Master Service Manual Product Family PT: BT PPT 1400C BT PPT 1400 MX BT PPT 1400Mxc BT PPT 1600Mx BT PPT 2000Mx

Master Service Manual
Product family PT
BT PPT 1400C
BT PPT 1400 MX
BT PPT 1400MXC
BT PPT 1600MX
BT PPT 2000MX
© BT Industries AB Part number: 147637-040

Issued: 1995-04-07 SSD
F-code Section C-code
PT
Contents Master Service Manual (MSM)
IIssued by Approved by Version no T-code
SSD Iréne Karlsson 001 200,201,202,454
Contents
Master Service Manual (MSM)
Part number: 147637-040
Issued1999-06-23
Valid from serial number:
T-code Model Serial No Notes

200 PPT 1400MX/MXC 276898AA-
201 PPT 2000MX 276898AA-
202 PPT 1600MX 276898AA-
454 PPL 2000MX 305210AA-
1. Document list
Section C-code T-code Document Issued
Introduction 1998-11-04
M Contents, M 1998-11-04
M1 200, 201, Issued Operator’s manual 1999-04-14
202, 454
M2 200, 201, 202 General product information 1999-06-02
454 General product information 1998-09-02
M4 200, 201, 202 Technical data 1994-03-24
454 Technical data 1998-06-12
M6 Ordering Spare Parts 1998-11-04
M7 200, 201, 202 Quality Parts 1999-06-21
M8 200, 201, Recommended Spare Parts 1999-06-21
202, 454
P Contents, P 1998-11-04
P1 Introduction, maintenance 1998-11-04
P2 200, 201, 202 Preventive maintenance 1994-01-21
454 Preventive maintenance 1998-01-09
© BT Industries AB Service Manual 1998-11-04 English 1 (2)

PT
Contents Master Service Manual (MSM)
Version no T-code
001 200,201,202,454
Section C-code T-code Document Issued

P3 200, 201, 202 Oil and grease specification 1996-08-20
454 Oil and grease specification 1998-01-09
S Contents, S 1998-11-04
S1 1700 200, 201, 202 Electric drive motor 1999-05-11
1700 454 Electric drive motor 1999-02-03
S2 2550 200, 201, Drive gear 1998-01-09
202, 454
S3 3360 200, 201, Mechanical brakes 1999-02-03
202, 454
S5 5000.1 200, 201, 202 Electrical system, resistance 1994-03-01
regulator
5000.2 200, 201, 202 Electrical system, transistor 1994-03-12
regulator
5000 454 Electrical system, transistor 1998-01-09
regulator
5230 200, 201, Battery controller/hourmeter 1999-01-02
202, 454
5460.1 200, 201, 202 Transistor regulator 1994-03-01
5460.2 200, 201, 202 Transistor regulator 1997-03-19
5460.3 200, 201, Transistor regulator 1998-06-23
202, 454
5710.1 200, 201, 202 Electronic card, resistence 1994-03-03
control
5710.2 200, 201, 202 Transistor card, transistor 1994-03-12
control
2 (2) Service Manual 1998-11-04 English

PT
Introduction to BT’s Service Manual
SSD 001
Introduction to BT’s
Service Manual
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: Section M 4 means that it is Tech-
nical Data; F-code means it deals with this specific truck fam-
ily; T-code means specific products; Date and Version
number 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

PT
Introduction to BT’s Service Manual
Version no T-code
001

PT M
Contents, M
SSD
Contents, M
1 Truck information
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

PT M
Contents, M
Version no T-code

PT M1
Operator’s manual
Operator’s manual

200 PPT 1400MX/MXC 276898AA-
201 PPT 2000MX 276898AA-
202 PPT 1600MX 276898AA-
454 PPL 2000MX 305210AA-
1 General
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.
1.1 Issued operator’s manuals

T-code Model Serial number Order Issued
number
200/201/202 PPT 1400/1600/2000MX 135329 1996-12-21
200 PPT 1400MX/MXC 276898AA-293314AA 147334 1996-04-10
200/201/202 PPT 1400/1600/2000MX 293315AA-298799AA 156067 1996-10-15
202 PPT 1600MX 276898AA-293314AA 147377 1996-04-11
201 PPT 2000MX 276898AA-293314AA 147336 1996-04-18
200/201/202 PPT 1400/1600/2000MX 298800AA-306954AA 157089 1997-04-02
200/201/202 PPT 1400/1600/2000MX 306955AA- 161043 1997-09-22
200/201/202 PPT 1400/1600/2000MX 306955AA-316911AA 161280 1998-02-06
200/201/202 PPT 1400/1600/2000MX 316912AA-324213AA 163579 1998-04-01
200/201/202 PPT 1400/1600/2000MX 324214AA-335438AA 166152 1998-08-12
200/201/202 PPT 1400/1600/2000MX 335439AA- 169983 1999-02-03
454 PPL 2000MX 305210AA-329899AA 160279 1998-02-10
454 PPL 2000MX 329900AA- 166904 1998-11-23
One of these Operator’s Manuals is supplied with the Manual

as general information.
PT M1
Operator’s manual
Version no T-code
001 200,201,202,454

PT M2
General product information
SSD L-G Andersson 001 200,201,202


200 PPT 1400MX/MXC 307085AA-
201 PPT 2000MX 307085AA-
202 PPT 1600MX 307085AA-
1 Presentation of the truck

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.
PPT 1400C is a battery-powered support-arm truck for load-
ing and leaving loads in confined areas. Thanks to its small
format it is also suitable to carry on lorries.
The trucks PPT 1400MX and PPT 1400C have a maximum
lifting capacity of 1400 kg.
PPT 1600MX has a maximum lifting capacity of 1600 kg.
PPT 2000MX has a maximum lifting capacity of 2000 kg.
The truck has a 24 V electrical system with two speed control
options: A stepless transistor controlled system that gives
smooth control of the speed while driving or a resistor control-
led system with three speed steps.
The truck can be equipped with different accessories such as
integrated charger, load support and running meter/battery
status. 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.
The forks are lifted by using a powerful and compact hydraulic
unit that is automatically shut-off when the forks reach their
highest lifting position. The automatic shut-off is used to
increase the service life of the hydraulic components and
reduce the power consumption from the battery.
Note that some of the truck models described in the Opera-
tor’s Manual may not be marketed in your country.

PT M2
Version no T-code
001 200,201,202
1.1 Intended application of the truck

The truck is solely designed and manufactured for indoor
transportation, collecting and leaving of loads. The truck
should be fitted with the appropriate accessories relevant to
the application.
1.2 Forbidden application of the truck

The truck is designed for handling goods indoors. It is not 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.

PT M2
Version no T-code
001 200,201,202
2 Truck data
The table provides information regarding some technical
data, which is of value with daily use of the truck.
Truck type PPT PPT PPT PPT

1400MX 1400C 1600MX 2000MX
Lifting capacity with rated 1400 1400 1600 2000
load, kg*
Lift height, mm 205 205 205 205
Operating speed without 1.7 1.7 1.7 1.7
load, m/s
Operating speed with rated
load, m/s 1.4 1.4 1.3 1.3
Max. operating gradient with
rated load, % 11 11 10 8
Weight without battery, kg 305 (240) 290 325 (240) 325 (240)
(Ah) 320 (320) 340 (320) 340 (320)
Weight with battery, kg (Ah) 505 (240) 455(160) 535(240) 535(240)
565(320) 585(320) 585(320)
Turning radius (Wa), mm 1463 (240) 1445 1463 (240) 1463 (240)
(Ah) 1511 (320) 1511 (320) 1511 (320)
Continuous noise level
according to CE prEN
12053, dB (A) < 70 <70 <70 <70
Continuous noise level
according to ASME B56, 11,
5_1992, db (A) 71 71 71 71
Permitted drive wheel, mate- Vulkollan Vulkollan Vulkollan Vulkollan
rial siped Vulkol- siped Vulkol- siped Vulkol- siped Vulkol-
lan lan lan lan
Tractothan Tractothan Tractothan Tractothan
Elastomer Elastomer Elastomer Elastomer
* 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.
PT M2
Version no T-code
001 200,201,202
3 Truck dimensions
The illustration shows external dimensions for the truck in its
standard design.
PPT 1400, 1600 & 2000MX
1235
PPT PPT PPT PPT

1400C 1400MX 1600MX 2000MX
L2 516 562 (240 Ah) 562 (240 Ah) 562 (240 Ah)
610 (320 Ah) 610 (320 Ah) 610 (320 Ah)
e 156 156 180 180

PT M2
Version no T-code
001 200,201,202
4 Identification plate
The illustration shows the identification plate used on the
A
truck.
B
C
D Item Text Unit
E A MODEL
E
B NO
F
C RATED CAPACITY kg
G D WEIGHT WITHOUT BATTERY kg

E BATTERY WEIGHT MAX kg
MIN kg
F BATTERY VOLTAGE V
G BATTERY TYPE ACCORD-
ING TO ASME-NORM UL583
(ONLY ASME)
5 Modification plate
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.
Item Text
A Modification plate
B Type
C Serial number
D Place of manufacture
E Place of manufacture
F Modification number
G Date

PT M2
Version no T-code
001 200,201,202
6 Main components
1. Tiller arm:
The truck is manoeuvred by the driver while walking. 208
degree steering area.
The brakes are applied in the tiller arm’s upper and lower
positions.
2. Covers:
Removable which provides good accessibility when serv-
icing.
3. Emergency disconnector and battery connector:
The battery is charged via the permanently fitted charging
connector.
4. Hydraulic unit:
Pump motor and pump are integrated in a compact unit.
5. Drive unit with brake:
Fixed drive unit with spring-loaded mechanical brake,
travel motor, gears and drive wheel combined into a com-
pact unit. Steering bearings between motor and gears.
6. Serial number:
The serial number plate fitted to the chassis.
7. Support castor wheels:
Two support castor wheels to ensure stability.
8. Electric panel:
Removable, which provides good access when servicing.
24 volt electrical supply. The speed is controlled by resis-
tor or transistor (variable) systems.
9. Fork carriage:
The forks are held horizontal by a link system. The fork
carriage requires no lubrication.
10. Battery:
24 V with different Ah values.
11. Instrument:
Combined hour meter/battery controller or hour meter
only.
12. Identification plate:
With model designation, serial number, year of manufac-
ture, weight without battery, battery weight, rated capacity,
battery voltage and manufacturer.

