLIWHGIURPWKHOLIWLQJH\HVLQWHQGHGIRUWKLVSXU
SRVHXVLQJDOLIWLQJGHYLFHWKDWLVXQGDPDJHGDQGGLPHQ
VLRQHGIRUWKHZHLJKWRIWKHWUXFN:RUNPXVWQRWEHFDUULHG
RXWXQGHUWKHWUXFNZKHQOLIWHG
• Lift the truck and place the drive wheel in the cradle (see
chapter ”Special tools”).
• Remove the motor attachment bracket from the chassis
(four bolts).
• Lift the truck straight up with the drive wheel resting in the
cradle. Check carefully that the drive unit does not follow
up with the truck or fall to the side.

The necessary service and repairs can now be carried out on

the motor.

5HDVVHPEOLQJ
• Lift the motor carefully down into the drive gearbox. The
four studs on the motor must fit into the corresponding
holes on the drive gearbox. In order for the motor to fit fully
into the drive gearbox upper surface, the drive gearbox
must sometimes be rotated by hand so that the motor shaft
gear engages with the drive gearbox gear. Care must be
taken that the motor O ring seal is not damaged.
• Tighten the nuts on the studs to the prescribed torque,
26.6 Nm.
• Replace the tiller arm bracket and brake unit. Adjust the
brake as per instructions.
• Replace the drive unit in the truck and re-connect the
motor cables. Check that the polarity is correct.
• After the completed re-assembly, the brake function must
be tested before the truck is moved.

4 (12) Service Manual 1999-02-03 English

 F-code Section C-code
36 6 
'ULYHPRWRU
Version no T-code
 

6HUYLFH5HSDLUV
&OHDQLQJ
For correct functioning, it is important that the motor is kept as
clean as possible. The motor and motor compartment must
be regularly checked for dust, oil and other contamination.
If the motor windings and interior are dry, use a vacuum
cleaner with suitable mouthpiece to clean the motor. Com-
pressed air can be used in combination with a vacuum
cleaner. In this case the compressed air must be clean and
dry.
If the windings have a coating, use a lint-free cloth, damped if
necessary with an organic and volatile cleaning agent that
can dissolve grease and which will not damage the windings.
The cleaning agent must not be used in such quantity that it
can enter the motor.
Remains of cleaning agent must be removed with a suitable
solvent if an oily surface is left.
If the motor parts are badly dirtied it can be necessary to
spray them with a solvent. It is especially important for the
armature that the solvent is applied in such a way that dis-
solved dirt does not enter into the motor section.
One method of cleaning the armature is to dip it in solvent. If
this is done the armature must always be heat dried. Good
ventilation is necessary during drying which must continue
until a number of insulation measurements give similar and
approved results.

© BT Industries AB Service Manual 1999-02-03 English 5 (12)

F-code Section C-code
36 6 
'ULYHPRWRU
Version no T-code
 

'LVPDQWOLQJ
11

15

03

02

10

26

25

09

24

• Remove the brake unit from the motor commutator end.

• Remove the tiller arm bracket from the motor by removing
the four bracket bolts.
• Remove the four nuts for motor attachment to the drive
gearbox and lift the motor carefully straight up, without
damaging the sealing surfaces to the drive gearbox.
• Protect the drive gearbox from contamination by placing a
suitable cover over the opening, for example, a piece of
plastic.
• Remove the four plugs that cover the carbon brushes, lift
the springs to one side and lift up the carbon brushes.

6 (12) Service Manual 1999-02-03 English

 F-code Section C-code
36 6 
'ULYHPRWRU
Version no T-code
 

• Remove the brake disk collar by first removing the circlip

and washer at the end of the armature shaft. The collar
can then be lifted off. It may need to be drawn off with a
suitable tool.
• Dismantle the bearing bracket (11) at the commutator end
together with the brush holder (03) and carbon brushes
(02) by removing the six hexagon socket bolts. Next, lay
the motor with a fixed stop against the edge of the bearing
shield. Strike the end of the armature shaft carefully with a
rubber mallet.
• Remove the bearing shield (25) on the drive end together
with the armature (09). Be careful not to damage the motor
windings when the armature is removed from the motor
yoke.
• Remove the gear wheel on the armature drive end. This is
done by removing the gear wheel nut and then pulling the
gear wheel off with a puller. Note that the gear wheel is
locked with Loctite onto the armature shaft.
• Next remove the inner circlip and washer under it. Pull the
armature shaft out of the bearing (24).
• Remove the outer circlip and washer and remove the bear-
ing from the bearing shield.
• Remove the bearing shield seal (26) and clean the bearing
shield carefully.
• Install a new seal in the bearing bracket.

5HDVVHPEOLQJ
• Reassembling of the motor is carried out in the reverse
order to dismantling. Check carefully that the armature can
move freely in the rotation direction and that the carbon
brushes are lying against the commutator.
• Check the insulation resistance of the motor (between
respective windings and the motor yoke). For a new motor
this must be between 2 and 3 Mohm. A used motor has
been subjected to contamination and in this case a resist-
ance of down to approx. 1 Mohm can be acceptable.
• Install a new O ring in the drive shaft end bearing shield
and a new seal in the bearing shield collar.

© BT Industries AB Service Manual 1999-02-03 English 7 (12)

F-code Section C-code
36 6 
'ULYHPRWRU
Version no T-code
 

$UPDWXUHEHDULQJV
The armature bearings are comprised of a permanently lubri-
cated and double sealed bearing type 6204-2Z/C3 in the
armature commutator end and a single sealed type 6205/2Z-
C3 bearing in the armature drive end.
The grease used in both bearings is high temperature type
HT24.
The bearing open spaces are partially filled with Texaco SRi2
grease from the factory to protect the inside of the bearing
against the penetration of dust and contamination.
The life of the bearing is between 5 000 and 20 000 hours,
depending upon the speeds and other stresses it has been
subjected to.
During heavy loading the bearing temperature can rise to
180°. An abnormal temperature increase, or excessive noise,
indicates insufficient lubrication or bearing wear.

&KDQJLQJWKHGULYHHQGEHDULQJ
Clean the new bearing and fill to max. 50% with grease, type
HT24. Install the bearing in the bearing shield with the
unsealed side in toward the shield. Put the washer between
the circlip and bearing in place and lock the bearing with the
outer circlip.
Install the armature in the bearing shield and lock it in place
with the washer and circlip.
Remove all grease and other contamination from the arma-
ture shaft gear wheel taper. The same applies for the gear
wheel inner surface.
Apply a film of Loctite 603 onto the armature shaft taperand
install the gear wheel onto the shaft. Put the washer in place,
apply a film of Loctite 243 onto the shaft threads and screw
on the nut. The nut must be tightened to the prescribed
torque, 30 Nm, and then locked with a centre punch.
Care must be taken not to damage the field and armature
windings during refitting of the armature and bearing shield.

&KDQJLQJWKHFRPPXWDWRUHQGEHDULQJ
After the commutator end bearing shield has been removed,
the bearings can be removed from the armature shaft with a
suitable extractor.
The new bearing is installed onto the armature shaft with the
aid of a brass drift.

8 (12) Service Manual 1999-02-03 English

 F-code Section C-code
36 6 
'ULYHPRWRU
Version no T-code
 

&DUERQEUXVKHVDQGEUXVKKROGHU
The following checks must be carried out during the service
and repair of the motor:
• The brush bridge and brush holder must be firmly
attached.
• The carbon brushes must move freely in their holders.
• The brush holders must be free from contamination.
• Worn brushes must be replaced. The minimum permissible
length for the carbon brushes is 11 mm.
The carbon brushes are normally supplied with a preformed
radius that corresponds to the commutator radius.

&KDQJLQJFDUERQEUXVKHV
Carbon brushes can be replaced without the drive unit need-
ing to be removed from the truck.
To change the four carbon brushes, the plastic plugs that
cover the brushes in the motor yoke must be removed. Then
remove the screw that holds the cable for the brush in ques-
tion. When the cable has been disconnected, lift the spring to
one side so that the carbon brush can be withdrawn from the
holder.
Refitting is carried out by installing a new carbon brush into
the holder, lifting back the spring and then reconnecting the
carbon brush connection cable.
After fitting, check carefully that the carbon brush can move
freely in the holder and that it is lying correctly against the
commutator.

&RPPXWDWRU
The commutator should normally have an even colour over
the whole surface. The appearance of the commutator can,
however, vary quite considerably, depending on how it has
been used. If the commutator shows burn marks or uneven
black coloured areas, it must be cleaned with fine glass
paper. Emery cloth must never be used.

0DFKLQLQJWKHFRPPXWDWRU
If it should become necessary to machine the commutator on
a lathe, this must be done accurately and carefully.
To achieve an acceptable result the cutting speed must be at
least 200 m/min if a hard metal tool is used. If a diamond cut-
ting tool is used, which will produce the best results, the cut-
ting speed must be considerably higher.
© BT Industries AB Service Manual 1999-02-03 English 9 (12)
F-code Section C-code
36 6 
'ULYHPRWRU
Version no T-code
 

The feed should be between 0.08–0.1 mm and cutting depth

not more than 0.05 mm.
After machining, the commutator eccentricity must not exceed
0.02 mm and surface unevenness must be less than 4 µm.
An eccentricity of max. 0.04 mm can be accepted during use.
The commutator design allows for machining a number of
times. The diameter, however, may not be less than 60 mm.
It is normal for machining to be carried out for each third car-
bon brush replacement.
After each machining, the Micanite between the segments
must be undercut down to a depth of 0.6 mm with a special
tool. Micanite remains must not be left on the sides of the
segments. After machining and undercutting of the Micanite,
the segment edges must be chamfered. When this work has
been completed, the space between the segments and the
segment sides must be as shown in the illustration below.
PP

5 ƒ

6WRUDJH7UDQVSRUW
If a motor is to be stored for a longer period, for example,
more than a month, it must be packed so that it will not be
damaged during storage.
The motor components that can be damaged if the motor is
not stored correctly are the carbon brushes, commutator and
bearings. The motor can be damaged by:
• Dust and other contamination.
• Moisture and condensation if the motor is stored in a loca-
tion with large temperature variations.
• Rust, especially if the motor is stored in a location with cor-
rosive gases.
• Mechanical influences such as vibration.

10 (12) Service Manual 1999-02-03 English

 F-code Section C-code
36 6 
'ULYHPRWRU
Version no T-code
 

6WRUDJH
The following actions are recommended for storage:
• Lift all four carbon brushes.
• Wrap the armature in paper or other protective material.
• Store the motor as an assembled unit.
• Wrap the motor in dust and moisture protective material.
• Avoid placing the motor where it can be subjected to vibra-
tion.
The motor must be stored in a room with even temperature.
Condensation in the windings can be avoided by keeping the
winding temperature a few degrees higher than the surround-
ing temperature.
Oxidation, especially on the commutator, can appear even
under normal storage conditions. These problems are wors-
ened if the air contains corrosive gases. These problems are
especially prevalent if sulphur dioxide (SO2), chlorine (Cl2)
and ammoniac (NH3) exists.
Vibration causes damage to the motor bearings. This can be
avoided if the armature is rotated a few turns each month.
Check that the motor shaft ends and other clean metal sur-
faces are covered with a film of rust protecting oil.

© BT Industries AB Service Manual 1999-02-03 English 11 (12)

F-code Section C-code
36 6 
'ULYHPRWRU
Version no T-code
 

'DWD
7RUTXH 1P
Nut for drive end gear wheel 30 + locking with centre
punch
Nuts for motor attachment to 26,6
drive gearbox

*UHDVHVSHFLILFDWLRQ
Armature bearings HT24

&RPSRQHQW ,WHP 0LQ 0D[ 8QLW

Insulation resist- New motor 2 Mohm
ance
Insulation resist- Used motor 1 Mohm
ance
Carbon brushes Length 11 mm
Commutator Diameter 60 mm
Machining the Cutting 200 m/min
commutator speed, hard
metal cut-
ting tool
Machining the Cutting >200 m/min
commutator speed, dia-
mond cut-
ting tool
Machining the Cutting 0,05 mm
commutator depth
Machining the Feed 0,08 0,1 mm
commutator
Commutator Eccentricity 0,02 mm
Commutator Surface une- 4 µm
venness
Commutator seg- Height differ- 0,02 mm
ment ence

12 (12) Service Manual 1999-02-03 English

 F-code Section C-code
36 6 
'ULYLQJJHDU
IIssued by Approved by Version no T-code
66' .+DOOPDQ  

'ULYLQJJHDU
Valid from serial number:

7FRGH 0RGHO 6HULDO1R 1RWHV

204 PPH 1600MX 270001AA-
349 PPS 1600MXD 270001AA-
350 PPS 1200MXF 270001AA-
351 PPS 1000MX 270001AA-
352 PPS 1200MX 270001AA-
353 PPS 1200MXS 270001AA-

*HQHUDOWHFKQLFDOGHVFULSWLRQ

© BT Industries AB Service Manual 1999-01-19 English 1 (12)

F-code Section C-code
36 6 
'ULYLQJJHDU
Version no T-code
 

7HFKQLFDOGDWD
'DWD 'HVFULSWLRQ
Type 2-step angular
Upper gear wheels Cylindrical with helical gear
Lower gear wheels Angle gear 90 degrees
Gear ratio, overall PPS, 19.14:1
PPH
Gear ratio, upper gear PPS, 4:1
PPH
Gear ratio, lower gear 4.86:1
Oil volume 1.0 litre
Oil type, normal temperature Hypoid oil SAE 80W/90
Oil type, < -15oC Hypoid oil SAE 75
Oil change First time: 250 hours
Regular change: 3000 hours

2 (12) Service Manual 1999-01-19 English

 F-code Section C-code
36 6 
'ULYLQJJHDU
Version no T-code
 

*HDUFRPSRQHQWV

3
4
5

A
12
11

10 6

9 7
8

3RV1R &RPSRQHQW
1 Primary gear wheels
2 Upper pinion bearing L2
3 Bearing shim S2
4 Bearing shim S1
5 Lower pinion bearing L1
6 Set of pinion and crown wheel
7 Inner drive shaft bearing L3
8 Bearing shim S3
9 Outer drive shaft bearing L4
10 Bearing shim S4

© BT Industries AB Service Manual 1999-01-19 English 3 (12)

F-code Section C-code
36 6 
'ULYLQJJHDU
Version no T-code
 

3RV1R &RPSRQHQW
11 Drive shaft
12 Drive shaft seal
A Built-in measure, pinion height 65 mm

6SHFLDOWRROV

3RV1R 7RRO
1 Bearing withdrawer: part no = 08-13022
2 Dial indicator with magnetic bracket
3 Thickness 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

4 (12) Service Manual 1999-01-19 English

 F-code Section C-code
36 6 
'ULYLQJJHDU
Version no T-code
 

5HPRYLQJWKHJHDUIURPWKHWUXFN
• Lift the machine so the bolts for the driving gear are easily
accessible from beneath. The truck can also be laid on the
side after removal of the battery and sealing off the hydrau-
lic system.
• Remove the drive wheel (17 mm spanner).

