Download Complete Service Repair Manual for 1989-2002 BT Prime Mover OE35 Electric Counterbalance Order Selector.
This Factory Service Repair Manual offers all the service and repair information about BT Prime Mover OE35 Electric Counterbalance Order Selector. The information on this manual covered everything you need to know when you want to repair or service BT Prime Mover OE35 Electric Counterbalance Order Selector.
Models Covered:
BT Prime Mover OE35 Electric Counterbalance Order Selector
Manuals Covered:
Service manuals
Parts manuals
Master Parts Manuals
Electrical Schematics
Operators manuals
NDC System Information
Specials
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Service Manual Contents:
BT Standard Codes …………………………………………………………………………… 1
Warning Symbols ……………………………………………………………………………… 9
Warning Levels ……………………………………………………………………………… 9
Prohibitory Symbols ………………………………………………………………………… 10
Ordinance Symbols ………………………………………………………………………. 10
Introduction, Service Manual ……………………………………………………………. 11
Contents, Section M …………………………………………………………………………. 13
Machine Information ……………………………………………………………………… 13
General Product Information ……………………………………………………………. 15
Presentation of the OE35 ………………………………………………………………. 15
Main Components …………………………………………………………………………. 20
Inch (SAE) and Metric Fasteners ………………………………………………………. 23
Introduction ………………………………………………………………………………….. 23
Nomenclature, Threads …………………………………………………………………. 24
Strength Identification ……………………………………………………………………. 25
Conversion of Metric and English Units ……………………………………………. 31
Technical Service Data …………………………………………………………………….. 33
Ordering Spare Parts ……………………………………………………………………….. 37
Service Schedule …………………………………………………………………………….. 39
Planned Maintenance Schedule ……………………………………………………… 39
Planned Maintenance Procedures …………………………………………………….. 43
Services to be performed daily or at each 8 hour operating shift …………. 43
Services to be performed monthly or every 250 operating hours …………. 45
Services to be performed annually or every 1200 operating hours ………. 48
Lubrication Chart …………………………………………………………………………….. 51
Oil and Grease Specifications ………………………………………………………….. 53
Approved Oils and Grease …………………………………………………………….. 53
Contents, Section S …………………………………………………………………………. 55
Service Instructions ………………………………………………………………………. 55
Inspection Covers ……………………………………………………………………………. 57
Removal Of Plastic Dash Panel ………………………………………………………. 58
Drive Motor ……………………………………………………………………………………… 61
General Information ………………………………………………………………………. 61
Operating Conditions …………………………………………………………………….. 61
Troubleshooting ……………………………………………………………………………. 61
Drive Motor 24 Volt ………………………………………………………………………….. 67
Component Repair ………………………………………………………………………… 68
Inspection and Troubleshooting ………………………………………………………. 69
When changing brushes ………………………………………………………………… 74
Drive Motor 36 Volt ………………………………………………………………………….. 75
Component Repair ………………………………………………………………………… 76
Inspection and Troubleshooting ………………………………………………………. 77
When Changing Brushes ……………………………………………………………….. 82
Transmission …………………………………………………………………………………… 83
System description ……………………………………………………………………….. 83
Troubleshooting ……………………………………………………………………………. 83
Removal ………………………………………………………………………………………. 84
Transmission Disassembly / Assembly …………………………………………….. 87
Disassembly ………………………………………………………………………………… 88
Installation ……………………………………………………………………………………. 95
Drive Wheel ……………………………………………………………………………………… 97
Load Wheels ……………………………………………………………………………………. 99
Stabilizing Caster Spring Loaded …………………………………………………….. 101
Removal ……………………………………………………………………………………… 102
Inspection …………………………………………………………………………………… 104
Disassembly ……………………………………………………………………………….. 105
Torque Generator ……………………………………………………………………………. 107
Disassembly ……………………………………………………………………………….. 109
Assembly ……………………………………………………………………………………. 114
Steering System Pump ……………………………………………………………………. 121
General Information ……………………………………………………………………… 122
Removal ……………………………………………………………………………………… 122
Installation …………………………………………………………………………………… 123
Disassembly ……………………………………………………………………………….. 125
Inspection …………………………………………………………………………………… 126
Assembly ……………………………………………………………………………………. 126
Steering System ……………………………………………………………………………… 129
General Information ……………………………………………………………………… 129
Electrical System with TX and TT Card …………………………………………….. 131
Electrical Schematic Part 1 ……………………………………………………………. 131
Electrical Schematic Part 2 ……………………………………………………………. 132
Basics Of Circuit Operation …………………………………………………………… 133
Control Features ………………………………………………………………………….. 135
General Maintenance Instructions ………………………………………………….. 143
Trouble-shooting Instructions ………………………………………………………… 144
Battery Controller / Hourmeter / Lift Interrupt …………………………………… 147
General Information ……………………………………………………………………… 147
Electrical …………………………………………………………………………………….. 147