PT M2
Version no T-code
001 200,201,202
12
11
2
10
3
9 8 7

PT M2
Version no T-code
001 200,201,202
7 Warning and information plates and

symbols
The figure shows the position and significance of the plates
and symbols located on the truck.
1. Signal/Horn
2. Hydraulic control: Lower
3. Hydraulic control: Lift
4. Travel direction
5. Hydraulic oil filling
6. Serial number
7. Lifting points
8. Identification plate
9. Modification plate
10. Passengers prohibited

PT M2
SSD L-G Andersson 001 454

T-code Model Serial No. Notes

454 PPL 2000MX 305210AA-
1 Presentation of the truck

The truck is a battery powered support arm truck. In its basic
design the truck is equipped with a tiller arm for alternative
control: standing on the ride-on platform or walking.
The truck has a maximum lifting capacity of 2000 kg.
The truck has a 24 V electrical system with variable transistor
control that gives smooth control of the speed while driving.
The truck can be equipped with different accessories including
an integrated charger, load support and running meter/battery
guard. The truck can also be fitted with stainless steel axles
and low temperature oil with use in cold and damp environ-
ments.
The forks are lifted by a powerful and compact hydraulic unit,
which is shut off automatically when the forks reach the high-
est lifting height. The automatic shut off is employed to
increase the longevity of the hydraulic components and to
reduce the energy drain on the battery.
2 Intended use of the truck

The truck is designed and manufactured solely for indoor
transportation, loading and unloading of goods. The truck
should be equipped with the appropriate accessories relevant
to its working situation.
3 Forbidden use of the truck

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 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.
PT M2
Version no T-code
001 454
4 Truck data
The table provides information on specific technical data,
which is of value with the daily use of the truck.
Truck type PPL 2000MX

Lifting capacity, classified load, kg 2000
Lifting height, mm 205
Ride-on platform height (collapsed) , mm 150
Operating speed without load, m/s 1.65
Operating speed with classified load, m/s 1.4
Max. gradient with classified load, % 8
Weight without battery, kg
(240 Ah) 375
(320 Ah) 390
Weight with battery, kg
(240 Ah) 575
(320 Ah) 640
Turning radius with raised forks and raised
platform (medium battery compartment) 1570-2300
(Wa), mm (depending of fork length)
Continuous sound pressure level value
according to CE prEN12053, dB A < 70
Permitted drive wheel, material vulkollan
vulkollan siped
tractothane
elastomer
rubber
The lifting capacity, lifting height and weight of the truck can
be found on the truck’s type plates.

PT M2
Version no T-code
001 454
5 Truck dimensions
The diagram shows the outside dimensions of the truck in its
standard design.
PPL 2000MX
1360
805
620
150 85
L2 810-1520
725
R2
R1
PPL 2000MX 240 Ah PPL 2000MX 320 Ah

L2 665 713
R1 1570 2188
R2 1954 2618

PT M2
Version no T-code
001 454
6 Type plate
The diagram shows the truck’s type plate.
A
Item Text Unit
B
C A MODEL
D B NO
E C RATED CAPACITY kg
E
D WEIGHT WITHOUT BATTERY kg
F
E BATTERY WEIGHT MAX kg
MIN kg
G
F BATTERY VOLTAGE V
G BATTERY TYPE ACCORDING
TO ASME-NORM UL583
(ONLY ASME)
7 Modification plate
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.
Character Text
A Modification plate
B Type
C Serial number
D Place of manufacture
E Place of manufacture
F Modification number
G Date

PT M2
Version no T-code
001 454
8 Main components
1. Tiller arm:
The truck is operated by the driver when walking. Steering
range 208 degrees. The brakes are applied in the tiller’s
upper and lower positions.
2. Hoods:
Easily removable, providing good accessibility when serv-
icing.
3. Battery switch and Charging plug:
The battery is charged via the fixed charging plug.
4. Hydraulic unit:
Pump motor and pump are integrated into a compact unit.
5. Drive unit with brakes:
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. The pressure on the drive wheel is automati-
cally adjusted to the weight of the load.
6. Machine number:
Punched plate on the chassis.
7. Support castor wheel:
2 support castors to ensure stability.
8. Electrical panel:
Removable, providing good accessibility for servicing.
24 volt electrical system. The speed is regulated variably
by means of a transistor regulator.
9. Fork carriage:
The forks are kept parallel by a link system. The fork car-
riage is lubrication free.
10. Battery:
24 V with different Ah-rates.
11. Instruments:
Combined running meter/battery guard or just a running
meter.
12. Type plate:
Indicating the type designation, machine number, year of
manufacture, weight without battery, battery weight, clas-
sified lifting capacity, battery voltage, type of battery and
manufacturer.
13. Platform:
Collapsible ride-on platform, which is automatically raised
when it is not loaded.

PT M2
Version no T-code
001 454
12
11
2
10
3
6
9 8 7
13

PT M2
Version no T-code
001 454
9 Warning and information plates

The diagram shows the placement and significance of the
plates on the truck.
1. Horn
2. Hydraulic control: Lower
3. Hydraulic control: Lift
4. Direction of travel
5. Hydraulic oil filling point
6. Machine number
7. Lifting points
8. Type plate
9. Modification plate

PT M2
Version no T-code
001 454

PT M4
Technical data
SSD K Hallman 001 200,201,202
Technical data
T-kod Modell Maskinnr Anm.

200 PPT 1400MX/MXC 237000AA-
201 PPT 2000MX 237000AA-
202 PPT 1600MX 237000AA-
Model PPT 1400MX PPT 1600MX PPT 2000MX

Drive motor
Type TTL 140S-M2 TTL 140S-M2 TTL 140S-M2
Power, kW 1.2 1.2 1,2
Intermittens, % 60 60 60
Min carbon brush length, 12 12 12
mm
Min commutator diame- 47 47 47
ter, mm
Part No 138052 138052 138052
Transmission/gear
Type 2-step angular 2-step angular 2-step angular
Gear ratio 19,14:1 19,14:1 19.14:1
Oil volume, litre 1.0 1.0 1,0
Oil type Hypoid oil Hypoid oil Hypoidolja
Normal temperature SAE 80W/90 SAE 80W/90 SAE 80W/90
< -15oC SAE 75W SAE 75W SAE 75W
Wheels
Drive wheel, mm Dia 215x70 Dia 215x70 Dia215x70
Axle pressure without 415 425 425
load, kg
Axle pressure with rated 750 780 870
load, kg
Torque wheel bolts 65 Nm 65 Nm 65 Nm

PT M4
Technical data
Version no T-code
001 200,201,202

Fork wheel, mm Dia 85x75 Dia 85x75 Dia 85x75
Axle pressure with rated 1150 1350 1650
load, kg
Torque axle bolts ------------- 65 Nm 65
Support wheel, mm Dia 125x40 Dia 125x40 Dia 125x40
Axle pressure, kg 140 140 140
Hydraulic unit
Power, kW 1.2 2.0 2.0
Revolutions/min at work 5500 2700 2400
pressure
Intermittens, % 10 10 10
Min carbon brush length, 7.5 12 12
mm
Min commutator thick- 4.75
ness/diameter, mm
Pressure at rated load, 110 125 150
bar
Relief pressure, bar 130 140 170
Pump flow, litre/min 4.7 5.1 4.6
Tank volume, litre 0,5 1,0 1,0
Oil type Hydraulic oil Hydraulic oil Hydraulolja
Normal ISO-L-HM32 ISO-L-HM32 ISO-L-HM32
temperature
< -15oC ISO-L-HV32 ISO-L-HV32 ISO-L-HV32
Fuses
Motor circuits, A 29228 29228 29228
Ampere, A 100 100 100
Control circuit, A 122308-075 122308-075 122308-075
Ampere, A 7,5 7,5 7,5

PT M4
Technical data
Version no T-code
001 200,201,202

Batteries All models
Dimension WxLxH, mm 193x642x450 193x642x510 193x642x570
Capacity, Ah 180 210 240
Weight, kg 150 175 200
Part No 134364 133991 134365
Driving speeds
Without load, km/h 5,8 5,8 5,8
Without load, m/s 1.61 1.61 1,61
With rated load, km/h 5.0 4.9 4,8
With rated load, m/s 1.39 1.36 1,33
Lifting/lowering time
Lift without load, sec 2.4 1.7 1,7
Lift with rated load, sec 2.8 2.3 2,6
Lower without load, sec 2.2 2.2 2,2
Lower with rated load, 2.0 1.9 1,9
sec
Current consumption
Driving without load, A 18 18 18
Driving with rated load, A 27 29 31
Lifting without load, A 25 38 38
Lifting with rated load, A 66 97 122

PT M4
Technical data
Version no T-code
001 200,201,202

PT M4
Technical data
Technical data

454 PPL 2000MX 305210AA-
MODEL PPL 2000MX

Drive motor
Type TTL 140S-M2
Power, kW 1,2
Intermittens, % 60
Min. carbon brush length, mm 12
Min. commutator diameter, mm 47
Transmission/drive gear
Type 2-step angular
Gear ratio 19,14:1
Oil volume, litre 1,0
Oil Hypoid oil
Normal temperature SAE 80W/90
< -15oC SAE 75W
Wheels
Drive wheel, mm Dia 215x70
Axle pressure without load, kg 325
Axle pressure at rated load, kg 475
Tightening torque for wheel bolts, Nm 65
Fork wheels, mm Dia 80x75
Tightening torque for axle bolts -------------
Support wheels, mm Dia 125x40

PT M4
Technical data
Version no T-code
001 454
MODEL PPL 2000MX

Hydraulic unit
Output, kW 1,2
Speed/min. at working pressure 5500
Operating conditions, % 10
Min. carbon brush length, mm 7,5
Min. commutator 4,75
thickness/diameter, mm
Pressure at rated load, bar 110
Relief pressure, bar 130
Pump flow, litre/min. 4,7
Tank volume, litre 0,5
Oil type Hydraulic oil
Normal temperature ISO-L-HM32
< -15oC ISO-L-HV32
Fuses
Motor circuits 100 A
Control circuits 7,5 A
Batteries
Dimensions W x L x H, mm 196x645x570/
245x645x570
Capacity, Ah 240/320
Weight, kg 200/250
Driving speeds
Without load, km/h 5,9
Without load, m/s 1,65
With rated load, km/h 5,0
With rated load, m/s 1,40

PT M4
Technical data
Version no T-code
001 454
MODEL PPL 2000MX

Lifting and lowering times
Lift without load, s 1,7
Lift with rated load, s 2,6
Lowering without load, s 2,2
Lowering with rated load, s 1,9
Power consumption
Driving without load 29 A
Driving with rated load 50 A
Lifting without load 60 A
Lifting with rated load 150 A

PT M4
Technical data
Version no T-code
001 454

PT M6
Ordering Spare Parts
SSD 001

• 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.