• Drain the gear oil by removing the lower gear cover (6 mm

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

• Take the driving gear out of the machine.

• Reassemblying the driving gear into the truck is made in

the reversed order.

© BT Industries AB Service Manual 1999-01-19 English 5 (12)

F-code Section C-code
36 6 
'ULYLQJJHDU
Version no T-code
 

&KDQJHRIVHDORQWKHGULYHVKDIW
• Remove the gear from the truck as shown in chapter
”Removing the gear from the truck”.
• 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 spanner).

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

• Remove the crown wheel and bearing L3.

• Remove the old seal ring and re-fit with a new part.

6 (12) Service Manual 1999-01-19 English

 F-code Section C-code
36 6 
'ULYLQJJHDU
Version no T-code
 

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

• Put the crown wheel onto the splines of the drive shaft and
fit a QHZ 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 QHZ 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).

© BT Industries AB Service Manual 1999-01-19 English 7 (12)

F-code Section C-code
36 6 
'ULYLQJJHDU
Version no T-code
 

5HFRQGLWLRQLQJRIWKHJHDU
• Remove the gear from the truck as shown in chapter
”Removing the gear from the truck”.
• 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.

• Remove the old seal ring.

• 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.

8 (12) Service Manual 1999-01-19 English

 F-code Section C-code
36 6 
'ULYLQJJHDU
Version no T-code
 

• 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 with-

drawer, 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.
• Clean the covers, gear housing and drive shaft with a suit-
able 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.

© BT Industries AB Service Manual 1999-01-19 English 9 (12)

F-code Section C-code
36 6 
'ULYLQJJHDU
Version no T-code
 

• 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 so 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, measur-
ing gauge length 59 mm + the radius of the pin 5 mm +
1 mm shim or feeler gauge thickness. The GLIIHUHQFH from
65 mm gives you the thickness of shim S1.

• Fit the measured shim thickness under bearing L1.

10 (12) Service Manual 1999-01-19 English

 F-code Section C-code
36 6 
'ULYLQJJHDU
Version no T-code
 

• 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 crown wheel in three
different positions. Carefully point the dial indicator
90 degrees to the gear tooth surface.

• Shim (S3) bearing L3 so that a IODQNFOHDUHQFH 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.

• Check the gear tooth impression with engineer’s blue.
Adjust shim S1 when needed. After adjusting S1, S2 will
need to be set. S2 needs to be reduced if S1 thickness is
increased. But if the thickness of S1 is reduced, then S2 is
increased. Check the axial play on the pinion.

© BT Industries AB Service Manual 1999-01-19 English 11 (12)

F-code Section C-code
36 6 
'ULYLQJJHDU
Version no T-code
 

• 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 QHZ 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 cor-
rectly 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.

• Put the crown wheel onto the splines of the drive shaft and
fit a QHZ 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 groove 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).

12 (12) Service Manual 1999-01-19 English

 F-code Section C-code
36 6 
0HFKDQLFDOEUDNHV
IIssued by Approved by Version no T-code
66' /*$QGHUVVRQ  

0HFKDQLFDOEUDNHV
Valid from serial number:

7FRGH 0RGHO 6HULDOQXPEHU 1RWHV

204 PPH 1600 MX 270001AA-
349 PPS 1600 MXD 270001AA-
350 PPS 1200 MXF 270001AA-
351 PPS 1000 MX 270001AA-
352 PPS 1200 MX 270001AA-
353 PPS 1200 MXS 270001AA-

*HQHUDO
The brake is a mechanical spring-loaded brake. The brake
construction is as shown in the component list below.





3RVLWLRQ 'HVFULSWLRQ
1 Brake disk
2 Adjustment screws for braking force
3 Collar
4 Adjustment screws for clearance in off position
5 Pressure plate

© BT Industries AB Service Manual 1999-02-03 English 1 (4)

F-code Section C-code
36 6 
0HFKDQLFDOEUDNHV
Version no T-code
 

)XQFWLRQ
The mechanical brake provides both the driving and parking
brakes for the truck.

5HOHDVLQJWKHEUDNHV
The brakes are released when the tiller arm is in the driving
position.

%UDNLQJ
The truck is braked when the tiller arm is moved into one of
the two braking positions.

2 (4) Service Manual 1999-02-03 English

 F-code Section C-code
36 6 
0HFKDQLFDOEUDNHV
Version no T-code
 

0DLQWHQDQFH
The brakes require virtually no maintenance in normal work-
ing environments. It is, however, recommended that regular
cleaning, inspection of wear in brake disk and pressure plate
plus the clearance between these is carried out in accord-
ance with the schedule for preventative maintenance. Check
also the brake force adjustment.

16 mm
1 mm

3RVLWLRQ $GMXVWPHQWPHDVXUHPHQW
1 Clearance in un-braked position
2 Adjustment of brake force. Clearance in
braked position

© BT Industries AB Service Manual 1999-02-03 English 3 (4)

F-code Section C-code
36 6 
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Version no T-code
 

4 (4) Service Manual 1999-02-03 English

 F-code Section C-code
36 6 
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IIssued by Approved by Version no T-code
66' .+DOOPDQ  

(OHFWULFDOV\VWHP
7UDQVLVWRU&RQWURO
Valid from serial number:

7FRGH 0RGHO 6HULDO1R 1RWHV

204 PPH 1600MX 270001AA-

(OHFWULFDOSDQHOFRPSRQHQWV

© BT Industries AB Service Manual 1994-12-20 English 1 (16)

F-code Section C-code
36 6 
(OHFWULFDOV\VWHP
Version no T-code
 

/LVWRIV\PEROVDQGHOHFWULFDOGLD
JUDPV
/LVWRIV\PEROV

6\PERO 'HVFULSWLRQ )XQFWLRQ 5HPDUN

A1 Transistor controller
A2 Electronic card

BT Battery

F10 Fuse Motor circuit 100 A

F50 Fuse Control circuit 7,5 A

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 5 - 0 kOhm

RE1 Relay Valve closing delay Support arm valve
RV1 Potentiometer Speed reduction

S10 Switch ”Brake”

S15 Switch Drive direction Fork direction

2 (16) Service Manual 1994-12-20 English

 F-code Section C-code
36 6 
(OHFWULFDOV\VWHP
Version no T-code
 

6\PERO 'HVFULSWLRQ )XQFWLRQ 5HPDUN

S16 Switch Drive direction Steer wheel direction
S17 Switch Key
S18 Switch Horn
S20 Switch Safety
S34 Switch Fork lift
S40 Switch Support arm lower
S41 Switch Fork lower
S52 Switch Support arm lift

Y34 Magnetic valve Forks

Y41 Magnetic valve Lowering
Y52 Magnetic valve Support arm

© BT Industries AB Service Manual 1994-12-20 English 3 (16)

F-code Section C-code
36 6 
(OHFWULFDOV\VWHP
Version no T-code
 

(OHFWULFDOGLDJUDP

4 (16) Service Manual 1994-12-20 English

 F-code Section C-code
36 6 
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Version no T-code
 

(OHFWULFDOGLDJUDP

© BT Industries AB Service Manual 1994-12-20 English 5 (16)

F-code Section C-code
36 6 
(OHFWULFDOV\VWHP
Version no T-code
 

(OHFWULFDOGLDJUDP

6 (16) Service Manual 1994-12-20 English

 F-code Section C-code
36 6 
(OHFWULFDOV\VWHP
Version no T-code
 

'HVFULSWLRQRIIXQFWLRQ
*HQHUDO
The Transistor controller A1 regulates the speed step less up
to maximum speed. When starting the truck, does the control-
ler check the closing sequency of the micro switches in the
circuit. The controller is equipped with a lightdiode (LED)
showing system status and potentiometers for adjusting the
current limit and acceleration, placed under a sliding cover.
The electrical system have a electronic card A2 to group all
connections of the control circuits for input respectively output
signals to the transistor controller. The electronic card is
equipped with LED’s for indication of incomming or outgoing
signals and a potentiometer for adjustment of the maximum
speed.

$GMXVWDEOHVHWWLQJV
6HWWLQJ 6WGYDOXH 0LQYDOXH 0D[YDOXH
Current limit 150A 100A 150A
Acceleration 0.8 s 0.1 s 3s
Maximum speed, 5.8 km/h 3.0 km/h 5.8 km/h
without load 1.61 m/s 0.83 m/s 1.61 m/s

5HIHUHQFHV
For more information about: adjustment of the speed potenti-
ometer, the transistor controller and the connection card, see
C-code 5330, 5460 resp. 5710.

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

© BT Industries AB Service Manual 1994-12-20 English 7 (16)

F-code Section C-code
36 6 
(OHFWULFDOV\VWHP
Version no T-code
 

,JQLWLRQORFN6LQWKH21SRVLWLRQ

When S17 closes, the transistor controller A1 will check that

S10 is not closed. If this is the case, operation is not permit-
ted.
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.

7KHWLOOHUDUPLQGULYHSRVLWLRQ6

When the opersting arm is pushed down to the driving posi-

tion, 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 A1 now regulates the current through
the shunt field, 1,2 A, (-) return via terminal 302, 417 and
A1.1.

8 (16) Service Manual 1994-12-20 English

 F-code Section C-code
36 6 
(OHFWULFDOV\VWHP
Version no T-code
 

'ULYLQJIRUNGLUHFWLRQ

When the butterfly is activated for driving in the fork direction,

S15 will close. The transistor controller checks that S10 is
closed before S15 closes, if not driving is not permitted.
Battery voltage obtained via terminal 101 and 411 to A1.11,
LED 101 lights up.
Battery voltage to K11 via terminal 403. A1.2 now gives (-)
return to K11, (-)input on terminal 401, LED 401 lights up.
Depending on the position of the speed control R1 and
adjustment of potentiometer RV1 will A1.8 obtaine 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 nega-
tive via A1.

© BT Industries AB Service Manual 1994-12-20 English 9 (16)

F-code Section C-code
36 6 
(OHFWULFDOV\VWHP
Version no T-code
 

'ULYLQJVWHHUZKHHOGLUHFWLRQ

When the butterfly is activated for driving in the fork direction,

S16 will close. The transistor controller checks that S10 is
closed before S16 closes, if not driving is not permitted.
Battery voltage obtained via terminal 102 and 412 to A1.12,
LED 102 lights up. Battery voltage to K13 via terminal 403.
A1.3 now gives (-) return to K13, (-)input on terminal 402,
LED 402 lights up.
Depending on the position of the speed control R1 and
adjustment of potentiometer RV1 will A1.8 obtaine 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 nega-
tive via A1.

5HYHUVLQJPRWRUEUDNHIRUNGLUHFWLRQ
WRVWHHUZKHHOGLUHFWLRQ
S15 returns to neutral position while S16 closes. The current
in the series fiels causes the motor to work as a generator
since the drive wheel rotates in the ”wrong direction”.
The transistor controller A1 detects the generated current at
connection A2, and reduces the series field current to 60 A.
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 accel-
eration.
During braking sequence, the armature current passes in the
circuit A1–A2, K13, A2, the brake diode of the transistor con-
troller, M- and K13.

10 (16) Service Manual 1994-12-20 English

 F-code Section C-code
36 6 
(OHFWULFDOV\VWHP
Version no T-code
 

5HYHUVLQJPRWRUEUDNHVWHHUZKHHO
GLUHFWLRQWRIRUNGLUHFWLRQ
S16 returns to neutral position while S15 closes. The current
in the series fiels causes the motor to work as a generator
since the drive wheel rotates in the ”wrong direction”.
The transistor controller A1 detects the generated current at
connection A2, and reduces the series field current to 60 A.
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 accel-
eration.
During braking sequence, the armature current passes in the
circuit A2–A1, K11, A2, the brake diode of the transistor con-
troller, M- and K11.