Battery Controller (BC) …………………………………………………………………. 148
Troubleshooting …………………………………………………………………………… 151
Dash Display …………………………………………………………………………………… 155
General Information ……………………………………………………………………… 155
Location ……………………………………………………………………………………… 156
Operational Checks ……………………………………………………………………… 156
Status Codes ………………………………………………………………………………. 157
EV100 LX Control Status Codes ………………………………………………………. 159
SCR Component Checks …………………………………………………………………. 177
Main Logic Card …………………………………………………………………………… 177
Capacitor 1C ……………………………………………………………………………….. 178
Contactors Forward, Rearward, 1A, Power Steering, and Pump ………… 178
Potentiometer in Accelerator …………………………………………………………. 178
SCR’s (1REC, 2REC, 5REC) ………………………………………………………… 178
Rectifiers (3REC, 4REC, Diode Blocks) ………………………………………….. 180
Thermal Protector (TP) …………………………………………………………………. 180
Filter Block (23FIL, etc.) ………………………………………………………………… 181
Filter Block (23FIL, etc.) ………………………………………………………………… 181
1X Choke and Reactor T3-T4 ………………………………………………………… 181
Replacement of EV100 Components ……………………………………………… 181
Instructions – EV100 Plugs ……………………………………………………………. 183
Direction Contactor …………………………………………………………………………. 185
General Information ……………………………………………………………………… 186
Remove / replace contact tips ……………………………………………………….. 186
1A Speed Contactor ………………………………………………………………………… 191
General Information ……………………………………………………………………… 192
Disassembly ……………………………………………………………………………….. 192
Assembly ……………………………………………………………………………………. 194
Electrical System Troubleshooting ………………………………………………….. 197
Control Circuits and Power Circuits ………………………………………………… 199
Electrical System Troubleshooting Charts ……………………………………….. 201
Pump Contactor ……………………………………………………………………………… 213
General Information ……………………………………………………………………… 214
Disassembly ……………………………………………………………………………….. 214
Assembly ……………………………………………………………………………………. 216
Steering Pump Contactor ………………………………………………………………… 219
General Information ……………………………………………………………………… 220
Disassembly ……………………………………………………………………………….. 220
Assembly ……………………………………………………………………………………. 222
EV100 Handset Operation ……………………………………………………………….. 225
General Information ……………………………………………………………………… 225
Purpose ……………………………………………………………………………………… 226
Operation ……………………………………………………………………………………. 227
Function Set-Up Procedures …………………………………………………………. 228
Description and Location ………………………………………………………………. 230
Function Numbers for Controllers …………………………………………………… 231
Hydraulic System ……………………………………………………………………………. 239
Hydraulic Schematic …………………………………………………………………….. 239
General Information ……………………………………………………………………… 240
Maintenance ……………………………………………………………………………….. 242
Adjustments ………………………………………………………………………………… 242
Hydraulic Troubleshooting ……………………………………………………………… 243
Troubleshooting Chart ………………………………………………………………….. 243
Lift Pump Assembly ………………………………………………………………………… 247
Removal ……………………………………………………………………………………… 248
Disassembly ……………………………………………………………………………….. 249
Inspection …………………………………………………………………………………… 252
Assembly ……………………………………………………………………………………. 254
Mast, 2 Stage ………………………………………………………………………………….. 257
Shimming Mast on Truck. ……………………………………………………………… 258
Two Stage Mast …………………………………………………………………………… 262
Mast, 3 Stage ………………………………………………………………………………….. 267
Shimming Mast on Truck. ……………………………………………………………… 268
Three Stage Mast ………………………………………………………………………… 273
Lift Cylinder, 2 Stage ………………………………………………………………………. 279
Cylinder Repair ……………………………………………………………………………. 280
Freelift Cylinder, 3 Stage …………………………………………………………………. 283
Freelift Cylinder Repair …………………………………………………………………. 284
Staging Cylinder, 3 Stage ………………………………………………………………… 287
Micro 70 Wire Guidance Important Information ………………………………… 291
Powering Up: ………………………………………………………………………………. 291
Powering Down: …………………………………………………………………………… 291
Micro 70 Wire Guidance ………………………………………………………………….. 293
Electrical Schematic Part 1 ……………………………………………………………. 293
Electrical Schematic Part 2 ……………………………………………………………. 294
Electrical Schematic Part 3 ……………………………………………………………. 296
Electrical Schematic Part 4 ……………………………………………………………. 298
Cautions and Warnings ………………………………………………………………… 300
Operation Information …………………………………………………………………… 302
Component Function and Relationship ……………………………………………. 306
Truck Set Up On Site ……………………………………………………………………. 308
Troubleshooting Information ………………………………………………………….. 311
Troubleshooting Charts ………………………………………………………………… 314
Other manuals all cover full contents
This manual can be used by anyone from a first time owner/amateur to a professional technician.Even the most novice mechanic can also easily follow the step-by-step guides which are made simple by the illustrations and drawings.Keep this manual handy and use it often. Performing routine, preventive maintenance will save you time & money by helping to prevent premature failure and unnecessary repairs.
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