PT M6
Version no T-code
001

PT M7
Quality Parts
Quality Parts

200 PPT 1400MX/MXC 239400AA-
201 PPT 2000MX 239400AA-
202 PPT 1600MX 239400AA-
454 PPL 2000MX 305210AA-
1 Issued Quality Parts
T-kod Model Serial No Order Issued

number
200/201/202 PPT 1400/1600/2000MX 239400AA-243536AA 28995 1992-12-01
200 PPT 1400/1600/2000MX 243537AA-246663AA 29537 1993-05-01
200 PPT 1400/1600/2000MX 246664AA-247613AA 139696 1993-09-01
200 PPT 1400/1600/2000MX 247614AA-268676AA 140576 1994-03-01
200 PPT 1400/1600/2000MX 268677AA-284058AA 148185 1995-10-01
200 PPT 1400/1600/2000MX 284059AA-293314AA 152380 1996-05-01
200 PPT 1400/1600/2000MX 293315AA- 154710 1996-11-01
200/201/202 PPT 1400/1600/2000MX 306955AA-316739AA 160670 1997-10-29
201/201/202 PPT 1400/1600/2000MX 316740AA-324213AA 163526 1998-03-27
200/201/202 PPT 1400/1600/2000MX 324214AA-329899AA 166102 1998-09-04
200/201/202 PPT 1400/1600/2000MX 329900AA-335438AA 169011 1998-11-22
200/201/202 PPT 1400/1600/2000MX 335439AA-340959AA 169991 1999-03-14
201 PPT 2000MX 335439AA- 168526 1999-03-24
200/201/202 PPT 1400/1600/2000MX 340960AA- 172386 1999-06-10
454 PPL 2000MX 305210AA-316739AA 160275 1997-11-27
454 PPL 2000MX 316740AA-329899AA 164305 1998-03-30
454 PPL 2000MX 329900AA- 166906 1998-11-24

PT M7
Quality Parts
Version no T-code
001 200,201,202,454

PT M8
Recommended Spare Parts (RSP)


200 PPT 1400MX/MXC 239400AA-
201 PPT 2000MX 239400AA-
202 PPT 1600MX 239400AA-
454 PPL 2000MX 305210AA-
1 Issued RSP
T-code Version Model Serial No Issued

200/201/202 01 PPT 1400/1600/2000MX 239400AA-268676AA 1995-04-13
200/201/202 02 PPT 1400/1600/2000MX 268677AA-293314AA 1996-12-17
200/201/202 03 PPT 1400/1600/2000MX 293315AA-306954AA 1996-12-17
200/201/202 04 PPT 1400/1600/2000MX 306955AA-316740AA 1998-06-12
200/201/202 05 PPT 1400/1600/2000MX 316741AA-324213AA 1998-09-01
200/201/202 06 PPT 1400/1600/2000MX 324214AA-335438AA 1998-11-05
200/201/202 07 PPT 1400/1600/2000MX 335439AA- 1999-05-20
454 01 PPL 2000MX 305210AA- 1998-08-14

PT M8
Version no T-code
001 200,201,202,454

PT P
Contents, P
SSD 001
Contents, P
1 Preventive Maintenance
P1 Introduction
P2 Preventive Maintenance
P3 Oil and grease specification
P4 Tools

PT P
Contents, P
Version no T-code
001

PT P1
Introduction, maintenance
SSD 001
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.
1. Safety regulations with mainte-

nance work
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
WARNING!
Short-circuiting/Burns.
When working with the truck’s electrical system, short-
circuiting/burns can occur if a metal object comes into con-
tact with live electrical connections.
Remove watches, rings or other types of metal jewellery.
PT P1
Version no T-code
001
• 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. Never use your hand
• Bear in mind that the oil in the transmission or the hydraulic
system can be hot
WARNING!
Risk of burns.
Hot transmission and hydraulic oil.
Let the truck cool before changing the oil.
• Only fill the hydraulic system with new and clean oil
WARNING!
The hydraulic system can be damaged.
If the oil is contaminated hydraulic components can be
damaged.
Always use new and clean oil in the hydraulic system.
• 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
NOTE!
The battery can be damaged.
When welding using an electric power source the welding
current can enter the battery.
The battery should therefore be disconnected.
• 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
CAUTION!
Harmful gases.
Paint that is heated gives off harmful gases.
Remove 100 mm of paint from the work area.

PT P1
Version no T-code
001
2. Cleaning and washing

Cleaning and washing of the truck is important to ensure the
truck’s reliability.
• Carry out general cleaning and washing weekly
NOTE!
Risk of short-circuiting.
The electrical system can be damaged
Disconnect the battery before washing by pulling out the
battery connector.
2.1. External cleaning

• 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
NOTE!
Jamming, corrosion.
Mechanical components can be damaged.
After washing, the truck should be lubricated as set out in
the chapter Maintenance and lubrication chart.
2.2. Cleaning the motor compartment

• Cover the electric motors, connections and valves before
washing
NOTE!
The electrical system can be damaged.
Electrical components must not be cleaned with a high
pressure washing unit.
• Clean the motor compartment using a well-known
degreasing agent, diluted to a suitable concentration
• Rinse off loose grime using tepid water

PT P1
Version no T-code
001
2.3. Electrical components

• 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
NOTE!
Electrical components can be damaged.
Do not break the guarantee seal on the electronic board.
3. Safe lifting
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
• Never lift up the jack in order to lift higher
• Never work under a lifted truck unless it is well supported
WARNING!
Risk of crushing.
A badly supported truck can fall.
Never work under a truck that is not supported on trestle-
blocks and secured by a lifting device.

PT P2
Preventive maintenance
SSD K Hallman 001 200,201,202
T-kod Modell Maskinnr Anm.
200 PPT 1400MX 237000AA-
201 PPT 2000MX 237000AA-
202 PPT 1600MX 237000AA-
1 Service schedule
Pos. Work to carry out
n° Interval in hours 5 20 80 160 250 500 1000
Interval in Days/Weeks/Months 1d 1v 1m 2m 3m 6m 1m
0000 Chassis
0000.1 Check that the truck identification X
plate is legible
0000.2 Check all links and roll pins X
0000.3 Check the battery securing blocks for X
wear
0000.4 Check for cracks and damage X
0000.5 Check the lift cylinder brackets for X
wear or damage
0000.6 Check the cover lockings X
0380 Fork Carriage
0380.1 Check for cracks and damage X
0380.2 Check bushings for excess play X
0640 Operator Controls
0640.1 Check that the travel direction/speed X
selector is not binding
0640.2 Check that the horn button is opera- X
tional
0640.3 Check that the lift/lower button is oper- X
ational
0840 Drivers Protection
0840.1 Check that the red safety switch but- X
ton is not binding

PT P2
Version no T-code
001 200,201,202

1700 Drive Motor
1700.1 Check for arcing due to poor connec- X
tions
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 motor X
bearings
2550 Drive Gear
2550.1 Check for oil leakage X
2550.2 Check oil level X
2550.3 Check for abnormal noise X
3100 Brake
3100.1 Cleaning from dust and debris X
3100.2 Check brake disc for wear X
3100.3 Check correct clearence of brake disc X
3500 Wheels
3500.1 Remove string and other rubbish X
3500.2 Check drive wheel for wear and bolt X
torque
3500.3 Check castor wheel free to rotate and X
swivel
3500.4 Dismount and grease fork wheel bear- X
ings
4100 Tiller Arm
4100.1 Check fastening X
4100.2 Check steering force X
4100.3 Check the force of the gas suspension X

PT P2
Version no T-code
001 200,201,202

5110 Battery
5110.1 Electrolyte level, 10 - 15 mm above X
cell plates
5110.2 All connections: battery, battery and X
charger plugs
5110.3 All cell and link covers intact X
5110.4 Check of battery specific gravity and X
battery temperature
5200 Instrument Panel
5200.1 Check battery indicator and hour X
meter for correct operation
5300 Electrical Control System
5300.1 Check Ignition key switch operational X
5300.2 Check ”brake micro switch” (S10) X
operational
5300.3 Check the function of direction/speed X
micro switches
5300.4 Check control wiring harness for wear X
5400 Electrical Panel
5400.1 Cleaning and fixation to chassis X
5400.2 Tightening of connections X
5400.3 Check contactor points X
5400.4 Check contactor contacts for free X
movements
5400.5 Check all cable insulations for dam- X
age
5710 Electronic Card
5710.1 Cleaning of electronic card, blow with X
air and whipe off
5710.2 Check for play on cable connectors X
5710.3 Check of LED indications X

PT P2
Version no T-code
001 200,201,202

6000 Hydraulic System
6000.1 Check hoses and connections for X
leakage
6000.2 Check hoses for wear and damage X
6000.3 Check oil tank for cracks, leaks and X
mounting
6000.4 Check correct oil level X
6000.5 Change oil X
7310 Lift Cylinder
7310.1 Check for leakage X
7310.2 Check mounting X

PT P2

454 PPL 2000MX 305210AA-
1 Service schedule
No. Interval in hours 5 20 80 160 250 500 1000
Interval in days/weeks/months 1d 1w 1m 2m 3m 6m 12m
0000 Chassis
0000.1 Check that the truck’s rating plate is X
readable
0000.2 Check all links and pins X
0000.3 Check whether the battery’s locks are X
worn
0000.4 Check for crack formation and damage X
0000.5 Check the lift cylinder mountings for X
wear or damage
0000.6 Check the hood locks X
0380 Fork carriage
0380.2 Check whether there is too much play X
on the bushings
0380.3 Check that the pressure rods are not X
bent or damaged
0560 Platform and brackets
0560.2 Check whether there is too much play X
on the bushings
0560.3 Check the axles, washers and pins X
0560.4 Check whether the mat is worn X
0560.5 Check the operation of the gas sus- X
pension

PT P2
Version no T-code
001 454

0640 Control devices
0640.1 Check that the selector for the travel X
direction/speed does not jam
0640.2 Check the horn button X
0640.3 Check that the lift/lower buttons work X
0840 Driver protection
0840.1 Check that the red button for emer- X
gency revers does not jam
1700 Drive motor
1700.1 Check that there is no arcing due to X
bad connections
1700.2 All connections are tightened correctly X
1700.3 Check the carbon brushes X
1700.4 Clean off dust and dirt from the motor X
1700.5 Check that the motor mountings are X
tightened correctly
1700.6 Check that no abnormal sounds X
coming from the motor bearings
2550 Drive shaft
2550.1 Check for oil leakage X
2550.2 Check the oil level X
2550.3 Check for abnormal sounds X
3100 Brakes
3100.1 Remove dirt and dust X
3100.2 Check whether the brake discs are X
worn
3100.3 Check the brake discs’ play X

PT P2
Version no T-code
001 454

3500 Wheels
3500.1 Remove string and other rubbish X
3500.2 Check the drive wheel with regard to X
wear and the tightening torque of the
bolts
3500.3 Check that the castors turn and rotate X
freely
3500.4 Dismantle and grease the fork wheel X
bearings
4100 Tiller arm
4100.1 Check the mountings X
4100.2 Check the steering force X
4100.3 Check that the steering frame returns X
to its original position
5110 Battery
5110.1 Electrolyte level: 10 - 15 mm above X
the top edge of the cellplates
5110.2 All connections: battery, battery and X
charger connections
5110.3 Check that the cell and terminal pro- X
tection are undamaged
5110.4 Check the battery’s electrolyte con- X
centration and temperature
5200 Control panel
5200.1 Check that the battery indicator and X
hour meter work correctly
5300 Control system
5300.1 Check that the ignition works X
5300.2 Check that the “brake microswitch”, X
S10, works
5300.3 Check the operation of the micros- X
witch for direction/speed

PT P2
Version no T-code
001 454

5300.4 Check the control cable harness for X
wear
5400 Electrical panel
5400.1 Clean and inspect the chassis X
5400.2 Tighten all connections X
5400.3 Check the contacts on the contactors, X
they must not be dirty or burnt
5400.4 Check the movement of the contactors X
5400.5 Check the cable insulation X
5710 Electronic card
5710.1 Clean the electronic card using com- X
pressed air, then wipe
5710.2 Check that the cable connections are X
tight
5710.3 Check the LED indicators X
6000 Hydraulic system
6000.1 Check the hoses and couplings for X
leakage
6000.2 Check the hoses for wear and dam- X
age
6000.3 Check the oil tank for cracks, leakage X
and damaged mountings
6000.4 Check that the oil level is correct X
6000.5 Change the oil X
7310 Lift cylinder
7310.1 Check for leakage X
7310.2 Check the mountings X