© BT Industries AB Service Manual 1994-12-20 English 11 (16)

F-code Section C-code
36 6 
(OHFWULFDOV\VWHP
Version no T-code
 

6DIHW\UHYHUVLQJ

Possible breakages in the wiring for the safety reversing is

continously checked by the transistor controller, who sends a
small pulsed current through the circuit 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 will A1 provide (-) at A1.3 to K11,
LED 401 lights up.
The motor will now be connected for motor braking at maxi-
mum current limit 150 A, and subsequently accelerate in the
fork direction until S20 returns to its neutral position.
When S20 returns to neutral position, (+) disappears from ter-
minal 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 still is activated, the
transistor controller must be returned to the inactive position
by letting the speed control return to the neutral position, after
which a new direction of travel can be chosen.

12 (16) Service Manual 1994-12-20 English

 F-code Section C-code
36 6 
(OHFWULFDOV\VWHP
Version no T-code
 

/LIWQLQJWKHVXSSRUWDUPV

The micro switch S52 closes. K30 receives (+)voltage via ter-
minal 105, 210, the lift limit switch S31, terminal 211, 203,
battery controller or the jumper, terminal 201 and 405. The
magnetic valve Y52 opens, receiving (+)voltage from terminal
211 via diode and terminal 204. LED 105, 211, 203, 204 and
405 lights up. (-)return via wire 40. K30 closes and the pump
motor M3 starts.
When S52 closes (+)voltage is supplied to RE1 which closes,
(+)voltage feed to Y52 from terminal 204 and RE1. When the
lift button is released and S52 opens, RE1 stays closed a
short time (delay), keeping Y52 open while the speed of M3
reduces after the opening of K30.

© BT Industries AB Service Manual 1994-12-20 English 13 (16)

F-code Section C-code
36 6 
(OHFWULFDOV\VWHP
Version no T-code
 

'ULYLQJDQGVLPXOWDQHRXVO\OLIWLQJWKH
VXSSRUWDUPV

A1 detects the activation of K30, (+) at terminal 404 and

A1.14. A1 then reduces the speed to 70% and the motor cur-
rent to 100 A.

/RZHULQJWKHVXSSRUWDUPV

When lowering the forks S40 is activated. The magnetic

valves, Y41and Y52, receives (+)voltage via terminal 106 and
204(Y52), terminal 106, diode and terminal 209 (Y41), LED
106, 204 and 209 lights up. (-)return via wire 40.

14 (16) Service Manual 1994-12-20 English

 F-code Section C-code
36 6 
(OHFWULFDOV\VWHP
Version no T-code
 

/LIWLQJWKHIRUNV

The micro switch S34 closes. K30 receives (+)voltage via ter-
minal 112, 203, battery controller or the jumper, terminal 201
and 405. The magnetic valve Y34 opens, receiving (+)voltage
from terminal 106 and 204. LED 112, 203, 208 and 405 lights
up. (-)return via wire 40. K30 closes and the pump motor M3
starts.

'ULYLQJDQGVLPXOWDQHRXVO\OLIWLQJWKH
IRUNV

A1 detects the activation of K30, (+) at terminal 404 and

A1.14. A1 then reduces the speed to 70% and the motor cur-
rent to 100 A.

© BT Industries AB Service Manual 1994-12-20 English 15 (16)

F-code Section C-code
36 6 
(OHFWULFDOV\VWHP
Version no T-code
 

/RZHULQJWKHIRUNV

When lowering the forks S41 is activated. The magnetic

valves, Y41and Y34, receives (+)voltage via terminal 113 and
209 (Y41), terminal 113, diode and terminal 208 (Y34), LED
112, 208 and 209 lights up. (-)return via wire 40.

+RUQ

Micro switch S18 is activated. The horn H1 receives (+)volt-

age via terminal 107 and 406, LED 107 lights up. (-)return via
wire 40.

16 (16) Service Manual 1994-12-20 English

 F-code Section C-code
36 6 
(OHFWULFDOV\VWHP
IIssued by Approved by Version no T-code
66' /*$QGHUVVRQ  

(OHFWULFDOV\VWHP
7UDQVLVWRUUHJXODWHG
Valid from serial number:

7FRGH 0RGHO 6HULDOQXPEHU 1RWHV

349 PPS 1600 MXD 296773AA-
350 PPS 1200 MXF 296773AA-

(OHFWULFDOSDQHOFRPSRQHQWV
RV1

F50
A5

F1
K11

K13

K30

F3
A1

H1

© BT Industries AB Service Manual 1998-01-09 English 1 (16)

F-code Section C-code
36 6 
(OHFWULFDOV\VWHP
Version no T-code
 

/LVWRIV\PEROVDQGHOHFWULFDOGLD
JUDPV
/LVWRIV\PEROV
6\PERO 'HVFULSWLRQ )XQFWLRQ 1RWHV
A1 Transistor regulator
A5 Electronic card

F1 Fuse Drive motor circuit 100 A

F3 Fuse Pump motor circuit 160 A
F50 Fuse Control circuit 7.5 A
F51 Fuse Extra equipment Option

G1 Battery

H1 Horn

K11 Contactor Travel direction Direction of forks

K13 Contactor Travel direction Direction of steer
wheel
K30 Contactor Pump motor

M1 Motor Drive system

M3 Motor Pump

P3 Instrument Battery indicator/running

meter

R1 Potentiometer Speed 5 – 0 kOhm

RV1 Potentiometer Speed reduction

2 (16) Service Manual 1998-01-09 English

 F-code Section C-code
36 6 
(OHFWULFDOV\VWHP
Version no T-code
 

6\PERO 'HVFULSWLRQ )XQFWLRQ 1RWHV

S10 Switch “Brakes”
S15 Switch Travel direction Direction of forks
S16 Switch Travel direction Direction of steer
wheel
S17 Switch Ignition
S18 Switch Horn
S20 Switch Safety
S32 Switch Lifting limit MXF only
S33 Switch Lifting limit forks < 1600 MXF only
S34 Switch Lifting forks
S40 Switch Support arm, lowering
S41 Switch Lowering forks For electronic lower-
ing (option). Always
connected
S42 Switch Lowering forks Manual lowering
S52 Switch Support arm, lifting
S90 Switch Lifting limit, support arm MXF only

Y34 Solenoid valve Forks

Y41 Solenoid valve Lowering forks With electronic lower-
ing (option)
Y52 Solenoid valve Support arms

© BT Industries AB Service Manual 1998-01-09 English 3 (16)

F-code Section C-code
36 6 
(OHFWULFDOV\VWHP
Version no T-code
 

(OHFWULFDOGLDJUDP

4 (16) Service Manual 1998-01-09 English

 F-code Section C-code
36 6 
(OHFWULFDOV\VWHP
Version no T-code
 

(OHFWULFDOGLDJUDP

© BT Industries AB Service Manual 1998-01-09 English 5 (16)

F-code Section C-code
36 6 
(OHFWULFDOV\VWHP
Version no T-code
 

(OHFWULFDOGLDJUDP

6 (16) Service Manual 1998-01-09 English

 F-code Section C-code
36 6 
(OHFWULFDOV\VWHP
Version no T-code
 

(OHFWULFDOGLDJUDP

© BT Industries AB Service Manual 1998-01-09 English 7 (16)

F-code Section C-code
36 6 
(OHFWULFDOV\VWHP
Version no T-code
 

(OHFWULFDOGLDJUDP

8 (16) Service Manual 1998-01-09 English

 F-code Section C-code
36 6 
(OHFWULFDOV\VWHP
Version no T-code
 

(OHFWULFDOGLDJUDP

© BT Industries AB Service Manual 1998-01-09 English 9 (16)

F-code Section C-code
36 6 
(OHFWULFDOV\VWHP
Version no T-code
 

2SHUDWLQJGHVFULSWLRQ
*HQHUDO
The transistor regulator A1 regulates the speed variably up to
maximum speed. When the truck is started the regulator
checks the closing sequence for the microswitches in the cir-
cuit. The regulator is equipped with a LED that displays the
system status.
The electrical system has a electronic card A5 to group all the
connections to the control card for input and output signals to
the transistor regulator. The electronic card is equipped with
LEDs to indicate incoming and outgoing signals and a poten-
tiometer to adjust the maximum speed.
5HIHUHQFHV
For further information on the transistor regulator and elec-
tronic card, see C-code 5330, 5460 and 5710.

'HVFULSWLRQ
The description is divided into different phases that corre-
spond to the operating sequence stages.

10 (16) Service Manual 1998-01-09 English

 F-code Section C-code
36 6 
(OHFWULFDOV\VWHP
Version no T-code
 

,JQLWLRQVZLWFK6LQ21SRVLWLRQ
When S17 makes, the transistor regulator checks that S10 is
not made. If this is the case, driving is not permitted.
The battery voltage on A5 connection pin 202, LED 202
comes on. A5 (-) return connection pin 207. Battery voltage to
A1.16 via A5-connection pin 410, LED-status starts to flash.

7LOOHUDUPLQGULYLQJSRVLWLRQ6
When the tiller arm is pushed down to the driving position,
S10 makes and at the same time the mechanical brake is
released. The voltage goes, via connection pins 109 and 408
to A1.15; LED 109 lights, on to running meter’s connection
pin 206 and the shunt field’s connection pin 301.
The transistor regulator now regulates the current through the
shunt field. 1.2 A. (-) return via the connection pins 302, 417
and A1.1.

'ULYLQJGLUHFWLRQRIWKHIRUNV
When the throttle is activated for driving in the direction of the
forks, S15 is made. Battery voltage is supplied via connection
pins 101 and 411 to A1.11, LED 101 comes on. Battery volt-
age to K11 via connection pin 403. A1.2 now gives (-) return
to K11, (-) input on connection pin 401; LED 401 is on.
Depending on the throttle’s R1’s position and the adjustment
of potentiometer RV1, A1.8 will receive a voltage between
4.8–0.25 V.
The motor current now passes through F1, the series field
D2–D1, K11, the armature A2–A1 and K11 to the battery’s
negative pole via A1.

© BT Industries AB Service Manual 1998-01-09 English 11 (16)

F-code Section C-code
36 6 
(OHFWULFDOV\VWHP
Version no T-code
 

'ULYLQJGLUHFWLRQRIWKHVWHHUZKHHO
When the throttle is activated for driving in the direction of the
steering wheel, S16 is made. The transistor regulator checks
that S10 is closed before S16 is made, for driving to be per-
mitted. Battery voltage is received via the connect pin 102,
and 412 to A1.12; LED 102 is on.
Battery voltage to K13 via connection pin 403. A1.3 now gives
(-) return to K13, (-) input on connection pin 402; LED 402 is
on.
Depending on the throttle R1’s position and the adjustment of
potentiometer RV1, A1.8 will receive a voltage between 4.8
and 0.25 V.
The motor current now passes through F1, the series field
D2–D1, K13, the armature A1–A2 and K13 to the battery’s
negative pole via A1.

5HYHUVLQJPRWRUEUDNHGLUHFWLRQRI
IRUNVWRGLUHFWLRQRIVWHHUZKHHO
S15 returns to the neutral position and S16 makes. The cur-
rent in the series field makes the motor act as a generator as
the drive wheel is rotating in the “wrong direction”.
The transistor regulator senses the generated current on A2,
and reduces the series field current to 60 A. When the drive
wheel rotates in the “right direction” and the potential on con-
nection A2 is positive, acceleration occurs according to the
adjusted value for the current limit and acceleration.
The rotor current in the circuit passes A1–A2, K13, A2, tran-
sistor regulator’s brake diode, M- and K13 during the braking
sequence.

12 (16) Service Manual 1998-01-09 English

 F-code Section C-code
36 6 
(OHFWULFDOV\VWHP
Version no T-code
 

5HYHUVLQJPRWRUEUDNHGLUHFWLRQRI
VWHHUZKHHOWRGLUHFWLRQRIIRUNV
S16 returns to the neutral position and S15 makes. The cur-
rent in the series field makes the motor act as a generator as
the drive wheel is rotating in the “wrong direction”.
The transistor regulator senses the generated current on A2,
and reduces the series field current to 60 A. When the drive
wheel rotates in the “right direction” and the potential on con-
nection A2 is positive, acceleration occurs according to the
adjusted value for the current limit and acceleration.
The rotor current in the circuit passes A2–A1, K11, A2, tran-
sistor regulator’s brake diode, M- and K11 during the braking
sequence.

6DIHW\UHYHUVLQJ
The transistor regulator continuously monitors the safety
reversing circuit for a possible broken line, by sending a small
pulsed current through A1.10, connection pins 416, 111, line
32, S20, line 32, connection pins 110, 415 and A1.13.
S20 is activated and makes connections 110, 415 and A1.13
positive, A1 now cuts the (-) return to K13 which breaks. At
the same time A1 will deliver (-) at A1.2 to K11; LED 401
comes on.
The motor will now be connected for motor braking with a
maximal current limit of 150 A. The truck will then accelerate
in the direction of the forks until S20 returns to its neutral
position.
When S20 returns to its neutral position, the (+) disappears
from connection pin 110, A1 cuts the (-) return on A1.3 to K11
and the truck stops.
In order to start again while S16 is still active, the transistor
regulator must be reset to the inactive mode by allowing the
throttle to return to the neutral position whereafter a new driv-
ing direction can be selected.