PT P3
Oil and grease specification
SSD Gianni Jarvis 001 200,201,202


200 PPT 1400MXMXC 237000AA-
201 PPT 2000MX 237000AA-
202 PPT 1600 MX 237000AA-
Lubricant Type of lubricant Specification To be used for

> -15° C < -15o C
A Grease 26777 26777 Bearings and
(Spray) (Spray) bushings
B Hydraulic Oil ISO-L-HM32 ISO-L-VG 32 Hydraulic systems
C Transmission Oil Hypoid Oil Hypoid Oil Gears
SAE 80W/90 SAE 75W
D Grease 26778 26778 Chains and wires
(Spray) (Spray)

PT P3
Version no T-code
001 200,201,202

PT P3


454 PPL 2000MX 305210AA-
Lubri- Type of Specification Use

cant lubricant
> -15° C < -15o C
A Grease 26777 (Spray) 26777 (Spray) Bearings and
bushings
B Hydraulic oil ISO-L-HM32 ISO-L-VG 32 Hydraulic
system
C Transmission oil Hypoid oil Hypoid oil Gears
SAE 80W/90 SAE 75W
D Grease Staburags Staburags Guide bearings
NBU 8EP NBU 8EP

PT P3
Version no T-code
001 454

PT S
Contents, S
SSD 001
Contents, S
1 Service instructions
C-code
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

PT S
Contents, S
Version no T-code
001

PT S1 1700
Electric drive motor
SSD Jan Pettersson 001 200,201,202

T-code Model Serial number Notes

200 PPT 1400MX 237000AA-
201 PPT 2000MX 237000AA-
202 PPT 1600MX 237000AA-
1 General
The drive motor, drive gearbox and brake are combined as a
complete drive unit.
The drive 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 E1and
E2 are the shunt field connections. The motor rotation direc-
tion is changed by reversing armature connections A1 and
A2.
( (
' ' $ $
( (
' ' $ $

PT S1 1700
Version no T-code
001 200,201,202
1.1 Mechanical construction

The motor is comprised of a yoke into which the stator wind-
ings are mounted. At each end of the casing there is a bear-
ing 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
PT S1 1700
Version no T-code
001 200,201,202
1.2 Special tools
Tool
Torque wrench >30Nm
Undercut cleaner 60°, R=0.2 mm, D=0.6 mm
Cradle for drive unit Part number: 08-12432

PT S1 1700
Version no T-code
001 200,201,202
2 Dismantling/Refitting
2.1 Dismantling the motor from the truck
• 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 cover over the tiller arm. Disconnect the tiller
arm cable from the tiller arm and remove the tiller arm from
the bracket.

PT S1 1700
Version no T-code
001 200,201,202
• 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.
WARNING!
Pinch risk!
A lifted truck that is not secured can overturn.
The truck may only be lifted from the lifting eyes intended
for this purpose using a lifting device that is undamaged
and dimensioned for the weight of the truck.
Work must not be carried out under the truck when lifted.
• 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.
The necessary service and repairs can now be carried out on
the motor.
PT S1 1700
Version no T-code
001 200,201,202
2.2 Re-assembling
• 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.
• Install the brake unit and adjust as per the instructions.
• Replace the drive assembly 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.

PT S1 1700
Version no T-code
001 200,201,202
3 Service/Repairs
3.1 Cleaning
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 etc. 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 consistent
and acceptable results.

PT S1 1700
Version no T-code
001 200,201,202
3.2 Dismantling the motor
11
15
03
02
10
26
25
09
24
• Remove the four plugs that cover the carbon brushes, lift
the springs to one side and lift up the carbon brushes.
• 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, if necessary, with the aid of a suitable
puller tool.
• Remove the commutator end bearing shield (11) together
with brush holder (03) and carbon brushes (02) by remov-
ing the six hexagon socket bolts. Then lay the motor with a
fixed stop against edge of the bearing shield and carefully
striking the armature shaft with a rubber mallet.
PT S1 1700
Version no T-code
001 200,201,202
• 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.
• After removing the motor bearing shield and removing the
armature from the motor yoke, the gear wheel on the
armature drive end must be removed. 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.
• Remove next 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.
3.3 Re-assembling the motor

• 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 –3 Mohm. A used motor has been
subjected to contamination and in this case a resistance 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.

PT S1 1700
Version no T-code
001 200,201,202
3.4 Armature bearings

The armature bearings are comprised of a permanently lubri-
cated and double sealed type 6204-2Z/C3 bearing 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.
3.4.1 Changing the drive end bearing

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 taper and
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.
3.4.2 Changing the commutator end bearing

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.

PT S1 1700
Version no T-code
001 200,201,202
3.5 Carbon brushes and brush holder

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 of the carbon brushes is 11 mm.
The carbon brushes are normally supplied with a preformed
radius that corresponds to the commutator radius.
3.5.1 Changing carbon brushes

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.

PT S1 1700
Version no T-code
001 200,201,202
3.6 Commutator
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.
3.6.1 Machining the commutator

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.
Feed must be between 0.08 and 0.1 mm and cutting depth
must not exceed 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 in use.
The commutator design allows machining a number of times.
The diameter must not, however, 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

PT S1 1700
Version no T-code
001 200,201,202
4 Storage/Transport
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.
4.1 Storage
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 protective oil.

PT S1 1700
Version no T-code
001 200,201,202
5 Data
Torque Nm
Nut for drive end gear wheel 30 + locking
with centre
punch
Nuts for motor attachment to drive gearbox 26.6
Grease specification
Armature bearings HT24
Component Item Min. Max. Unit

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 4 µm
unevenness
Commutator seg- Height dif- 0,02 mm
ment ference

PT S1 1700
SSD Jan Pettersson 001 454

T-code Model Serial number Notes

454 PPL 2000MX 335887AA-
1 General
The drive motor, drive gearbox and brake are combined as a
complete drive assembly.
The drive motor is a compound type direct current motor, i.e.
it is comprised of an stator winding connected in series with
the armature and an 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 E1and
E2 are the shunt field connections. The motor rotation direc-
tion is changed by reversing armature connections A1 and
A2.
( (
' ' $ $
( (
' ' $ $

PT S1 1700
Version no T-code
001 454
1.1 Mechanical construction

The motor is comprised of a yoke into which the field windings
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
PT S1 1700
Version no T-code
001 454
1.2 Special tools
Tool
Torque wrench >30Nm
Undercut cleaner 60°, R=0,2 mm, D=0,6 mm

PT S1 1700
Version no T-code
001 454
2 Removal/Refitting
2.1 Removing the motor from the truck
• 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), tiller arm cable from the
electrical panel, the blue cable in the battery cable shoe
and the hydraulic pump cables. Remove any cable ties.
• Remove the four nuts for the motor attachment to the drive
gearbox.
• Remove the cover over the tiller arm. Disconnect the tiller
arm cable from the tiller arm and remove the tiller arm from
the bracket.
• Remove the cables for the battery indicator and ignition
switch. Pull all cables out of the cable ducting in the cover.

PT S1 1700
Version no T-code
001 454
• Remove the tiller arm bracket and the brake unit from the
motor. Remove the cover over the motor compartment
together with the tiller arm bracket.
• 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.
The necessary service and repairs can now be carried out on
the motor.
2.2 Re-assembly
• 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 dam-
aged.
• 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. Screw down the cover and con-
nect the cables previously disconnected. Check that the
polarity is correct.
• After the completed re-assembly, the brake function must
be tested before the truck is moved.

PT S1 1700
Version no T-code
001 454
3 Service/Repairs
3.1 Cleaning
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 is 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. The cloth
can be dampened with an organic and volatile cleaning agent
if necessary, that can dissolve grease and which will not dam-
age 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 etc. 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 and it must continue
until a number of insulation measurements give similar and
approved results.

PT S1 1700
Version no T-code
001 454
3.2 Dismantling the motor
11
15
03
02
10
26
25
09
24
• 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 pulled off with a
suitable tool.
• Remove the four plugs that cover the carbon brushes, lift
the springs to one side and lift up the carbon brushes.
• 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. Lay the
motor down with a fixed stop against the edge of the bear-
ing shield and then strike the armature shaft carefully with
a rubber mallet.

PT S1 1700
Version no T-code
001 454
• 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.
• After removing the motor bearing shield and removing the
armature from the motor yoke, the gear wheel on the arma-
ture drive end must be removed. 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.
• Remove next 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.
3.3 Refitting of motor

• Reassemble the motor 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.

PT S1 1700
Version no T-code
001 454
3.4 Armature bearings

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 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 5000 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.
3.4.1 Changing the drive end bearing

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 cone. The same applies for the gear
wheel inner surface.
Apply a film of Loctite 603 onto the armature shaft cone and
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.
During refitting of the armature and bearing shield, care must
be taken not to damage the field and armature windings.
3.4.2 Changing the commutator end bearing

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.

PT S1 1700
Version no T-code
001 454
3.5 Carbon brushes and brush holder

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 of the carbon brushes is 11 mm.
The carbon brushes are normally supplied with a preformed
radius that corresponds to the commutator radius.
3.5.1 Changing carbon brushes

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.

PT S1 1700
Version no T-code
001 454
3.6 Commutator
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.
3.6.1 Turning the commutator

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.
Feed must be between 0.08 - 0.1 mm and cutting depth must
not exceed 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 in
use.
The commutator design allows for machining a number of
times. The diameter must not, however, 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

PT S1 1700
Version no T-code
001 454
4 Storage/Transport
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.
4.1 Storage
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 increase if
the air contains corrosive gases. These problems are espe-
cially 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 protective oil.

PT S1 1700
Version no T-code
001 454
5 Data
Torque Nm
Nut for drive end gear wheel 30 + locking
with centre
punch
Nuts for motor attachment to drive gearbox 26,6
Grease specification
Armature bearings HT24
Component Item Min. Max. Unit

Insulation resist- New motor 2 Mohm
ance
Insulation resist- Used motor 1 Mohm
ance
Carbon brushes Length 11 mm
Commutator Diameter 60 mm
Turning the com- Cutting 200 m/min
mutator speed,
hard metal
cutting tool
Turning the com- Cutting >>200 m/min
mutator speed, dia-
mond cut-
ting tool
Turning the com- Cutting 0.05 mm
mutator depth
Turning the com- Feed 0.08 0.1 mm
mutator
Commutator Eccentricity 0.02 mm
Commutator Surface 4 µm
uneven-
ness
Commutator seg- Height dif- 0.02 mm
ment ference

PT S1 1700
Version no T-code
001 454

PT S2 2550
Drive gear
SSD L-G Andersson 001 200,201,202,454
Drive gear

200 PPT 1400MX 246664AA-
201 PPT 2000MX 246664AA-
202 PPT 1600MX 246664AA-
454 PPL 2000MX 305210AA-
1 General technical description

PT S2 2550
Drive gear
Version no T-code
001 200,201,202,454
1.1 Technical data
Data Description
Type 2-step angular
Upper gear wheels Cylindrical with helical gear
Lower gear wheels Angle gear 90 degrees
Gear ratio, overall 19,14:1
PPT1400/1600, PPL2000
Gear ratio, upper gear 4:1
PPT1400/1600, PPL2000
Gear ratio, lower gear 4,86:1
PPT1400/1600, PPL2000
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

PT S2 2550
Drive gear
Version no T-code
001 200,201,202,454
1.2 Gear components
3
4
5
A
12
11
10 6
9 7
8
Pos No Component
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

PT S2 2550
Drive gear
Version no T-code
001 200,201,202,454
Pos No Component
11 Drive shaft
12 Drive shaft seal
A Built-in measure, pinion height 65 mm
1.3 Special tools
Pos No Tool
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 = 08-13020
7 Assembly axle: part no 08-13021

PT S2 2550
Drive gear
Version no T-code
001 200,201,202,454
2 Removing the gear from the truck

• 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.

PT S2 2550
Drive gear
Version no T-code
001 200,201,202,454
3 Change of seal on the drive shaft

• 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.

PT S2 2550
Drive gear
Version no T-code
001 200,201,202,454
• 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 new washer and nut. Tighten the drive shaft nut
300 Nm (217 ft-lb) with a torque wrench.
• Lock the shaft nut with a punch into the groove in the shaft.
• Fit the covers to the gear with new gaskets. Tightening

torque: 26,6 Nm (19,5 ft-lb).
• Fit the driving gear into the truck. Tightening torque:
26,6 Nm (19,5 ft-lb). Fill up with new oil.
• Fit the drive wheel. Tightening torque: 65 Nm (47,7 ft-lb).

PT S2 2550
Drive gear
Version no T-code
001 200,201,202,454
4 Reconditioning of the gear

• 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.

PT S2 2550
Drive gear
Version no T-code
001 200,201,202,454
• 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.

PT S2 2550
Drive gear
Version no T-code
001 200,201,202,454
• 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 difference from
65 mm gives you the thickness of shim S1.
• Fit the measured shim thickness under bearing L1.

PT S2 2550
Drive gear
Version no T-code
001 200,201,202,454
• 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 08-13021 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 flank clearence of 0,10–

0,15 mm is attained. Remove the same shim thickness
from S4 that is fitted on S3, before the tool with bearings
and crown wheel is reassembled.
• Check the flank clearence and measure the axial play on
the tool 08-13021.
• Adjust the axial play to Zero-play by adjusting shim S4.

• 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.

PT S2 2550
Drive gear
Version no T-code
001 200,201,202,454
• Fit the tool 08-13021 with bearings and crown wheel.

Check the flank clearence. Adjust shim S3 when needed.
S4 is to be adjusted, reduced if S3 is increased and
increased if S3 is reduced, correspondingly to the change
on S3. Check the axial play on tool 08-13021.
• Check the gear tooth impression. When the impression is
correct fit a new washer and pinion nut. Tighten the nut
70 Nm (50,5 ft-lb) and lock it with a punch in the key-
groove.
• 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 new washer and nut. Tighten the drive shaft nut
300 Nm (217 ft-lb) with a torque wrench. Check the axial
play on the drive shaft, shall be Zero. Lock the nut with a
punch in the 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)

PT S3 3360
Mechanical brakes
SSD L-G Andersson 001 200,201,202,454
Mechanical brakes

200 PPT 1400MX 335887AT-
201 PPT 2000MX 335887AA-
202 PPT 1600MX 335887AT-
454 PPL 2000MX 335887AT-
1 General
The brake is a mechanical spring-loaded brake. The brake
construction is as shown in the component list below.
4
3
5
Position Description
1 Brake disk
2 Adjustment screws for braking force
3 Collar
4 Adjustment screws for clearance in off
position
5 Pressure plate

PT S3 3360
Mechanical brakes
Version no T-code
001 200,201,202,454
2 Function
The mechanical brake provides both the driving and parking
brakes for the truck.
2.1 Releasing the brakes

The brakes are released when the tiller arm is in the driving
position.
2.2 Braking
The truck is braked when the tiller arm is moved into one of
the two braking positions.

PT S3 3360
Mechanical brakes
Version no T-code
001 200,201,202,454
3 Maintenance
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
Position Adjustment measurement

1 Clearance in un-braked position
2 Adjustment of brake force. Clearance in
braked position

PT S3 3360
Mechanical brakes
Version no T-code
001 200,201,202,454

PT S5 5000
Electrical System
SSD K Hallman 001 200,201,202
Electrical System
Resistance Control

200 PPT 1400MX 237000AA-
200 PPT 1400MXC 237000AA-
201 PPT 2000MX 237000AA-
202 PPT 1600MX 237000AA-
1 Electrical panel, components

PT S5 5000
Electrical System
Version no T-code
001 200,201,202
2 List of symbols
Symbol Description Function Remark

A1 Electronic card
BT Battery
F10 Fuse Motor circuit 100 A

F50 Fuse Control circuit 7,5 A
H1 Horn
K11 Contactor Drive direction

K13 Contactor Drive direction
K17 Contactor 2:nd speed
K18 Contactor 3:rd speed
K30 Contactor Pump motor
M1 Motor Driving
M3 Motor Pump
P1 Indicator Hour meter

P3 Indicator Battery indicator/Hour
meter
R11 Resistor Speed control

R12 Resistor Speed control
S10 Micro switch

S12 Micro switch Speed step2
S13 Micro switch Speed step3

PT S5 5000
Electrical System
Version no T-code
001 200,201,202

S15 Micro switch Drive direction
S16 Micro switch Drive direction
S17 Switch Key
S18 Micro switch Horn
S20 Micro switch Emergency switch off
S41 Micro switch Fork lowering
S52 Micro switch Fork lifting
Y41 Magnetic valve Fork lowering

PT S5 5000
Electrical System
Version no T-code
001 200,201,202
2.1 Circuit diagram 1(3)

PT S5 5000
Electrical System
Version no T-code
001 200,201,202

PT S5 5000
Electrical System
Version no T-code
001 200,201,202

PT S5 5000
Electrical System
Version no T-code
001 200,201,202
3 Description of function
3.1 General
The BT PPT 1400MX/1600MX/2000MX controller contains a
logic-unit (micro processor) which detects signals from micro-
switches, armature voltage, etc. The controller’s inputs and
outputs are equiped with connectors for connection/discon-
nection of cables.
The controller is equipped with a green LED (labelled PWR/
ERROR), which indicates correct main voltage. The LED for
PWR/ERROR also indicates faults in the emergency stop cir-
cuit or in the contactor circuits.
The inputs are suited for the 24 V voltage level and will draw
a certain current in order to clean the opening contacts and,
also, to indicate input signals with green LED’s.
The contactor outputs are electronically short circuit proof
and indicate output signals with red LED’s. The drive contac-
tor outputs are controlled by transistors and will receive the
full main voltage when the current is turned on, i.e. 24 V and
after the contactors have closed, the voltage will drop to half
this value, i.e. 12 V.
In addition to signals from switches, the drive motor’s arma-
ture voltage is monitored, so that speed step 3 will be
engaged at a pre-determined voltage level or, alternatively,
after a fixed time lapse.
The description is divided into the different phases which cor-
respond to the operational sequense steps. For each
sequense step the correct LED-pattern is shown below. A
filled circle denotes a LED emitting light.
PT S5 5000
Electrical System
Version no T-code
001 200,201,202
3.2 Ignition lock S17 in the ON position
When S17 closes, the micro-processor will check that S10 is

not closed. If this is the case, operation is not permitted.
Battery voltage via F50, terminals 407 and 205 to S17 and
terminal 202 for the controller’s internal voltage. The control-
ler gets (-) return through cable 40 and terminal 207, the
PWR/ERROR-diode lights up. Controller terminal 108 distrib-
utes the battery voltage to S10, S52, S41 and S18.
3.3 The operating arm in drive position,

S10
When the operating arm is pushed down to the driving posi-

tion, S10 is activated and closes and at the same time the
brake is mechanically released. LED 109 lights up when the
voltage is fed via terminal 109 to the run-time totalizer’s termi-
nal 206 and to the shunt field’s terminal 301.
The controller sends a fixed current through the shunt field,
1,2 A and (-) return is provided via terminals 302 ans 207.

PT S5 5000
Electrical System
Version no T-code
001 200,201,202
3.4 Driving in the fork direction, 1:st speed
When the butterfly is activated for driving forward, S15 will

close. Battery voltage is fed to terminal 101 and LED 101
lights up. The micro-processor now feeds 24 V closing volt-
age to terminal 401, red LED 401 lights up and K11 closes,
(-) return is provided via terminals 409 and 207. After K11 has
closed, the micro-processor reduces the contactor’s holding
voltage to 12 V.
The transistor regulator checks that S10 is closed before S15
is made, for driving to be permitted.
The motor current now passes F10, R11, R12, K11, the
armature A2-A1, K11 and the series field D2-40 to the bat-
tery’s negative pole.
3.5 Driving in the fork direction, 2:nd

speed
When S12 is activated by the butterfly, battery voltage is fed

to terminal 103 and LED 103 lights up. The micro-processor
now feeds 24 V voltage to terminal 403, red LED 403 lights
up and K17 closes, (-) return is provided via terminals 409
and 207. After K17 has closed, the micro-processor reduces
the contactor’s holding voltage to 12 V.
The motor current now passes through F10, K17, R12, K11,
the armature A2-A1, K11 and the seriesfield D2-40 to the bat-

PT S5 5000
Electrical System
Version no T-code
001 200,201,202
3.6 Driving in the fork direction, 3:rd

speed

to terminal 104 and LED 104 lights up.
The micro-processor now measures the armature voltage
over terminal 408 in order to determine the delay for the 3:rd
speed.
The delay of the 3:rd speed is determined either by the arma-
ture voltage reaching 13 V when a light load or no load is on
the forks, or alternatively, after a one second delay via a timer
circuit for heavier loads.
The micro-processor now sends 24 V voltage to terminal 404,
red LED 404 lights up and K18 closes and (-) return is pro-
vided via terminal 409 and 207.
After K18 has closed, the micro-processor will interrupt the
holding voltage to K17, which now opens.
The motor current now passes through F10, K18, K11, the
3.7 Driving in the steering wheel direction,

1:st speed
When the butterfly is activated for driving in the steering

wheel direction, S16 will close. Battery voltage is fed to termi-
nal 102 and LED 102 lights up. The micro-processor now
feeds 24 V voltage to terminal 402, red LED 402 lights up and
K13 closes, (-) return is provided via terminals 409 and 207.
After K13 has closed, the micro-processor reduces the con-
tactor’s holding voltage to 12 V.
PT S5 5000
Electrical System
Version no T-code
001 200,201,202
The controller checks if S10 is closed before S16 is made, for

driving to be permitted.
The motor current now passes F10, R11, R12, K13, the

2:nd speed

to terminal 103 and LED 103 lights up. The micro-processor
now feeds 24 V voltage to terminal 403, red LED 403 lights
up and K17 closes, (-) return is provided via terminals 409
and 207. After K17 has closed, the micro-processor reduces
the contactor’s holding voltage to 12 V.
The motor current now passes through F10, K17, R12, K13,
the armature A1-A2, K13 and the seriesfield D2-40 to the bat-

3:rd speed

to terminal 104 and LED 104 lights up.
The micro-processor now measures the armature voltage
over terminal 408 in order to determine the delay for the 3:rd
speed.
The delay of the 3:rd speed is determined either by the arma-
ture voltage reaching 13 V when a light load or no load is on
the forks, or alternatively, after a one second delay via a timer
circuit for heavier loads.
PT S5 5000
Electrical System
Version no T-code
001 200,201,202
The micro-processor now feeds 24 V voltage to terminal 404,

red LED 404 lights up and K18 closes and (-) return is pro-
vided via terminal 409 and 207.
After K18 has closed, the micro-processor will interrupt the
holding voltage to K17, which now opens.
The motor current now passes through F10, K18, K13, the
3.10 Reversing/ motor brake fork direction

to steering wheel direction
When reversing, the speed control is moved from fork direc-

tion to steering wheel direction. S15 returns to the neutral
position when 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 micro-processor
detects the negative potential over terminal 408 and inter-
rupts the holding voltage to K17 and K18, causing these to
open.
The motor is now braking in the 1:st speed.
When the drive wheel rotates in the "right direction" and the
potential over terminal 408 becomes positive, acceleration is
done in the usual way.
During the braking sequence, the motor current passes F10,
R11, R12, K13, A1-A2, K13 and the series field D2-40 to the
negative pole.