© BT Industries AB Service Manual 1998-01-09 English 13 (16)

F-code Section C-code
36 6 
(OHFWULFDOV\VWHP
Version no T-code
 

/LIWLQJWKHIRUNV0;'
Microswitch S34 makes. K30 receives (+) voltage via the con-
nection pins 112, 203, the battery controller or strap, connec-
tion pins 201 and 405. Solenoid valve Y34 breaks and
receives (+) voltage from connection pin 206. LEDs 112, 206
and 405 come on.
(-) return via line 40. K30 makes and the pump motor M3
starts.

/LIWLQJWKHIRUNV/LIWOLPLW0;)
Microswitch S34 makes. K30 receives (+) voltage via the con-
nection pins 112, 203, the battery controller or strap, connec-
tion pins 201 and 405. Solenoid valve Y34 breaks and
receives (+) voltage from connection pin 206. LEDs 112, 206
and 405 come on.
(-) return via line 40. K30 makes and the pump motor M3
starts, if S90 is open, support arm = 0, or if S90 is made, sup-
port arm height> 0, and S33 is made, fork lift height
<1600 mm.

/LIWLQJWKHIRUNV
When the forks are lowered S41 is activated. The solenoid
valve Y41 receives (+) voltage via connection pins 113 and
209, LEDs 113 and 209 come on.
(-) return via line 40.

/LIWLQJWKHVXSSRUWDUP0;'
Microswitch S52 makes. K30 receives (+) voltage via connec-
tion pins 105 and 405. Solenoid valve Y52 opens and
receives (+) voltage from connection pin 204. LEDs 105, 204
and 405 come on. (-) return via line 40. K30 makes and the
pump motor M3 starts.

14 (16) Service Manual 1998-01-09 English

 F-code Section C-code
36 6 
(OHFWULFDOV\VWHP
Version no T-code
 

/LIWLQJWKHVXSSRUWDUP/LIWOLPLW0;)
Microswitch S52 makes. K30 receives (+) voltage via connec-
tion pins 105 and 405. Solenoid valve Y52 opens and
receives (+) voltage from connection pin 204. LEDs 105, 204
and 405 come on.
(-) return via line 40. K30 makes and the pump motor M3
starts if S33 and S32 are closed, fork lift height <1600 mm.

/RZHULQJWKHVXSSRUWDUP
When the forks are lowered S40 is activated. The solenoid
valveY41 receives (+) voltage via connection pins 106 and
209, LEDs 106 and 209 come on.
(-)-return via line 40.

+RUQ
Microswitch S18 is activated. The horn H1 receives (+) volt-
age via connection pins 107 and 406, LED 107 comes on.
(-) return via line 40.

© BT Industries AB Service Manual 1998-01-09 English 15 (16)

F-code Section C-code
36 6 
(OHFWULFDOV\VWHP
Version no T-code
 

16 (16) Service Manual 1998-01-09 English

 F-code Section C-code
36 6 
(OHFWULFDOV\VWHP
IIssued by Approved by Version no T-code
66' .+DOOPDQ  

(OHFWULFDOV\VWHP
Valid from serial number:

7FRGH 0RGHO 6HULDO1R 1RWHV

351 PPS 1000MX 270001AA-
352 PPS 1200MX 270001AA-
353 PPS 1200MXS 270001AA-

(OHFWULFDOSDQHOFRPSRQHQWV
RV1

F50
A5

F1
K11

K13

K30

F3
A1

H1

© BT Industries AB Service Manual 1995-12-04 English 1 (12)

F-code Section C-code
36 6 
(OHFWULFDOV\VWHP
Version no T-code
 

/LVWRIV\PEROVDQGHOHFWULFDOGLD
JUDPV
/LVWRIV\PEROV

6\PERO 'HVFULSWLRQ )XQFWLRQ 5HPDUN

A1 Transistor controller
A5 Electronic card

BT Battery

F3 Fuse Pump motor circuit 160 A

F10 Fuse Drive motor circuit 100 A
F50 Fuse Control circuit 7,5 A

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 5 - 0 kOhm

RV1 Potentiometer Speed reduction

S10 Switch ”Brake”

S15 Switch Drive direction Fork direction

2 (12) Service Manual 1995-12-04 English

 F-code Section C-code
36 6 
(OHFWULFDOV\VWHP
Version no T-code
 

6\PERO 'HVFULSWLRQ )XQFWLRQ 5HPDUN

S16 Switch Drive direction Steer wheel direction
S17 Switch Key
S18 Switch Horn
S20 Switch Safety reverse
S41 Switch Fork lower For optional electric
lowering.
Always connected
S52 Switch Fork lift

Y41 Magnetic valve Fork lower When having optional

electric lowering

© BT Industries AB Service Manual 1995-12-04 English 3 (12)

F-code Section C-code
36 6 
(OHFWULFDOV\VWHP
Version no T-code
 

(OHFWULFDOGLDJUDP

4 (12) Service Manual 1995-12-04 English

 F-code Section C-code
36 6 
(OHFWULFDOV\VWHP
Version no T-code
 

&LUFXLWGLDJUDP

© BT Industries AB Service Manual 1995-12-04 English 5 (12)

F-code Section C-code
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6 (12) Service Manual 1995-12-04 English

 F-code Section C-code
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&LUFXLWGLDJUDP
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© BT Industries AB Service Manual 1995-12-04 English 7 (12)

F-code Section C-code
36 6 
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'HVFULSWLRQRIIXQFWLRQ
*HQHUDO
The transistor regulator A1 regulates the speed variably up to
maximum speed. When the truck is started the regulator checks
the closing sequence for the microswitches in the circuit. The
regulator is equipped with a LED that displays the system sta-
tus.
The electrical system has a electronic card A5 to group all the
connections to the control card for input and output signals to
the transistor regulator. The electronic card is equipped with
LEDs to indicate incoming and outgoing signals and a poten-
tiometer to adjust the maximum speed.
5HIHUHQFHV
For further information on the transistor regulator and electron-
ic card, see C-code 5330, 5460 and 5710.

'HVFULSWLRQ
The description is divided into different phases that corre-
spond to the operating sequence stages.

8 (12) Service Manual 1995-12-04 English

 F-code Section C-code
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Version no T-code
 

,JQLWLRQORFN6LQWKH21SRVLWLRQ
When S17 closes, the transistor controller will check that S10
is not closed. If this is the case, operation is not permitted.
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.

7KHWLOOHUDUPLQGULYHSRVLWLRQ6
When the tiller arm is pushed 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.

'ULYLQJIRUNGLUHFWLRQ
When the butterfly is activated for driving in the fork direction,
S15 will close.
Battery voltage obtained via terminal 101 and 411 to A1.11,
LED 101 lights up. Battery voltage to K11 via terminal 403.
A1.2 now gives (-) return to K11, (-)input on terminal 401,
LED 401 lights up.
Depending on the position of the speed control R1 and
adjustment of potentiometer RV1, A1.8 will obtain 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 nega-
tive via A1.

© BT Industries AB Service Manual 1995-12-04 English 9 (12)

F-code Section C-code
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Version no T-code
 

'ULYLQJVWHHUZKHHOGLUHFWLRQ
When the butterfly 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 not permit-
ted.
Battery voltage obtained via terminal 102 and 412 to A1.12,
LED 102 lights up. Battery voltage to K13 via terminal 403.
A1.3 now gives (-) return to K13, (-)input on terminal 402,
LED 402 lights up.
Depending on the position of the speed control R1 and
adjustment of potentiometer RV1, A1.8 will obtain 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 nega-
tive via A1.

5HYHUVLQJPRWRUEUDNHIRUNGLUHFWLRQ
WRVWHHUZKHHOGLUHFWLRQ
S15 returns to neutral position while S16 closes. The current
in the series field causes the motor to work as a generator
since the drive wheel rotates in the ”wrong direction”.
The transistor controller detects the generated current at con-
nection 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
adjusted according to the values of current limit and accelera-
tion.
During braking sequence, the armature current passes in the
circuit A1–A2, K13, A2, the brake diode of the transistor con-
troller, M- and K13.

10 (12) Service Manual 1995-12-04 English

 F-code Section C-code
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Version no T-code
 

5HYHUVLQJPRWRUEUDNHVWHHUZKHHO
GLUHFWLRQWRIRUNGLUHFWLRQ
S16 returns to neutral position while S15 closes. The current
in the series field causes the motor to work as a generator
since the drive wheel rotates in the ”wrong direction”.
The transistor controller detects the generated current at con-
nection A2, and reduces the series field current to 60 A.
When the drive wheel rotates in the ”right direction” and the
potential at connection A2 becomes positive, acceleration is
adjusted according to the values of current limit and accelera-
tion.
During braking sequence, the armature current passes in the
circuit A2–A1, K11, A2, the brake diode of the transistor con-
troller, M- and K11.

6DIHW\UHYHUVHIXQFWLRQ
Possible breakages in the wiring for the safety reverse is con-
tinously checked by the transistor controller, who sends a
small pulsed current through the circuit 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 will A1 provide (-) at A1.3 to K11,
LED 401 lights up.
The motor will now be connected for motor braking at maxi-
mum current limit 150 A, and subsequently accelerate in the
fork direction until S20 returns to its neutral position.
When S20 returns to neutral position, (+) disappears from ter-
minal 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 still is activated, the
transistor controller must be returned to the inactive position
by letting the speed control return to the neutral position, after
which a new direction of travel can be chosen.

/LIWLQJWKHIRUNV
The micro switch S52 closes. K30 receives (+)voltage via ter-
minal 105, 203, battery controller or the jumper, terminal 201
and 405, LED 105 and 405 lights up. (-)return via wire 40.
K30 closes and the pump motor M3 starts.
© BT Industries AB Service Manual 1995-12-04 English 11 (12)
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+RUQ
Micro switch S18 is activated. The horn H1 receives (+)volt-
age via terminal 107 and 406, LED 107 lights up. (-)return via
wire 40.

2SWLRQV
(OHFWULFDOORZHULQJRIWKHIRUNV
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.

2QERDUGFKDUJHU
The onboard charger is connected to the electrical system of
the truck as shown in electrical diagram 4(4).
When the charger is connected to a wall outlet, the charger
cuts all electrical functions in the truck for safety reasons.
Consequently it is not possible to use the truck when the
charger is on.

12 (12) Service Manual 1995-12-04 English

 F-code Section C-code
36 6 
%DWWHU\FRQWUROOHUKRXUPHWHU
IIssued by Approved by Version no T-code
66' .+DOOPDQ  

%DWWHU\FRQWUROOHUKRXUPHWHU
Valid from serial number:

7FRGH 0RGHO 6HULDO1R 1RWHV

204 PPH 1600MX 270001AA-
349 PPS 1600 MXD 270001AA-
350 PPS 1200 MXF 270001AA-
351 PPS 1000MX 270001AA-
352 PPS 1200MX 270001AA-
353 PPS 1200MXS 270001AA-

*HQHUDO
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 [Link] 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 on last digit. This provoides a read-
ing of 0.1 hours or 6 minutes.

© BT Industries AB Service Manual 1999-01-20 English 1 (8)

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Version no T-code
 

(OHFWULFDO
9ROWDJH
The instrument is supplied as a pin selectable dual voltage
unit with the voltage of 24/48 VDC.

7KHFRQWDFWYROWDJHDQGFXUUHQWUDWLQJVIRUVZLWFK
LQJUHVLVWLYHORDGV

Open Contact Voltage 200 VDC Max

Closed Contact Current 3 ADC Max
Volt Ampere Product 50 W Max

0HPRU\UHWHQWLRQ
The instrument contains an internal battery which allows (BC)
memory retention when external power is remowed. Typical
battery life is 10 years. The hourmeter has a solid state non
volatile memory which does not require battery backup.

%DWWHU\FRQWUROOHU
*HQHUDO
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
lit. As the battery discharges, LEDs further and further to the
left 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 opening.

'LVFKDUJH$GMXVWPHQW
The BC features an adjustable discharge setting. The setting
designators K-U appear at the rear of the gage at the peri-
phery of the adjusting screw. 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.

2 (8) Service Manual 1999-01-20 English

 F-code Section C-code
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Version no T-code
 

A hydrometer must be used for exact adjustment. When the

two lower LEDs flash, the density of the battery fluid should not
fall below 1.14. If the LEDs start to flash at a higher density the
discharge potentiometer U must be turned anticlockwise (to-
wards K). If both diodes flash at a density lower than 1.14, turn
the potentiometer clockwise (towards P).
If necessary, adjust one step at a time. Charge the battery and
drive the truck until the instrument starts to flash again. Meas-
ure once again using the hydrometer to ensure the adjustment
is correct. If not, the procedure must be repeated until the set-
ting is correct.
The letter designation in the table below shows the voltage
value per cell (VPC) with a discharged battery.

6(77,1* 93&
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

© BT Industries AB Service Manual 1999-01-20 English 3 (8)

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Version no T-code
 

3,112 )81&7,21
1 Hour meter (-)
2 Keyswitch (+)
3 Relay arm (+)
4 Relay NC (-)
5 Battery (-)
6 Hour meter (+)
7 24 Volt (+)
8 48 Volt (+)

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5HVHW
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.

4 (8) Service Manual 1999-01-20 English

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Version no T-code
 

.H\VZLWFK
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 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.

+RXUPHWHU
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.

7URXEOHVKRRWLQJ
This section is separated into two parts: battery discharge
indicator and hour meter.

%DWWHU\'LVFKDUJH,QGLFDWRU
1RUHVHW
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 ter-
minals 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.

© BT Industries AB Service Manual 1999-01-20 English 5 (8)

F-code Section C-code
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Version no T-code
 

The second method of resetting the instrument is by using the

high voltage reset. This reset function also has two require-
ments 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.

$OZD\VUHVHWVDIWHUEUHDNLQSRZHU
If the voltage of the batteries to which the instrument is con-
nected is below 2.09 volts per cell and the gauge was not for-
merly 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.
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The instrument monitors loaded battery voltages. If con-
nected 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 the gauge indication downwards from a full
reading.

1RORFNRXW
The two far left red LEDs on the LED display must be fashing
alternately 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.

6 (8) Service Manual 1999-01-20 English

 F-code Section C-code
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%DWWHU\FRQWUROOHUKRXUPHWHU
Version no T-code
 

After replacing the wire if the lift operates, the instrument is

defective, or there could be a leakage current somewhere in
lift circuit. Check across the lift switch.

1ROLIW
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 test the lift switch and contactor.

(DUO\ORFNRXW
It is very important that the instrtument 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 nega-
tive lead on pin 7 or 8 (whichever 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 calcu-
late battery state-of-charge from incorrect readings.

/('VGRQ¶WOLJKW
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.

© BT Industries AB Service Manual 1999-01-20 English 7 (8)

F-code Section C-code
36 6 
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Version no T-code
 

+RXUPHWHU
1RGLVSOD\
The 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.

+RXUJODVVLFRQGRHVQRWIODVK
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.

+RXUPHWHUJODVVLFRQDOZD\VIODVKHV
When the icon is flashing the hour meter is accumulating
time. Turn the truck’s keyswitch off. This should remove volt-
age 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.

8 (8) Service Manual 1999-01-20 English

 F-code Section C-code
36 6 
7UDQVLVWRUFRQWUROOHU
IIssued by Approved by Version no T-code
66' .+DOOPDQ  

7UDQVLVWRUFRQWUROOHU
Valid from serial number:

7FRGH 0RGHO 6HULDO1R 1RWHV

204 PPH 1600MX 270001AA-293314AA
351 PPS 1000MX 270001AA-295606AA
352 PPS 1200MX 270001AA-295606AA
353 PPS 1200MXS 270001AA-295606AA

0RWRUFLUFXLW
The transistor controller have four terminals for the high cur-
rent circuits according to the table below.

7HUPLQDO &RQQHFWLQJ
M- Output to motor armature
B- Negative connection to battery
B+ Positive connection to battery/series field
A2 Plug diode to motor armature

© BT Industries AB Service Manual 1995-12-07 English 1 (8)

F-code Section C-code
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Version no T-code
 

&RQWUROFLUFXLW
The transistor controller have an integrated 16-pin connector
to provide the low power logic control connections. The desig-
nation of the pins are according to the table below.

3LQ1R &RQQHFWLQJ
&RQWDFWRUGULYHUV
P1 Shunt field driver output
P2 Fork direction contactor driver output
P3 Steer wheel direction contactor driver output
P4 Not connected
7KURWWOHFRQQHFWLRQV
P5 Not connected
P6 Not connected
P7 Throttle: pot low
P8 Throttle: 2-wire 5 kOhm-0 input
%DVLFFRQWUROVLJQDOV
P9 Not connected
P10 Safety reverse check output
P11 Drive fork direction input
P12 Drive steer wheel direction input
P13 Safety reverse input
P14 Speed range selection input
P15 Brake switch input
P16 Key switch input (KSI)

2 (8) Service Manual 1995-12-07 English

 F-code Section C-code
36 6 
7UDQVLVWRUFRQWUROOHU
Version no T-code
 

7HFKQLFDOVSHFLILFDWLRQ
The technical specification for the BT-version of the Curtis
1207 transistor controller is according to the table below.

3DUDPHWHU 5DQJH 67' 8QLWV 'HVFULSWLRQ

6HWWLQJ
Operating voltage 24 24 Volt
Maximum voltage 45 Volt Overvoltage point
Minimum operating voltage 16 Volt Undervoltage point
Electrical isolation to heat- 500 Volt ac Minimum
sink
Frequency 15 kHz
Contactor voltage 24 Volt
Contactor current 1 Amp Maximum (current limit at 2
amp)
Shunt driver current 2 1.2 Amp
KSI input current 80 mA
Logic input current 10 mA At 24 Volt
Logic input threshold 8 Volt
oC
Ambient operating temper- -40 -
ature +50
Heatsink overtemperature 85 o
C
cutback
o
Heatsink undertempera- -25 C
ture cutback
Plug Braking Variable Variable Plug current dependant upon
throttle position
Current Limit, Main 100-150 150 Amp
Current Limit, Low Speed, 100 Amp Maximum current in low
Main speed mode
Current Limit, Plug 60 Amp Maximum plug current in the
series field
Current Limit, Low Speed, 60 Amp Maximum plug current in the
Plug series field in low speed
mode

© BT Industries AB Service Manual 1995-12-07 English 3 (8)

F-code Section C-code
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7UDQVLVWRUFRQWUROOHU
Version no T-code
 

3DUDPHWHU 5DQJH 67' 8QLWV 'HVFULSWLRQ

6HWWLQJ
Current Limit, 150 Amp Maximum field current in
Emergency Reverse safety reverse
Current Limit, Low speed, 150 Amp Max. field current when in
Emr. Reverse low speed for safety reverse
Throttle Type 5k-0 Ohm
Min. Duty Cycle 0 % Speed (duty factor) at mini-
mum throttle setting
Low Speed 70 % Maximum speed (duty factor)
in low speed mode
Emergency Reverse 50 % Speed during emergency
Speed reverse
Acceleration Rate 0.1 - 3 0.8 Sec Time to reach full output from
zero output

$GMXVWPHQWSDQHO

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.

$GMXVWDEOHSRWHQWLRPHWHUV
MAIN and ACCEL potentiometers can be adjusted with a
screwdriver within the range given in the technical specifica-
tion.
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4 (8) Service Manual 1995-12-07 English

 F-code Section C-code
36 6 
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Version no T-code
 

&RQQHFWLRQRIKDQGKHOGWHUPLQDO
To adjust the parameters with the handheld terminal the cor-
responding potentiometer must be set to ”off”.

6WDWXV/('
The LED displays flashing codes to indicate controller status.
The codes are listed with explanations in chapter ”Diagnos-
tics and troubleshooting”.

0DLQWHQDQFH
There are no user-servicable parts inside the transistor con-
troller.
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23(1,1*7+(&21752//(5:,//92,'7+(:$55$17<
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.

6DIHW\
The controller is inherently a high power device. When work-
ing around any battery powered vehicle, proper safety pre-
cautions 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.
:$51,1*
5LVNRIVKRUWFLUFXLWV
5HPRYHDOOZDWFKHVDQGMHZHOU\DQGDOZD\VXVHLQVXODWHG
WRROV

&OHDQLQJ
Although the controller requires virtually no maintenance if
properly installed, the following minor maintenance is recom-
mended on a regular 250 hours basis.
• Remove power by disconnecting the battery.

© BT Industries AB Service Manual 1995-12-07 English 5 (8)

F-code Section C-code
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Version no T-code
 

• Discharge the capacitors in the controller, by connecting a

load (such as a contactor coil or the horn) across the con-
troller’s B+ and B- terminals, before doing any work on the
controller.
• 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.
• 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.

'LDJQRVWLFVDQGWURXEOHVKRRWLQJ

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 conti-
nously until the fault is corrected, see the table below.
If using a handheld terninal for the diagnostics, switched over
to diagnostic mode, the diagnostic information can be read in
the terminal display, see the table below.

/HGFRGH 7HUPLQDO/&' ([SODQDWLRQ 3RVVLEOHFDXVH

'LVSOD\
1,2 ¤ ¤¤ +:)$,/6$)( Hardware fail-safe 1. Controller defective
error
1,3 ¤ ¤¤¤ 0)$8/7 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 ¤ ¤¤¤¤ 652 SRO fault 1. Improper sequence of KSI,
brake and direction inputs
2. Brake or direction switch circuit
open

6 (8) Service Manual 1995-12-07 English

 F-code Section C-code
36 6 
7UDQVLVWRUFRQWUROOHU
Version no T-code
 

/HGFRGH 7HUPLQDO/&' ([SODQDWLRQ 3RVVLEOHFDXVH

'LVSOD\
2,1 ¤¤ ¤ 7+5277/( 5kOhm-0 or wiper 1. Throttle input wire open
)$8/7 fault 2. Throttle input wire shorted to
ground or B+
3. Throttle pot defective.
4. Wrong throttle type
2,2 ¤¤ ¤¤ %%:,5,1* safety reverse wir- 1. Safety reverse wire open
&+(&. ing fault 2. Safety reverse check wire open
2,3 ¤¤ ¤¤¤ +3' HPD sequencing 1. Improper sequence of KSI,
fault brake, throttle inputs
2. Misadjusted throttle
2,4 ¤¤ ¤¤¤¤ 7+5277/( Pot Low broken or 1. Pot low wire open
)$8/7 shorted 2. Pot low wire shorted
3. Wrong throttle type
3,1 ¤¤¤ ¤ &217'5952& Driver output over- 1. Direction contactor coil shorted
current 2. Shunt field shorted
3,2 ¤¤¤ ¤¤ ',5&217 Welded direction 1. Direction contactor stuck closed
:(/'(' contactor
3,4 ¤¤¤ ¤¤¤¤ 0,66,1*&21 Missing contactor 1. Direction contactor open coil
7$&725 or shunt 2. Direction contactor missing
3. Shunt field open
4. Wire to shunt or direction con-
tactor open
4,1 ¤¤¤¤ ¤ /2:%$77(5< Low battery volt- 1. Battery voltage <16 volts
92/7$*( age 2. Corroded battery terminal
3. Loose battery or controller ter-
minal
4,2 ¤¤¤¤ ¤¤ 29(592/7$*( Overvoltage 1. Battery voltage > 45 volts
2. Vehicle operating with charger
attached
4,3 ¤¤¤¤ ¤¤¤ 7+(50$/ Over-/undertem- 1. Temperature >85oC or < 25 oC
&87%$&. perature cutback 2. Excessive load on vehicle.
3. Improper mounting of controller
4. Operation in extreme environ-
ments

© BT Industries AB Service Manual 1995-12-07 English 7 (8)

F-code Section C-code
36 6 
7UDQVLVWRUFRQWUROOHU
Version no T-code
 

8 (8) Service Manual 1995-12-07 English

 F-code Section C-code
36 6 
7UDQVLVWRUFRQWUROOHU
IIssued by Approved by Version no T-code
66' *LDQQL-DUYLV  

7UDQVLVWRUFRQWUROOHU
Valid from serial number:

7FRGH 0RGHO 6HULDO1R 1RWHV

204 PPH 1600MX 293315AA-
349 PPS 1600MXD 296773AA-
350 PPS 1200MXF 296776AA-
351 PPS 1000MX 295607AA-
352 PPS 1200MX 295607AA-
353 PPS 1200MXS 295607AA-

*HQHUDO
The &XUWLV  version 137197-003 incorporates a
new function called neutral braking. When the function is
active it allows the truck to function in the neutral braking
mode, also known as auto-plug braking mode. The function is
activated by setting a parameter with the handheld terminal.
See chapter “Curtis 1307 handheld programmer”.

&RQQHFWLRQV
The transistor controller has four terminals for the high current
circuits, a control circuit connector and a connector for a hand
held terminal according to the table below.

7HUPLQDO &RQQHFWLRQ
1 Connector for handheld terminal
2 16 pin low power logic connector
M- Output to motor armature
B- Negative connection to battery
B+ Positive connection to battery/series
field
A2 Plug diode to motor armature

© BT Industries AB Service Manual 1997-03-19 English 1 (14)

F-code Section C-code
36 6 
7UDQVLVWRUFRQWUROOHU
Version no T-code
 

&RQWUROFLUFXLW
The transistor controller has an integrated 16-pin connector to
provide the low power logic control connections. The designa-
tion of the pins is according to table below.

3LQ1R &RQQHFWLRQ
&RQWDFWRUGULYHUV
P1 Shunt field driver output
P2 Fork direction contactor driver output
P3 Steer wheel direction contactor driver
output
P4 Not connected
7KURWWOHFRQQHFWLRQV
P5 Not connected
P6 Not connected
P7 Throttle: potentiometer low
P8 Throttle: 2-wire 5 kOhm-0 input
%DVLFFRQWUROVLJQDOV
P9 Not connected
P10 Safety reverse check output
P11 Drive fork direction input
P12 Drive steer wheel direction input
P13 Safety reverse input
P14 Speed range selection input - 3RZHU
7UDN6HHQRWH
P15 Brake switch input
P16 Key switch input KSI

Note #1: This input is not connected on PPS models.