PT S5 5000
Electrical System
Version no T-code
001 200,201,202
3.11 Reversing/ motor brake steering

wheel direction to fork direction
When reversing, the butterfly is moved from the steering

wheel direction to fork direction. S16 returns to the neutral
position when 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 micro-processor
detects the negative potential over terminal 408 and inter-
rupts the holding voltage to K17 and K18, causing these to
open.
The motor is now braking in the 1:st speed.
When the drive wheel rotates in the "right direction" and the
potential over terminal 408 becomes positive, acceleration is
done in the usual way.
During the braking sequense, the motor current passes F10,
R11, R12, K11, A2-A1, K11 and the series field D2-40 to the
battery negative pole.
3.12 Safety reversing
Possible breakages in the cables for safety reversing are

always checked by the micro-processor, which sends a small
current through the circuit comprising terminal 110, cable 32,
S20, cable 32 and terminal 111.
S20 is activated causing terminal 110 to become positive and
the micro-processor now interrupts the holding voltage to K13
and K18, which opens. At the same time the processor pro-
vides voltage to terminal 401 to K11 and terminal 403 to K17.
The motor is now in the motor braking stage and will subse-
quently accelerate in the fork direction until S20 returns to the
neutral position. Safety reversing is done using the 2:nd
speed.
PT S5 5000
Electrical System
Version no T-code
001 200,201,202
When S20 returns to neutral position, (+) voltage will be inter-

rupted to terminal 110, the micro-processor will interrupt the
holding voltage to terminals 401 and 403 to K11 and K17 and
the truck will stop.
In order to be able to start again if S16 still is activated, the
micro-processor 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.
3.13 Lifting of the forks
The micro-switch S52 closes. K30 receives (+) voltage via

terminal 105, terminal 203, by use of a jumper or via the bat-
tery indicator, terminal 201 and terminal 405 and LED’s 105
and 405 lights up. (-) return via terminal 409 and 207. K30
closes and pump motor M3 starts.
3.14 Driving in fork direction in 3:rd speed

and simultaneously lifting the forks
In order to reduce the load on the motor fuse when driving in

3:rd speed in fork direction and simultaneously lifting the
forks, the micro-processor interrupts the holding voltage to
K18 during the time S52 is activated.
When lifting is completed and S52 is not activated, the micro-
processor will activate the 3:rd speed, K18, with a normal
delay time.

PT S5 5000
Electrical System
Version no T-code
001 200,201,202
3.15 Driving in steering wheel direction in

3:rd speed and simultaneously lifting the
forks
In order to reduce the load on the motor fuse when driving in

3:rd speed in steering wheel direction and simultaneously lift-
ing the forks, the micro-processor interrupts the holding volt-
age to K18 during the time S52 is activated.
When lifting is completed and S52 is not activated, the micro-
processor will activate the 3:rd speed, K18, with a normal
delay time.
3.16 Lowering the forks
When the forks are lowered, S41 is activated. The magnetic

valve, Y41, is provided with (+) voltage from terminal 106,
LED 106 lights up, and terminal 204. (-) return through termi-
nal 409 and 207.
3.17 Horn
Micro-switch S18 is activated. The horn, H1, receives (+) volt-

age from terminal 107, LED 107 lights up, and terminal 406.
(-) return through cabel 40.

PT S5 5000
Electrical System
Version no T-code
001 200,201,202
3.18 Fault indication
During operation, the cables to S20 are checked. If breakage

is detected, the LED labelled PWR/ERROR will flash. The
truck is fully manouverable as long as S10 is closed. When
the operating arm is released, or the brake is activated in the
lower position, and S10 interrupts the voltage, the micro-proc-
essor will not permit further operation of the truck by interrupt-
ing the output signal to all drive contactors.
PLEASE NOTE! The interruption can be deactivated for tem-
porarily driving to a service area (key off and then on). If the
brake is activated, deactivation of the interruption must be
done again.
The LED labelled PWR/ERROR also flashes when a short cir-
cuit occurs at the contactor outputs 401-404. After the fault is
repaired, the LED will cease to flash.

PT S5 5000
Electrical System
SSD K Hallman 002 200,201,202
Electrical System
Transistor Control

200 PPT 1400 MX 243537AA-
200 PPT 1400MXC 243537AA-
201 PPT 2000MX 243537AA-
202 PPT 1600MX 243537AA-

PT S5 5000
Electrical System
Version no T-code
002 200,201,202
1.1 List of symbols

A1 Transistor controller
A2 Electronic card
BT Battery

F50 Fuse Control circuit 7,5 A
H1 Horn
K11 Contactor Drive direction Fork direction

K13 Contactor Drive direction Steer wheel direction
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
S16 Switch Drive direction Steer wheel direction
S17 Switch Key
S18 Switch Horn

PT S5 5000
Electrical System
Version no T-code
002 200,201,202

S20 Switch Safety
S41 Switch Fork lowering
S52 Switch Fork lift
Y41 Magnetic valve Fork lowering

PT S5 5000
Electrical System
Version no T-code
002 200,201,202
1.2 Electrical diagram 1(3)

PT S5 5000
Electrical System
Version no T-code
002 200,201,202

PT S5 5000
Electrical System
Version no T-code
002 200,201,202

PT S5 5000
Electrical System
Version no T-code
002 200,201,202
2 Description of function
2.1 General
The Transistor controller (A1) regulates the speed step less
up to maximum speed. When starting the truck, does the con-
troller 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.

PT S5 5000
Electrical System
Version no T-code
002 200,201,202
2.2 Adjustable settings
Setting Std. value Min. value Max. value

Current limit 150 A 100 A 150 A
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
REFERENCES:
For more information about adjustment of the transistor con-
troller and the electronic card, see C-code 5460 resp. 5710.
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.

PT S5 5000
Electrical System
Version no T-code
002 200,201,202
2.3 Ignition lock S17 in the ON position
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.
2.4 The operating arm in drive position,

S10
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 now regulates the current through
the shunt field, 1,2 A, (-) return via terminal 302, 417 and
A1.1.

PT S5 5000
Electrical System
Version no T-code
002 200,201,202
2.5 Driving, fork direction
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 negative
via A1.
2.6 Driving, steer wheel direction
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.

PT S5 5000
Electrical System
Version no T-code
002 200,201,202
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 negative
via A1.
2.7 Reversing/motor brake fork direction

to steer wheel direction
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 detects the generated current at connec-
tion 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.
2.8 Reversing/motor brake steer wheel

direction to fork direction
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 detects the generated current at connec-
tion 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.

PT S5 5000
Electrical System
Version no T-code
002 200,201,202
2.9 Switch for safety reversing
Possible breakages in the wiring for safety reversing is conti-

nously 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 drive direction can be chosen.

PT S5 5000
Electrical System
Version no T-code
002 200,201,202
2.10 Lifting the forks
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.
2.11 Driving and simultaneously lifting the

forks
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.

PT S5 5000
Electrical System
Version no T-code
002 200,201,202
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.
2.13 Horn
Micro switch S18 is activated. The horn, H1, receives (+)volt-

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

PT S5 5000
Electrical system
Electrical system
Transistor regulator
T-code Model Serial no. Notes

454 PPL 2000MX 305210AA-

RV1
F50
A5
F10
K11
K13
K30
A1
H1

PT S5 5000
Electrical system
Version no T-code
001 454
1.1 List of Symbols
Symbol Description Function Notes

A1 Transistor regulator
A5 Electronic card
E8 Heater Handle heater Only freezer trucks

F50 Fuse Control circuit 7.5 A
F51 Fuse Extra equipment Option
G1 Battery
H1 Horn
K11 Contactor Drive direction Direction of forks

K13 Contactor Drive direction Direction of steer wheel
M1 Motor Driving
M3 Motor Pump
P3 Instrument Battery indicator/run-

ning meter
R1 Potentiometer Speed 5 - 0 kOhm

RV1 Potentiometer Speed reduction
S10 Switch ”Brakes”

S15 Switch Drive direction Direction of forks

PT S5 5000
Electrical system
Version no T-code
001 454
Symbol Description Function Notes

S16 Switch Drive direction Direction of steer wheel
S17 Switch Ignition key
S18 Switch Horn
S20 Switch Safety reversing
S31 Switch Lifting limit
S40 Switch Lowering forks
S52 Switch Lifting forks
Y41 Magnetic valve Lowering forks

Y52 Magnetic valve Lifting forks

PT S5 5000
Electrical system
Version no T-code
001 454
1.2 Electrical diagram 1/6

PT S5 5000
Electrical system
Version no T-code
001 454

PT S5 5000
Electrical system
Version no T-code
001 454

PT S5 5000
Electrical system
Version no T-code
001 454

PT S5 5000
Electrical system
Version no T-code
001 454


PT S5 5000
Electrical system
Version no T-code
001 454

PT S5 5000
Electrical system
Version no T-code
001 454
2 Operating description
2.1 General
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 connection card A5 to group all
the connections to the control card for input and output sig-
nals to the transistor regulator. The connection card is
equipped with LEDs to indicate incoming and outgoing sig-
nals and a potentiometer to adjust the maximum speed.
REFERENCES
For further information on transistor regulation and the elec-
tronic card, see C-code 5460 and 5710.
2.2 Description
The description is divided into different phases that corre-
spond to the operating sequence stages. The correct LED
patterns are shown below for each sequence stage. A filled
circle represents the LED when on.
2.3 Ignition switch S17 in the ON position
• 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.
PT S5 5000
Electrical system
Version no T-code
001 454
2.4 Tiller arm in driving position, S10
• When the tiller arm is pushed down to the driving position,

S10 makes and the mechanical brake releases at the same
time. The voltage goes via connection pins 109 and 408 to
A1.15. LED 109 lights on the 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 connection pin 302, 417
and A1.1.
2.5 Driving, direction of the forks
• When the throttle is activated for driving in the direction of

the forks,S15 makes. Battery voltage goes via connection
pins 101 and 411 to A1.11, LED 101 comes on.
• Battery voltage to K11 via connection pin 403. A1.2 now
gives (-) return to K11, (-) input on connection pin 401, LED
401 comes on.
• Depending on throttle’s, R1’s, position and the position of
potentiometer RV1, A1.8 will receive a voltage between
4.8–0.25 V.