2 (14) Service Manual 1997-03-19 English

 F-code Section C-code
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7UDQVLVWRUFRQWUROOHU
Version no T-code
 

7HFKQLFDOVSHFLILFDWLRQ
The technical specification for the BT-version of the Curtis
1207-1131 transistor controller is according to table below.
1RWH
&ROXPQ30LQGLFDWHVKRZSDUDPHWHUFDQEHDGMXVWHG
3 3URJUDPPHU0 0DQXDODGMXVWPHQWSRVVLEOH
 1RWDGMXVWDEOH

3DUDPHWHU 5DQJH 67' 8QLWV 30 'HVFULSWLRQ

(Programmer display) 9DOXH
Operating voltage 24–36 24 Volt -
Maximum voltage 45 Volt - Overvoltage point
Minimum operating 16 Volt - Undervoltage point
voltage
Electrical isolation to 500 Volt - Minimum
heatsink ac
Frequency 15 kHz -
Contactor voltage 24 Volt -
Contactor current 1 Amp - Maximum, current limit at 2
amp
Shunt driver current 2 1.2 Amp -
KSI input current 80 mA -
Logic input current 10 mA - At 24 Volt
Logic input threshold 8 Volt -
o
Ambient operating -40 – C -
temperature +50
oC
Heatsink overtempera- 85–95 -
ture cutback
o
Heatsink undertemper- -25 C -
ature cutback
Plug Braking Variable Variable - Plug current dependant
upon throttle position

© BT Industries AB Service Manual 1997-03-19 English 3 (14)

F-code Section C-code
36 6 
7UDQVLVWRUFRQWUROOHU
Version no T-code
 

3DUDPHWHU 5DQJH 67' 8QLWV 30 'HVFULSWLRQ

(Programmer display) 9DOXH
Current Limit, Main 100–150 150 Amp P
(M1 MAIN C/L)
Current Limit, Low 60–100 100 Amp P Maximum current in low
Speed, Main- speed mode
(M2 MAIN C/L) NOT VALID FOR PPS
Current Limit, Plug 20–60 60 Amp P Maximum plug current in
Main (M1 PLUG C/L) the series field
Current Limit, Low 20–60 60 Amp P Maximum plug current in
Speed, Plug- the series field in low
(M2 PLUG C/L) speed mode
NOT VALID FOR PPS
Current Limit, 25–250 150 Amp - Maximum field current in
Emergency Reverse emergency reverse
(EMR REV C/L)
Throttle Type (1) 5k-0 Ohm -
Min. Duty Cycle 0 % - Speed, duty factor, at mini-
mum throttle setting
Low Speed 40–100 100 % - Maximum speed, duty fac-
(M2 MAX SPEED) tor, in low speed mode
NOT VALID FOR PPS
Emergency Reverse 25–100 70 % - Speed during emergency
Speed reverse
(EMR REV SPEED)
Acceleration Rate 0 –1.5 0.8 Sec P,M Time to reach full output
(ACCEL RATE) from zero output
Acceleration ramp 20–70 30 % P Percentage of output drive
shape (RAMP SHAPE) when speed input is at 50%
Neutral brake ON/OFF OFF P Selects braking or free-
(NEUTRAL BRAKE) wheeling when speed con-
trol returns to neutral
Neutral brake current 10–100 10 Amp P Maximum field current dur-
(NEUT BRAKE C/L) ing neutral braking

4 (14) Service Manual 1997-03-19 English

 F-code Section C-code
36 6 
7UDQVLVWRUFRQWUROOHU
Version no T-code
 

$GMXVWPHQWSDQHO

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.

$GMXVWDEOH3RWHQWLRPHWHUV
The parameter $FFHOHUDWLRQ 5DWH can be manually adjusted
via potentiometer (ACCEL) with a screwdriver within the
range given in the technical specification.
127(
,QWKH%7YHUVLRQRIWKH&XUWLVRQO\WKH$&&(/SRWHQWL
RPHWHULVLQRSHUDWLRQ$OORWKHUSRWHQWLRPHWHUVDUHGLVD
EOHGIURPIDFWRU\

&RQQHFWLRQRIKDQGKHOGSURJUDPPHU
For information about how to use the handheld programmer
see chapter “Curtis 1307 handheld programmer”.
To adjust the parameters with the handheld terminal the cor-
responding potentiometer must be set to ”off”.

6WDWXV/('
The LED displays flashing codes to indicate controller status.
The codes are listed with explanations in chapter “Diagnos-
tics and troubleshooting”.

© BT Industries AB Service Manual 1997-03-19 English 5 (14)

F-code Section C-code
36 6 
7UDQVLVWRUFRQWUROOHU
Version no T-code
 

0DLQWHQDQFH
There are no user-servicable parts inside the transistor con-
troller.
1RWH
1RDWWHPSWVKRXOGEHPDGHWRRSHQWKHFRQWUROOHU
23(1,1*7+(&21752//(5:,//92,'7+(:$55$17<
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.

6DIHW\
The controller is inherently a high power device. When work-
ing around any battery powered vehicle, proper safety pre-
cautions 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.

:$51,1*
5LVNRIVKRUWFLUFXLWV
5HPRYHDOOZDWFKHVDQGMHZHOU\DQGDOZD\VXVHLQVXODWHG
WRROV

&OHDQLQJ
Although the controller requires virtually no maintenance if
properly installed, the following minor maintenance is recom-
mended on a regular 250 hours basis.
• Remove power by disconnecting the battery.
• Discharge the capacitors in the controller, by connecting a
load, such as a contactor coil or the horn, across the con-
troller’s B+ and B- terminals, before doing any work on the
controller.
• 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.
• 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 (14) Service Manual 1997-03-19 English

 F-code Section C-code
36 6 
7UDQVLVWRUFRQWUROOHU
Version no T-code
 

'LDJQRVWLFVDQGWURXEOHVKRRWLQJ

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 conti-
nously until the fault is corrected, see table below.
If using a handheld programmer for the diagnostics, select
DIAGNOSTIC mode, the diagnostic information can be read
in the programmer display, see table below.

/('FRGH 3URJUDPPHU ([SODQDWLRQ 3RVVLEOHFDXVH

/&'GLVSOD\
1,2 ¤ ¤¤ +:)$,/6$)( Hardware fail-safe 1. Controller defective
error
1,3 ¤ ¤¤¤ 0)$8/7 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 ¤ ¤¤¤¤ 652 SRO fault 1. Improper sequence of KSI,
brake and direction inputs.
2. Brake or direction switch cir-
cuit open.
2,1 ¤¤ ¤ 7+5277/( 5kOhm-0 or wiper 1. Throttle input wire open.
)$8/7 fault 2. Throttle input wire shorted to
ground or B+
3. Throttle pot defective
4. Wrong throttle type
2,2 ¤¤ ¤¤ %%:,5,1* Emergency reverse 1. Safety reverse wire open
&+(&. wiring fault 2. Safety reversie check wire
open
2,3 ¤¤ ¤¤¤ +3' HPD sequencing 1. Improper sequence of KSI,
fault brake, throttle inputs
2. Misadjusted throttle

© BT Industries AB Service Manual 1997-03-19 English 7 (14)

F-code Section C-code
36 6 
7UDQVLVWRUFRQWUROOHU
Version no T-code
 

/('FRGH 3URJUDPPHU ([SODQDWLRQ 3RVVLEOHFDXVH

/&'GLVSOD\
2,4 ¤¤ ¤¤¤¤ 7+5277/( Potentiometer Low 1. Pot low wire open
)$8/7 broken or shorted 2. Pot low wire shorted
3. Wrong throttle type
3,1 ¤¤¤ ¤ &217'5952& Driver output over- 1. Direction contactor coil
current shorted
2. Shunt field shorted
3,2 ¤¤¤ ¤¤ ',5&217 Welded direction 1. Direction contactor stuck
:(/'(' contactor closed
3,4 ¤¤¤ ¤¤¤¤ 0,66,1* Missing contactor or 1. Direction contactor open coil
&217$&725 shunt 2. Direction contactor missing
3. Shunt field open
4. Wire to shunt or direction
contactor open
4,1 ¤¤¤¤ ¤ /2:%$77(5< Low battery voltage 1. Battery voltage <16 volts
92/7$*( 2. Corroded battery terminal
3. Loose battery or controller
terminal
4,2 ¤¤¤¤ ¤¤ 29(592/7$*( Overvoltage 1. Battery voltage > 45 volts
2. Vehicle operating with
charger attached
4,3 ¤¤¤¤ ¤¤¤ 7+(50$/ Over-/under tem- 1. Temperature >85oC or
&87%$&. perature cutback < 25 oC
2. Excessive load on vehicle
3. Improper mounting of
controller
4. Operation in extreme
environments

&XUWLVKDQGKHOGSURJUDPPHU
The Curtis 1307 handheld programmer allows you to pro-
gram, test, and diagnose Curtis PMC 1207 controllers. The
programmer is powered by the host 1207 controller, via an
RJ11 modular connector located in the adjustment panel on
top of the controller.

8 (14) Service Manual 1997-03-19 English

 F-code Section C-code
36 6 
7UDQVLVWRUFRQWUROOHU
Version no T-code
 

© BT Industries AB Service Manual 1997-03-19 English 9 (14)

F-code Section C-code
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7UDQVLVWRUFRQWUROOHU
Version no T-code
 

3RV )XQFWLRQ 1RWH

1 Display window 4-line LCD display
2 PROGRAM MODE button Select this mode to display (and change) the control-
ler’s parameters
3 TEST MODE button Select this mode to display status of inputs/outputs
etc.
4 DIAGNOSTICS MODE but- Select this mode to display currently active faults
ton detected by the controller
5 SCROLL DISPLAY buttons Scroll the display text lines, up and down
6 MORE INFO button Press this button to obtain further information rele-
vant to the current mode
7 Key active LEDs Indicates whether the relevant CHANGE VALUE
button is active. When extinguished no further
adjustment is possible
8 CHANGE VALUE buttons Increase or decrease the value of selected item
9 Operating mode LEDs Indicates which operating mode is currently active

8VLQJWKHKDQGKHOGSURJUDPPHU
• Plug the handheld programmer into the controller’s pro-
grammer socket located on the top of the adjustment
panel.
• Ensure the truck power is on.
When the programmer is first plugged into the controller, the
brake switch must be open (brake applied) until the program-
mer has acquired all the controller parameters. When this
step has been completed, the programmer displays the con-
troller's model number, date of manufacture, and software
revision code. Following this initial display, the programmer
displays a prompt for further instructions.
The programmer has three main operating modes: PRO-
GRAM, TEST and DIAGNOSTICS.
• PROGRAM mode is used to display the controller’s param-
eters. Displayed parameters can also be changed in this
mode.

10 (14) Service Manual 1997-03-19 English

 F-code Section C-code
36 6 
7UDQVLVWRUFRQWUROOHU
Version no T-code
 

• TEST mode displays real time information about the status

of the inputs, outputs, and controller temperature. In the
TEST mode, the item of interest does not need to be the
top item on the list; it only needs to be among the four
items visible in the window. The Test mode is useful for
checking out the operation of the controller during initial
installation, and also for troubleshooting should problems
occur.
• DIAGNOSTICS mode displays the active faults detected
by the controller.

&KHFNLQJDQGDGMXVWLQJSDUDPHWHUV
• Press the PROGRAM mode button. The PROGRAM oper-
ating mode LED illuminates.
The programmer now displays the first four parameters. See
illustration below.

Parameters are displayed four at a time. Each line represents

a parameter. A indicates the parameter name. The arrow B
indicates the parameter which is currently selected for adjust-
ment. C indicates the current parameter value.
To display other parameters press either of the
SCROLL DISPLAY buttons.
To adjust a particular parameter scroll the display up or down
so that the arrow B is pointing at it.
• Increase the value by pressing the CHANGE VALUE –”up”
button or decrease the value by pressing the CHANGE
VALUE –”down” button
127(
$VVRRQDVDQ\GLVSOD\HGSDUDPHWHUYDOXHLVFKDQJHGWKH
QHZYDOXHLVWUDQVPLWWHGGLUHFWO\WRWKHFRQWUROOHU
Refer to the relevant service manual covering the controller
itself for information about standard parameter values and
adjustments.
© BT Industries AB Service Manual 1997-03-19 English 11 (14)
F-code Section C-code
36 6 
7UDQVLVWRUFRQWUROOHU
Version no T-code
 

8VLQJWKH7(67PRGH
• Press the TEST mode button. The TEST operating mode
LED illuminates
The programmer now displays the real time status of various
inputs, outputs and values. See illustration below.

Values are displayed four lines at a time. Each line represents

an input, output or value. A is the name and B is the present
value.
To display other values press either of the SCROLL DISPLAY
buttons.
([DPSOH
The action of the truck’s speed control can be checked by
moving the butterfly in either forward or reverse direction.
The value THROTTLE % will change correspondingly to
show the percentage of full speed demanded. A value of
100% should be possible in both travel directions.
Table showing meaning of TEST values.

7HVWYDOXH 'HVFULSWLRQ
THROTTLE % Speed control input in percent
BATT VOLTAGE Present battery voltage
HEATSINK °C Present controller temperature
BRAKE INPUT Status of brake input, on/off
SPEED IN Status of pin 14 input to controller, on/off
EMR REV INPUT Status of safety reverse input, on/off
FORWARD INPUT Status of drive forward input, on/off
REVERSE INPUT Status of drive reverse input, on/off
FWD CONTACT Status forward direction contactor output, on/off

12 (14) Service Manual 1997-03-19 English

 F-code Section C-code
36 6 
7UDQVLVWRUFRQWUROOHU
Version no T-code
 

7HVWYDOXH 'HVFULSWLRQ
REV CONTACT Status reverse direction contactor output, on/off
MAX TEMP °C Maximum recorded temperature of the controller since DIAGNOSTIC
HISTORY was last cleared
MIN TEMP °C Minimum recorded temperature of the controller since DIAGNOSTIC
HISTORY was last cleared

8VLQJWKHGLDJQRVWLFVPRGH
• Press the DIAGNOSTICS mode button. The DIAGNOS-
TICS operating mode LED illuminates.
The programmer now displays a list of currently active faults
detected by the controller. The illustration below shows the
display when no faults are detected.

127(
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FRQWUROOHULWVHOIIRULQIRUPDWLRQDERXWSRVVLEOHIDXOWFRGHV
GLVSOD\HGLQ',$*1267,&6PRGH

© BT Industries AB Service Manual 1997-03-19 English 13 (14)

F-code Section C-code
36 6 
7UDQVLVWRUFRQWUROOHU
Version no T-code
 

14 (14) Service Manual 1997-03-19 English

 F-code Section C-code
36 6 
(OHFWURQLFFDUG
IIssued by Approved by Version no T-code
66' .+DOOPDQ  

(OHFWURQLFFDUG
7UDQVLVWRUFRQWURO
Valid from serial number:

7FRGH 0RGHO 6HULDO1R 1RWHV

204 PPH 1600MX 270001AA-

(OHFWURQLFFDUG
The connection card is equipped with green LED’s on the
inputs from micro switches and red LED’s on the outputs to
the contactors. The card is also equipped with a potentiome-
ter for adjustment of the maximum speed.

© BT Industries AB Service Manual 1994-12-20 English 1 (4)

F-code Section C-code
36 6 
(OHFWURQLFFDUG
Version no T-code
 

&RQQHFWLRQVDQGDGMXVWPHQWV
3RVLWLRQ &RQQHFWLRQ$GMXVWPHQW
1 Key switch (S17), battery -, instrument, mag-
netic valves (Y34, Y41, Y52)
2 Battery +, armature voltage, contactors, horn
3 Shunt field
4 RV1, adjustment of maximum speed
5 Micro switches

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

7HUPLQDO /('1R &RQQHF )XQFWLRQ

1R WLRQ
101 101 I Driving, fork direction
102 102 I Driving, steer wheel direction
103 O Speed control
104 I Referens value, speed

2 (4) Service Manual 1994-12-20 English

 F-code Section C-code
36 6 
(OHFWURQLFFDUG
Version no T-code
 

7HUPLQDO /('1R &RQQHF )XQFWLRQ

1R WLRQ
105 105 I Support arm lift
106 106 I Support arm lower
107 107 I Horn
108 O 24 V (+)
109 109 I Brake
110 I Safety reversing, (S20)
111 I Safety reversing, supervision, (S20)
112 112 I Fork lift
113 113 I Fork lower
201 I Battery controller
202 202 I 24 V (+)
203 203 O Battery controller
204 204 O Support arm valve, Y52
205 O 24 V (+)
206 206 O Hour meter
207 I (-), common with 409
208 208 O Fork valve, Y34
209 209 O Lowering valve, Y41
210 O Support arm lift
211 211 I Support arm lift
301 O Shunt field(+)
302 O Shunt field(-)
401 401 I Contactor (-), fork direction
402 402 I Contactor (-), steer wheel direction
403 403 O Contactor drive direction, common (+)
404 404 O Input signal, pump contactor closed
405 405 O Contactor, pump motor
406 O Horn
407 I 24 V (+)

© BT Industries AB Service Manual 1994-12-20 English 3 (4)

F-code Section C-code
36 6 
(OHFWURQLFFDUG
Version no T-code
 

7HUPLQDO /('1R &RQQHF )XQFWLRQ

1R WLRQ
408 O Input 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 Referens value, speed
415 O Safety reversing, (S20)
416 O Safety reversing, supervision, (S20)
417 I Shunt field(-)

4 (4) Service Manual 1994-12-20 English

 F-code Section C-code
36 6 
(OHFWURQLFFDUG
IIssued by Approved by Version no T-code
66' *LDQQL-DUYLV  

(OHFWURQLFFDUG
Valid from serial number:

7FRGH 0RGHO 7UXFN1R 1RWH

349 PPS 1600MXD 296773AA-
350 PPS 1200MXF 296776AA-

*HQHUDO
The electronic card is equipped with green LED’s on the
inputs from micro switches and red LED’s on the outputs to
the contactors. The card is also equipped with a potentiome-
ter for adjustment of the maximum speed.

© BT Industries AB Service Manual 1997-03-25 English 1 (4)

F-code Section C-code
36 6 
(OHFWURQLFFDUG
Version no T-code
 

&RQQHFWLRQVDQGDGMXVWPHQW

3RVLWLRQ &RQQHFWLRQ$GMXVWPHQW
1 Key switch, S17, battery -, instrument, mag-
netic valves, Y34, Y41, Y52
2 Battery +, armature voltage, contactors, horn
3 Shunt field
4 RV1, adjustment of maximum speed
5 Micro switches

,QSXWRXWSXWWHUPLQDOV

7HUPLQDO 6LJQDOQDPH )XQFWLRQ

QR
I101* ,13'5,9()25.',5 Input from drive fork direction switch S15
I102* ,13'5,9(67((5:+ Input from drive steer wheel direction switch S16
',5
103 ‘Low’ connection for speed potentiometer R1
I104 ,1363(('5()9$/8( Reference value from speed potentiometer R1
I105* ,136833257$50 Input from support arm lift switch S52
/,)7
I106* ,136833257$50 Input from support arm lower switch S40
/2:(5
I107* ,13+251 Input from horn switch S18
O108 287%5$.(6: +24 V feed to brake switch S10
I109* ,13%5$.(6: Input from brake switch S10
I110 ,13%% Input from safety reverse switch S20
I111 ,13683(59%% Input for supervision of safety reverse circuit S20
I112* ,13)25./,)7 Input from fork lift button S34
I113* ,13)25./2:(5 Input from fork lower button S41

I201 ,13/,)7/2&.287 Input from LOCK OUT contacts in Battery dis-

charge indicator P3

2 (4) Service Manual 1997-03-25 English

 F-code Section C-code
36 6 
(OHFWURQLFFDUG
Version no T-code
 

7HUPLQDO 6LJQDOQDPH )XQFWLRQ

QR
I202* ,139'&.(< Input from key switch S17
6:,7&+
O203 287/,)7/2&.287 Output signal to LOCK OUT contacts is Battery
dischage indicator P3
O204* 2876833257$50 Output signal to Support arm solenoid valve Y52
9$/9(
O205 2879'&.(< Output signal to key switch S17
6:,7&+
O206* 287+2850(7(5 Output signal to hourmeter P3
207 9 Common battery -ve connection
O208* 287)25.9$/9( Output signal to fork solenoid valve Y34
O209* 287/2:(59$/9( Output signal to lower solenoid valve Y41
O210 287)25.6/,0,7 Output signal to height limit switch S32
(fork height < 1600 mm). MXF only
Connected directly to 211 on MXD models
I211* ,13)25.6/,0,7 Input signal from height limit switch S32
(fork height < 1600 mm).MXF only
Connected directly to 210 on MXD models
O212* 287/2:63((' Output signal to magnetic switch S24
(fork height < 1200 mm) MXD only
Connected directly to 213 on MXF models
I213* ,13/2:63((' Input signal from magnetic switch S24
(fork height < 1200 mm) MXD only
Connected directly to 212 on MXF models

O301 2876+817),(/' +24 V feed to shunt field winding

I302 ,136+817),(/' Return connection from shunt field winding

O401* 287'5,9()25. Indicates status of output signal from transistor

',5(&7,21 regulator for fork direction contactor K11
O402* 287'5,9(67((5 Indicates status of output signal from transistor
:+((/',5(&7,21 regulator for steer wheel direction contactor K13
O403 287&217$&7256 +24 V feed to direction contactors

© BT Industries AB Service Manual 1997-03-25 English 3 (4)

F-code Section C-code
36 6 
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7HUPLQDO 6LJQDOQDPH )XQFWLRQ

QR
O405* 2873803&217$& Output signal to pump motor contactor K30
725 Note extra switches on MXF models
O406* 287+251 Output signal to horn H1
I407 ,139'&%$77(5< Supply to A5 card
O408 Output signal, brake switch, to transistor regula-
tor
409 9 Common battery -ve connection
O410 Output signal, key switch, to transistor regulator
O411 Output signal, drive fork direction, to transistor
regulator
O412 Output signal, drive steer wheel direction, to tran-
sistor regulator
I413 “Low” connection for speed potentiometer R1 to
transistor regulator
O414 Reference value from speed potentiometer R1 to
transistor regulator
O415 Output signal safety reverse S20 to transistor
regulator
O416 Output signal safety reverse S20 supervison to
transistor regulator
O417 2876+817),(/' Shunt field connection from A5 card to transistor
regulator

O = Output signal from electronic card A5

I = Input signal to electronic card A5
* = Presence of LED on A5 card
Input = green LED
Output = red LED

4 (4) Service Manual 1997-03-25 English

 F-code Section C-code
36 6 
(OHFWURQLFFDUG
IIssued by Approved by Version no T-code
66' .+DOOPDQ  

(OHFWURQLFFDUG
Valid from serial number:

7FRGH 0RGHO 6HULDO1R 1RWHV

351 PPS 1000MX 270001AA-
352 PPS 1200MX 270001AA-
353 PPS 1200MXS 270001AA-

*HQHUDO
The electronic card is a card to create a common connection
point in the electrical system for the different wiring har-
nesses. The card is equipped with green LED’s on the inputs
from micro switches and red LED’s on the outputs to the con-
tactors to 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.

© BT Industries AB Service Manual 1995-12-07 English 1 (4)

F-code Section C-code
36 6 
(OHFWURQLFFDUG
Version no T-code
 

&RQQHFWRUVDQGDGMXVWPHQWV


111
106 204 207 409 417
105 110 408 416
203
104 407 415
202 206 406 414
103 109 201 205
405
102 108

101 107
301 302
404 413 
403 412
402
411
410
401

3RVLWLRQ &RQQHFWLRQ$GMXVWPHQW
1 Key switch (S17), battery -, instrument, mag-
netic valve (Y41)
2 Battery +, armature voltage, contactors, horn
3 Shunt field
4 RV1, adjustment of maximum speed
5 Micro switches

2 (4) Service Manual 1995-12-07 English

 F-code Section C-code
36 6 
(OHFWURQLFFDUG
Version no T-code
 

7HUPLQDOVDQG/('¶V

111
106 204 207 409 417
105 110 408 416
203
104 407 415
202 206 406 414
103 109 201 205
405
102 108

101 107 404 413

301 302
403 412
402
411
410
401

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

7HUPLQDO /('1R &RQQHF )XQFWLRQ

1R WLRQ
101 101 I Driving, fork direction
102 102 I Driving, steer wheel direction
103 O Speed control
104 I Referens 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
108 O 24 V (+)
109 109 I Brake
110 I Safety reverse (S20)
111 I Safety reverse (S20)

201 I Battery controller

202 202 I 24 V (+)
203 O Battery controller
© BT Industries AB Service Manual 1995-12-07 English 3 (4)
F-code Section C-code
36 6 
(OHFWURQLFFDUG
Version no T-code
 

7HUPLQDO /('1R &RQQHF )XQFWLRQ

1R WLRQ
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
403 O Contactor drive direction, common (+)
404 Not connected
405 405 O Contactor, pump motor
406 O Horn
407 I 24 V (+)
408 O Input 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 Referens value, speed
415 O Safety reverse, (S20)
416 O Safety reverse, (S20)
417 I Shunt field(-)

4 (4) Service Manual 1995-12-07 English

 F-code Section C-code
36 6 
+\GUDXOLFV\VWHP
IIssued by Approved by Version no T-code
66' *LDQQL-DUYLV  

+\GUDXOLFV\VWHP
Valid from serial number:

7FRGH 0RGHO 6HULDO1R 1RWHV

204 PPH 1600MX 251000AA-

*HQHUDO
The hydraulic system consists of a compact hydraulic unit
(including a magnetic lowering valve), two magnetic valves for
the support arm lift and fork lift, one telescopic cylinder for the
support arm lift and one telescopic cylinder for the fork lift.

© BT Industries AB Service Manual 1995-01-10 English 1 (4)

F-code Section C-code
36 6 
+\GUDXOLFV\VWHP
Version no T-code
 

'HVFULSWLRQRIIXQFWLRQ
+\GUDXOLFGLDJUDPDQGFRPSRQHQWV

3RV1R 'HVFULSWLRQ 5HPDUN

1 Lift Cylinder Fork lift
2 Magnetic Valve Block Y52 = Fork lift
Y34 = Support arm lift
3 Hydraulic Unit Y41 = Lowering valve
M3 = Pump motor
4 Lift Cylinder Support arm lift

2 (4) Service Manual 1995-01-10 English

 F-code Section C-code
36 6 
+\GUDXOLFV\VWHP
Version no T-code
 

(OHFWULFDOFRQQHFWLRQV

© BT Industries AB Service Manual 1995-01-10 English 3 (4)

F-code Section C-code
36 6 
+\GUDXOLFV\VWHP
Version no T-code
 

'HVFULSWLRQ
6XSSRUWDUPOLIW
Closing micro switch S52 closes pump contactor K30 to start
the pump motor. At the same time support arm valve Y52
opens. The valve stays open for as long as the micro switch is
closed. When releasing S52 to stop the lift, the closing of Y52
is delayed by voltage supply from relay RE1 while the speed
of the pump motor is reduced somewhat after K30 has
opened.