PT S5 5000
Electrical system
Version no T-code
001 454
• The motor current now passes through F1, the series field
D2-D1, K11, the rotor A2-A1 and K11 to the battery’s nega-
tive pole via A1.
2.6 Driving, direction of the steering wheel
• When the throttle is activated for driving in the direction of

the steer wheel, S16 makes. The transistor regulator
checks that S10 is made before S16 makes, if not, driving
is not permitted.
• Battery voltage flows via connection pins 102 and 412 to
A1.12, LED 102 comes on. Battery voltage to K13 via con-
nection pin 403. A1.3 now gives (-) return to K13, (-) input
on connection pin 402, LED 402 comes on.
• Depending on the throttle’s, R1’s, position and the position
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, K13, the rotor A1-A2 and K13 to the battery’s nega-
tive pole via A1.

PT S5 5000
Electrical system
Version no T-code
001 454
2.7 Reversing/speed reduction, direction

of forks to direction of steer wheel
• S15 returns to the neutral position and S16 makes. The
current in the series field makes the motor act as a genera-
tor as the drive wheel is rotating in the “wrong direction”.
• The transistor regulator senses the generated current on
connection A2, and reduces the series field current to
60 A. When the drive wheel rotates in the “right direction”
and the potential on connection A2 is positive, acceleration
occurs according to the adjusted values for the current limit
and acceleration.
• The rotor current in the circuit passes A1-A2, K13, A2,
transistor regulator’s brake diode, M- and K13 during the
braking sequence.
2.8 Reversing/speed reduction, direction

of steer wheel to direction of forks
• S16 returns to the neutral position and S15 makes. The
current in the series field makes the motor act as a genera-
tor as the drive wheel is rotating in the “wrong direction”.
The transistor regulator senses the generated current on
connection A2, and reduces the series field current to
60 A.
• When the drive wheel rotates in the “right direction” and
the potential on connection A2 is positive, acceleration
occurs according to the adjusted values for the current limit
and acceleration.
• The rotor current in the circuit passes A2-A1, K11, A2,
transistor regulator’s brake diode, M- and K11 during the
braking sequence.

PT S5 5000
Electrical system
Version no T-code
001 454
2.9 Switch for safety reversing
• The transistor regulator continuously monitors the safety

reversing circuit for a possible broken line, by sending a
small pulsed current through A1.10, connection pin 416,
111, line 32, S20, line 32, connection pin 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 A1.3 to K11,
LED 401 comes on.
• The motor will now be connected for speed reduction with
a maximum current 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 driving direction is selected.

PT S5 5000
Electrical system
Version no T-code
001 454
2.10 Lifting the forks
• The microswitch S52 makes. K30 receives (+) voltage via

connection pins 105, 203, battery regulator or strapping,
connection pins 201 and 405. LEDs 105, 405 come on.
(-) return via line 40. K30 makes and the pump motor M3
starts.
2.11 Driving and lifting the forks at the

same time
• A1 sense the activation of K30, (+) on connection pin 404
and A1.14. A1 then reduces the speed to 70% and the
motor current to 100 A.

• S40 is activated when the forks are lowered S40. The
magnetic valve, Y41, receives (+) voltage via connection
pins 106 and 204, LED 106 comes on. (-)-return via line
40.
2.13 Horn
• Microswitch S18 is activated. The horn, H1, receives (+)
voltage via connection pins 107 and 406, LED 107 comes
on. (-) return via line 40.

PT S5 5000
Electrical system
Version no T-code
001 454

PT S5 5230
Battery controller/hourmeter
SSD K Hallman 001 200,201,202,454

200 PPT 1400MX/MXC 330613AA-
201 PPT 2000MX 330613AA-
202 PPT 1600MX 330613AA-
454 PPL 2000MX 330613AA-
1 General
This instrument consists of a single, quartz, hourmeter, H, a
10 bar multi color battery discharge controller (BC), and a
lockout relay. The lift lockout relay is operating in such a way
that if there is a current passing through the relay contacts
when the instrument registers empty battery, the contacts
stay closed until the current ceases. Meaning that there will
be no lockout of the lift during the lift operation. The hourme-
ter features a liguid crystal dispay (LCD) which has six seg-
ment digits with a decimal point on last digit. This provoides a
reading of 0.1 hours or 6 minutes.

PT S5 5230
Version no T-code
001 200,201,202,454
2 Electrical
2.1 Voltage
The instrument is supplied as a pin selectable dual voltage
unit with the voltage of 24/48 VDC.
2.1.1 The contact voltage and current ratings for switch-

ing resistive loads.
Open Contact Voltage 200 VDC Max

Closed Contact Current 3 ADC Max
Volt Ampere Product 50 W Max
2.1.2 Memory Retention

The instrument contains an internal battery which allows (BC)
memory retention when external power is remowed. Typical
battery life is 10 years. The hourmeter has a solid state non
volatile memory which does not require battery backup.
3 Battery Controller
3.1 General
The (BC) measures the state of the battery. The charge is
indicated on a column of ten LEDs.
Right: 1 – fully-charged battery.
Left: 0 – empty battery.
When the battery is fully charged, the LED to the right will be
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.

PT S5 5230
Version no T-code
001 200,201,202,454
3.1.1 Discharge Adjustment

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.
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.
.
SETTING VPC
K 1.57
L 1.63
M 1.68
N 1.73
O 1.78
P 1.82
Q 1.84
R 1.86
S 1.91
T 1.93

PT S5 5230
Version no T-code
001 200,201,202,454
Pin No. Function

1 Hour meter (-)
2 Keyswitch (+)
3 Relay arm (+)
4 Relay NC (-)
5 Battery (-)
6 Hour meter (+)
7 24 Volt (+)
8 48 Volt (+)
NOTE:
The instrument can be connected differently in different
trucks, please see diagrams in the electrical descriptions
C-code 5000.
NOTE:
The discharge adjustments can be made at any time during
a working cycle before lift lockout. However, discharge pot.
adjustments made late in a working cycle have little or no
effect in delaying the lift lockout in that particular working
cycle. Normally discharge pot. adjustments are made
before or at the beginning of a working cycle to effectively
change the discharge profile of that working cycle. Once lift
lockout does occur, the gauge must be reset before dis-
charge pot. adjustments can have an effect.

PT S5 5230
Version no T-code
001 200,201,202,454
3.2 Reset
The instrument is supplied with a fixed reset voltage setting.
This factory set, reset voltage brings the BC to full regardless
of its previous level. The reset will be done when the battery
has been charged and connected to the machine.
3.3 Keyswitch
The electronics of the BC and the LCD of the hourmeter are
energized as long as the machine battery remains connected
to the gauge. The display of the BC is turned on and 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.
3.4 Hourmeter
Hourmeter operation is indicated by flashing of the hourglass
icon on the face of the LCD. The flash rate is 15 times a
minute with a duty cycle of 3 seconds on and 1 second off.
When the hourmeter is not in operation the icon is visible but
does not flash.

PT S5 5230
Version no T-code
001 200,201,202,454
4 Trouble shooting
This section is separated into two parts: battery discharge
indicator and hour meter.
4.1 Battery Discharge Indicator

4.1.1 No reset
There are two ways to reset the instrument.
Using the open circuit reset, the instrument must first have a
break in the power and then measure a voltage greater than
2.09 volts per cell across its pin 7 or 8 and pin 5.
Verify that a leakage voltage is not present across these 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.
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.
4.1.2 Always resets after break in power

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.
NOTE:
New instruments are shipped from the factory with a full
reading in their memory. The first time the instrument is
connected to the truck’s battery it will always show a full
charge. It is either resetting to full because the battery is
fully charged, or if the battery is not fully charged it is
repeating the information in its memory which is a full read-
ing.
PT S5 5230
Version no T-code
001 200,201,202,454
4.1.3 No discharge, gauge does not run down

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.
4.1.4 No lockout
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
Vad är J ? will open as long as lift is inactive. To test this output remove
SCR? 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.
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.
4.1.5 No lift
First verify that the gauge is not at lockout with its two red
LEDs alternately flashing. The relay outputs should be closed
above lockout and should read 0 ohms with an ohmmeter
across pins 3 and 4. If not test the lift switch and contactor.
4.1.6 Early lockout

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 battery’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.

PT S5 5230
Version no T-code
001 200,201,202,454
4.1.7 LEDs don’t light

The battery discharge indicator LEDs are illuminated by the
keyswitch, pin 2. Verify that B+ is present across pin 2 and
pin 5. If voltage is present and the LEDs do not light the
instrument is defective.
4.2 Hour meter

4.2.1 No display
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.
4.2.2 Hour glass icon does not flash

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

When the icon is flashing the hour meter is accumulating
time. Turn the truck’s keyswitch off. This should remove 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

PT S5 5460
Version no T-code
001 200,201,202

200 PPT 1400MX 243537AA-293314AA
200 PPT 1400MXC 243537AA-293314AA
201 PPT 2000MX 243537AA-293314AA
202 PPT 1600MX 243537AA-293314AA
1 Transistor controller, Curtis 1207
M- B- B+ A2
2 Motor circuit
The transistor controller have four terminals for the high cur-
rent circuits according to the table below.
Terminal Connecting
M- Output to motor armature
B- Negative connection to battery
B+ Positive connection to battery/series field
A2 Plug diode to motor armature

PT S5 5460
Version no T-code
001 200,201,202
3 Control circuit
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 table below.
Pin No Connecting
Contactor drivers
P1 Shunt field driver output
P2 Fork direction contactor driver output
P3 Steer wheel direction contactor driver output
P4 Not connected
Throttle connections
P5 Not connected
P6 Not connected
P7 Throttle: pot low
P8 Throttle: 2-wire 5 kOhm-0 input
Basic control signals
P9 Not connected
P10 Safety reversing check output
P11 Drive fork direction input
P12 Drive steer wheel direction input
P13 Safety reversing input
P14 Speed range selection input
P15 Brake switch input
P16 Key switch input (KSI)

PT S5 5460
Version no T-code
001 200,201,202
4 Technical specification
The technical specification for the BT-version of the Curtis
1207 transistor controller is according to the table below.
Parameter Range STD setting Units Description

Operating voltage 24 24 Volt
Maximum voltage 45 Volt Overvoltage point
Minimum operating 16 Volt Undervoltage point
voltage
Electrical isolation to 500 Volt ac Minimum
heatsink
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 -40 - +50
temperature
o
Heatsink overtemper- 85 C
ature cutback
o
Heatsink undertem- -25 C
perature cutback
Plug Braking Variable Variable Plug current dependant
upon throttle position
Current Limit, Main 100-150 150 Amp