6XSSRUWDUPORZHU
Closing micro switch S40 provides voltage to both the support
arm valve Y52 and lowering valve Y41.

)RUNOLIW
Closing micro switch S34 provides voltage to fork valve Y34
and pump contactor K30.

)RUNORZHU
Closing micro switch S41 provides voltage to both fork valve
Y34 and lowering valve Y41.

3ULRULW\
A priority has been given to the support arm lift and lower
function by means of series connection of the micro switches
for two lift functions. This to block the possibility to operate
both lift functions at the same time.

4 (4) Service Manual 1995-01-10 English

 F-code Section C-code
36 6 
+\GUDXOLFV\VWHP
IIssued by Approved by Version no T-code
66' .+DOOPDQ  

+\GUDXOLFV\VWHP
Valid from serial number:

7FRGH 0RGHO 6HULDO1R 1RWHV

351 PPS 1000MX 270001AA-
352 PPS 1200MX 270001AA-
353 PPS 1200MXS 270001AA-

*HQHUDO
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.

© BT Industries AB Service Manual 1995-12-07 English 1 (4)

F-code Section C-code
36 6 
+\GUDXOLFV\VWHP
Version no T-code
 

'HVFULSWLRQRIIXQFWLRQ
+\GUDXOLFGLDJUDPDQGFRPSRQHQWV

A B

0DLQFRPSRQHQWV

3RV1R 'HVFULSWLRQ 5HPDUN

1 Lift Cylinders Fork lift
2 Hydraulic Unit A = Non return valve
B = Lowering valve
C = Relief valve
M = Pump motor

2 (4) Service Manual 1995-12-07 English

 F-code Section C-code
36 6 
+\GUDXOLFV\VWHP
Version no T-code
 

'HVFULSWLRQ
/LIW
When the pump motor starts, the oil flows through the non
return valve to the lift cylinders.

/RZHU
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 move-
ment of the lever.

2SHUDWLQJSUHVVXUH
The operating pressures at rated load are:
• PPS 1000MX: 150 bar
• PPS 1200MX: 180 bar
• PPS 1200MXS: 190 bar

5HOLHIYDOYH
The relief valve opens at the following pressures:
• PPS 1000MX: 170 bar
• PPS 1200MX: 200 bar
• PPS 1200MXS: 210 bar

© BT Industries AB Service Manual 1995-12-07 English 3 (4)

F-code Section C-code
36 6 
+\GUDXOLFV\VWHP
Version no T-code
 

4 (4) Service Manual 1995-12-07 English

 F-code Section C-code
36 6 
+\GUDXOLFV\VWHP
IIssued by Approved by Version no T-code
66' .+DOOPDQ  

+\GUDXOLFV\VWHP
Valid from serial number:

7FRGH 0RGHO 6HULDO1R 1RWHV

351 PPS 1000MX 270001AA-
352 PPS 1200MX 270001AA-
353 PPS 1200MXS 270001AA-

*HQHUDO
The hydraulic system consists of a compact hydraulic unit,
including a mechanical lowering valve, electromagnetic lower-
ing valve, pressure relief valve and the cylinders for the lift of
the forks.

© BT Industries AB Service Manual 1995-12-07 English 1 (4)

F-code Section C-code
36 6 
+\GUDXOLFV\VWHP
Version no T-code
 

'HVFULSWLRQRIIXQFWLRQ
+\GUDXOLFGLDJUDPDQGFRPSRQHQWV

0
D
A B

0DLQFRPSRQHQWV

3RV1R 'HVFULSWLRQ 5HPDUN

1 Lift Cylinders Fork lift
2 Hydraulic Unit A = Non return valve
B = Lowering valve
C = Relief valve
D = Electro-magnetic valve
M = Pump motor

2 (4) Service Manual 1995-12-07 English

 F-code Section C-code
36 6 
+\GUDXOLFV\VWHP
Version no T-code
 

'HVFULSWLRQ
/LIW
When the pump motor starts, the oil flows through the non
return valve to the lift cylinders.

/RZHUPHFKDQLFDO
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 move-
ment of the lever.

/RZHUHOHFWULFDO
When the electro-magnetic valve is affected 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.

2SHUDWLQJSUHVVXUH
The operating pressures at rated load are:
• PPS 1000MX: 150 bar
• PPS 1200MX: 180 bar
• PPS 1200MXS: 190 bar

5HOLHIYDOYH
The relief valve opens at the following pressures:
• PPS 1000MX: 170 bar
• PPS 1200MX: 200 bar
• PPS 1200MXS: 210 bar

© BT Industries AB Service Manual 1995-12-07 English 3 (4)

F-code Section C-code
36 6 
+\GUDXOLFV\VWHP
Version no T-code
 

4 (4) Service Manual 1995-12-07 English

 F-code Section C-code
36 6 
0DLQOLIWFKDLQV\VWHP
Issued by Approved by Version no T-code
,76 6%ORP  

0DLQOLIWFKDLQV\VWHP
Valid from serial number:

7 0RGHO 0DFKLQHQR 5HPDUNV

FRGH
204 PPH 1600MX all
349 PPS 1600MXD all
350 PPS 1200MXF all
351 PPS 1000MX all
352 PPS 1200MX all
353 PPS 1200MXS all

*HQHUDO
Applies to all machines with a mast.
127(
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55((DQG55(&(&WKHFKDLQVVKRXOGEH
UHSODFHGHYHU\\HDUV

&KHFNLQJWKHFKDLQVHWWLQJ
The lift chains must be adjusted at regular periods due to stretching,
see below. The chain setting is checked during servicing as set out
in the maintenance schedule.
Any adjustment is made with the chain mounting bolts.
Adjust the fork height according to C code 7100, 7420, 7700 and
7800 as applicable.

Service Manual 2002-12-02 English 1 (8)

F-code Section C-code
36 6 
0DLQOLIWFKDLQV\VWHP
Version no T-code
 

&KDLQLQVSHFWLRQ
The chains are exposed to two types of wear, outline wear and
stretching. Wear to the bolts and disc holes is caused by stretching.
The chains are also affected by the environment they are used in.

1RLVH
If lubrication has been insufficient there will be metallic friction on the
chain and this will result in noise.
7KHFKDLQVKRXOGEHUHSODFHG

6XUIDFHUXVW
Surface rust is easy to recognize as the chain will be reddish brown.
Deep-seated rust has generally started and the chain has impaired
strength.
7KHFKDLQVKRXOGEHUHSODFHG

5XVW\OLQNV
Fretting corrosion results in a reddish brown powder being visible by
the outer discs. It can also appear as if the chain is bleeding when
lubricated.
7KHFKDLQVKRXOGEHUHSODFHG

6WLIIOLQNV
If it is not possible to pull out the chain to its normal position this can
be because of link rust or seizing.
7KHFKDLQVKRXOGEHUHSODFHG

2 (8) Service Manual 2002-12-02 English

 F-code Section C-code
36 6 
0DLQOLIWFKDLQV\VWHP
Version no T-code
 

%ROWURWDWLRQ
Bolt rotation can be a phenomenon of stiff links. The fault is easy to
see when comparing with a new chain.
7KHFKDLQVKRXOGEHUHSODFHG
.

/RRVHEROWV
If a bolt is loose it will protrude from the side of the chain, which is
due to a stiff link or bolt rotation.
7KHFKDLQVKRXOGEHUHSODFHG

Service Manual 2002-12-02 English 3 (8)

F-code Section C-code
36 6 
0DLQOLIWFKDLQV\VWHP
Version no T-code
 

2XWOLQHZHDU

+ +

P = Pitch
H2 = Nominal disc height.
H3 = Minimum disc height.

A new lift chain has a specific nominal disc height, defined as H2 in

the figure. As the truck is used the lift chain wears radically, on the
side that runs over the chain sprocket. The minimum disc height is
define as H3 in the figure and denotes the minimum permitted value
of the disc height.
0D[LPDOSHUPLWWHGRXWOLQHZHDULVRIWKHKHLJKW+,IDOLIW
FKDLQUHDFKHVWKHPD[LPXPOHYHORIZHDUWKHFKDLQVKRXOGEH
UHSODFHG
The nominal and minimum disc heights for respective lift chains are
stated in the table in the chapter “Stretching”.

4 (8) Service Manual 2002-12-02 English

 F-code Section C-code
36 6 
0DLQOLIWFKDLQV\VWHP
Version no T-code
 

6WUHWFKLQJ
The amount of stretch on a lift chain is measured on the part of the
chain that runs over the chain sprocket. The amount of stretch may,
at the most, be 2% on the most worn section of the chain. Measure-
ment is suitably made over 300-1000 mm of the chain.
The nominal and maximum permitted chain lengths for lift chains
are stated in the table below.

7\SHRI 1RPLQDO 0LQLPXP 3LWFK3 1RPLQDOFKDLQ 0D[LPXPSHUPLW

FKDLQ GLVFKHLJKW GLVFKHLJKW PP OHQJWKIRU WHGFKDLQOHQJWKIRU
+PP +PP GLVFVPP GLVFVPP
3/4”, 2x3 17.8 16.9 19.05 381/572/953 389/583/972
3/4”, 3x4 17.8 16.9 19.05 381/572/953 389/583/972
3/4”, 4x6 17.8 16.9 19.05 381/572/953 389/583/972
1”, 4x4 23,6 22,4 25,4 508/762/1270 518/777/1295
1”, 6x6 23,6 22,4 25,4 508/762/1270 518/777/1295

:HDUWRWKHEROWVDQGDURXQGWKHKROHVRQWKHGLVFVDUHDUHDVRQ
ZK\WKHFKDLQVWUHWFKHV7KHFKDLQVKRXOGEHUHSODFHGLIVWUHWFK
LQJLVPRUHWKDQ

'DPDJH
7KHFKDLQVKRXOGEHUHSODFHGLIGDPDJHGLQDQ\ZD\

Service Manual 2002-12-02 English 5 (8)

F-code Section C-code
36 6 
0DLQOLIWFKDLQV\VWHP
Version no T-code
 

'DPDJHGGLVFV
If a disc has broken on the chain, this can be due to overloading or
corrosion.
7KHFKDLQVKRXOGEHUHSODFHG

'DPDJHGEROWV
It can be difficult to discover whether a bolt has broken. It can appear
as bolt rotation and/or that the outer disc is loose.
7KHFKDLQVKRXOGEHUHSODFHG

'LUW\FKDLQ
If a chain is very dirty it is first and foremost recommended that it is
replaced. It can also be dismantled and cleaned as set out in the
chapter “Cleaning”.

&OHDQLQJ
If a chain is very dirty it is recommended that it is replaced.
Dirty chains should be cleaned before they are lubricated, e.g. by
washing with solvent such as diesel or petrol.
The chain should be blown dry using compressed air and lubricated
directly after cleaning
127(
([HUFLVHFDUHZLWKGHJUHDVLQJDJHQWDVWKHVHFDQFRQWDLQDEUD
VLYHV

6 (8) Service Manual 2002-12-02 English

 F-code Section C-code
36 6 
0DLQOLIWFKDLQV\VWHP
Version no T-code
 

/XEULFDWLRQ
Mineral and synthetic oils can be used to relubricate Rexnord
chains.
127(
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GLVXOSKLGH37)(RUWKHOLNH
A lift chain should be offloaded from the weight of the fork carriage
(hanging free) when lubricated.
• /XEULFDWLRQLQWHUYDOV
- 500 hours with normal operations
- 100 hours when driving in rugged environments such as cold
stores and corrosive environments.
The chains are sprayed with lubricant. Note the entire chain must be
lubricated, even the fastening bolts. It is especially important that the
part of the chain which runs over the chain sprocket is well lubricat-
ed.
The lubricate must comply with the viscosity demands at respective
temperatures as set out in the table below. The following lubricants
are recommended:
$PELHQW 9LVFRVLW\ 5HFRPPHQGHG3URGXFWV
WHPSHUDWXUH FODVV
> - 40°C VG 15 Klüberoil 4UH 1-15, Klüber
< - 30°C Lubrication
> - 30°C VG 68 Klüberoil 4UH 1-68N, Klüber
< + 5°C Lubrication
Anticorit LBO 160 TT, Fuchs
DEA
> + 5°C VG 150 Klüberoil 4UH 1-150N, Klüber
< + 45°C Lubrication
Anticorit LBO 160, Fuchs DEA
Rexoil, Rexnord Kette
>+ 45°C VG 220 Klüberoil 4UH 1-220N, Klüber
<+ 80°C Lubrication
* Equivalent products from another manufacturer may be used.
127(
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UXVWRQWKHOLIWFKDLQV
7KHVHDJHQWVLPSDLUWKHOXEULFDWLRQRIWKHFKDLQV5HJXODUOXEUL
FDWLRQLVWKHEHVWPHWKRGWRSUHYHQWUXVWDWWDFN

Service Manual 2002-12-02 English 7 (8)

F-code Section C-code
36 6 
0DLQOLIWFKDLQV\VWHP
Version no T-code
 

8 (8) Service Manual 2002-12-02 English