Current Limit, Low 100 Amp Maximum current in low
Speed, Main speed mode
Current Limit, Plug 60 Amp Maximum plug current in
the series field

PT S5 5460
Version no T-code
001 200,201,202
Parameter Range STD setting Units Description

Current Limit, Low 60 Amp Maximum plug current in
Speed, Plug the series field in low
speed mode
Current Limit, 150 Amp Maximum field current in
Safety reversing safety reversing
Current Limit, Low 150 Amp Max. field current when in
speed, safety revers- low speed for safety
ing reversing
Throttle Type 5k-0 Ohm
Min. Duty Cycle 0 % Speed (duty factor) at mini-
mum throttle setting
Low Speed 70 % Maximum speed (duty fac-
tor) in low speed mode
Speed, safety revers- 50 % Speed during safety
ing reversing
Acceleration Rate 0.1 - 3 0.8 Sec Time to reach full output
from zero output

PT S5 5460
Version no T-code
001 200,201,202
5 Adjustment panel
The adjustment panel is located on top of the controller,

under a sliding protective cover. The panel provides access
to a set of adjustable potentiometers, a connector for a hand-
held terminal and the STATUS LED.
5.1 Adjustable potentiometers

MAIN and ACCEL potentiometers can be adjusted with a
screwdriver within the range given in the technical specifica-
tion.
NOTE:
In the BT-version of the Curtis 1207 are only two of the
potentiometers in operation, MAIN and ACCEL. The other
three potentiometers are disabled from factory.
5.2 Connection of handheld terminal

To adjust the parameters with the handheld terminal the cor-
responding potentiometer must be set to ”off”.
5.3 Status LED

The LED displays flashing codes to indicate controller status.
The codes are listed with explanations in section “Diagnos-
tics and troubleshooting”.

PT S5 5460
Version no T-code
001 200,201,202
6 Maintenance
There are no user-servicable parts inside the transistor con-
troller.
NOTE:
No attempt should be made to open the controller. OPEN-
ING THE CONTROLLER WILL VOID THE WARRANTY!
It is however recommended that the controller exterior be
cleaned periodically. When cleaning the controller gives a
good opportunity to check the controller’s diagnostic history
file with the handheld terminal, if available.
6.1 Safety
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.
WARNING
Risk of short circuits.
Remove all watches and jewelry and always use insulated
tools.
6.2 Cleaning
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.

PT S5 5460
Version no T-code
001 200,201,202
7 Diagnostics and troubleshooting
During normal operation, with no faults present, the Status

LED flashes a single flash at approximately 1 flash/second. If
the controller detects a fault, a 2-digit code is flashed 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.
Led code Terminal LCD Explanation Possible cause

Display
1,2 ¤ ¤¤ HW FAILSAFE hardware fail-safe 1. Controller defective
error
1,3 ¤ ¤¤¤ M- FAULT M- output shorted 1. M- output shorted to
ground
2. Direction contactor not
closing
3. Direction contactor not
closing fast enough
4. Internal motor short to
ground
1,4 ¤ ¤¤¤¤ SRO SRO fault 1. Improper sequence of
KSI, brake and direction
inputs
2. Brake or direction switch
circuit open
2,1 ¤¤ ¤ THROTTLE 5kOhm-0 or wiper 1. Throttle input wire open
FAULT 1 fault 2. Throttle input wire shorted
to ground or B+
3. Throttle pot defective.
4. Wrong throttle type
2,2 ¤¤ ¤¤ BB WIRING Safety reversing 1. Safety reversing wire
CHECK wiring fault open
2.Safety reversing check
wire open

PT S5 5460
Version no T-code
001 200,201,202
Led code Terminal LCD Explanation Possible cause

Display
2,3 ¤¤ ¤¤¤ HPD HPD sequencing 1. Improper sequence of
fault KSI, brake, throttle inputs
2. Misadjusted throttle
2,4 ¤¤ ¤¤¤¤ THROTTLE Potentiometer 1. Potentiometer low wire
FAULT 2 Low broken or open
shorted 2. Potentiometer low wire
shorted
3,1 ¤¤¤ ¤ CONT DRVR driver output 1. Direction contactor coil
OC overcurrent shorted
2. Shunt field shorted
3,2 ¤¤¤ ¤¤ DIR CONT welded direction 1. Direction contactor stuck
WELDED contactor closed
3,4 ¤¤¤ ¤¤¤¤ MISSING CON- missing contac- 1. Direction contactor open
TACTOR tor or shunt coil
2. Direction contactor miss-
ing
3. Shunt field open
4. Wire to shunt or direction
contactor open
4,1 ¤¤¤¤ ¤ LOW BATTERY low battery volt- 1. Battery voltage <16 volts
VOLTAGE age 2. Corroded battery terminal
3. Loose battery or controller
terminal
4,2 ¤¤¤¤ ¤¤ OVERVOLTAGE overvoltage 1. Battery voltage > 45 volts
2. Vehicle operating with
charger attached
4,3 ¤¤¤¤ ¤¤¤ THERMAL over-/under-tem- 1. Temperature >85oC or
CUTBACK perature cutback < 25 oC
2. Excessive load on vehicle.
3. Improper mounting of con-
troller
4. Operation in extreme
environments

PT S5 5460
Issued by Approved by Version no T-code
SSD G Jarvis 002 200,201,202,454
Valid for serial number:
T-code Model Machine No. Notes

200 PPT 1400MX 293315AA-319892AA
200 PPT 1400MXC 293315AA-319892AA
201 PPT 2000MX 293315AA-319892AA
202 PPT 1600MX 293315AA-319892AA
454 PPL 2000MX 305210AA-319892AA
1. General
This document describes the functions of Curtis 1207-1131
versions 137197-003 up to 137197-005. The functions are
activated by setting the parameters on the hand terminal. See
chapter “Curtis hand terminal”.
Version 137197-003 includes a new function called neutral
braking. When the function is activated it allows the truck to
work in the neutral braking mode, auto motor brake.
137194-004 contains an overhaul of parameters to obtain
improved driving characteristics. Acceleration and Ramp shape
have been changed. Quick start and Creep speed introduced.
137195-005 is a rebuild of the regulator to handle a “contact
bounce” from the brake’s microswitch and avoid error code
1.4. Introduced from Serial number: 317085AA.

PT S5 5460
Version no T-code
002 200,201,202,454
1.1. Connections
The transistor regulator has four terminals for the heavy cur-
rent circuits, one control current terminal and a connection for
a hand terminal as set out in the table below.
Connection Circuit
1 Connection for the hand terminal
2 16 way connection, logic’s control current
M- Output for motor armature
B- Negative connection to the battery
B+ Positive connection for the battery/series
field
A2 Brake LED for motor armature

PT S5 5460
Version no T-code
002 200,201,202,454
2. Control circuits
The transistor regulator has an integrated 16 way connector
for the connection of the logic’s control current. The designa-
tion of the pins is set out in the table below.
Pin No. Connection

Contactor drive
P1 Shunt field output
P2 Fork direction, contactor output
P3 Steering wheel direction, contactor output
P4 Not connected
Speed control connection
P5 Not connected
P6 Not connected
P7 Speed control, potentiometer low
P8 Speed control, 2-wire 5 kOhm-0 input
Regulator signals
P9 Not connected
P10 Safety reversing, check, output
P11 Driving, fork direction, input
P12 Driving, steer wheel direction, input
P13 Safety reversing, input
P14 Speed range, selection, input-
P15 Brake microswitch, input
P16 Ignition, input (KSI)
© BT Products AB Service Manual 1997-03-19 English 3 (14)

PT S5 5460
Version no T-code
002 200,201,202,454
3. Technical specification
The technical specification for the BT-version of the Curtis
1207-1131 transistor regulator is presented in the table
below.
NOTE! Column T/M shows how the parameter can be
adjusted.
T = Terminal, M = Manual adjustment possible,
- = Not adjustable.
Parameter Range STD Unit T/M Description

(Terminal display) value
Operating voltage 24-36 24 Volt -
Maximum voltage 45 Volt - Overvoltage point
Minimum operating 16 Volt - Undervoltage point
voltage
Electrical insulation 500 Volt ac - Minimum
against heatsink
Frequency 15 kHz -
Contactor voltage 24 Volt -
Contactor current 1 Amp - Maximum, current limit at
2 amp
Shunt field current 2 1.2 Amp -
KSI Input current 80 mA -
Logic Input current 10 mA - At 24 V
Logic minimal with- 8 Volt -
stand voltage
o
Ambient tempera- -40 - +50 C -
ture
Ambient tempera- 85 - 95 oC -
ture, reduction
o
Under tempera- -25 C -
ture, reduction
Motor brake Variable Variable - Motor brake current
depending on position of
accelerator pedal
Current limit, Main 100- 150 150 Amp P
current, M1 MAIN
C/L

PT S5 5460
Version no T-code
002 200,201,202,454

Current limit, low 60-100 100 Amp P Maximum current in low
speed, main current speed range
(M2 MAIN C/L)
Current limit, motor 20-60 60 Amp P Maximum current in series
brake field during motor braking
(M1 PLUG C/L)
Current limit, low 20-60 60 Amp P Maximum current in series
speed, motor brake field during motor braking
(M2 PLUG C/L) low speed range
Current limit, 25- 250 150 Amp - Maximal field current,
safety reversing safety reversing
(EMR REV C/L)
Accelerator type 1 5k-0 Ohm -
Minimal pulse 0 % - Speed at minimum setting
length of accelerator
Low speed 40-100 100 % - Maximum speed in low
(M2 MAX SPEED) speed range
Speed, 25- 100 70 % - Speed during safety revers-
safety reversing ing
(EMR REV SPEED)
Acceleration rate 0 - 1.5 0.8 Sec P,M Time to reach full output
(ACCEL RATE) 1.0 from zero output
137197-004 introduced
from Serial No.: 309922AA
Acceleration ramp 20- 70 30 % P Output signal in% at 50% of
shape speed’s input signal
(RAMP SHAPE) 50 137197-004 introduced
Neutral brake ON/OFF OFF P Selection, braking/free-
(NEUTRAL wheeling when the acceler-
BRAKE) ator is in neutral position
Neutral brake cur- 10- 100 10 Amp P Maximum field current dur-
rent ing neutral braking
(NEUT BRAKE C/L)

PT S5 5460
Version no T-code
002 200,201,202,454

Quick Start 0-4 0 Defines how quickly the
output signal changes when
changing the position of the
accelerator 137197-004
Introduced from
Serial No.: 309922AA
Creep speed/Min. 0-25 10 % The output signal jumps to
Duty Cycle this speed when you select
the travel direction
137197-004 introduced
4. Adjustment panel
The adjustment panel is located on top of the regulator, under

the sliding protective cover. The panel accommodates a set
of adjustable potentiometers, a connection for a hand termi-
nal and a STATUS LED.
4.1. Adjustable potentiometers

The parameter Acceleration Rate can be adjusted using a
screwdriver via the potentiometer ACCEL within the range
defined in the technical specification.
NOTE! Only the ACCEL potentiometer is functional in the BT-
version of Curtis 1207. All other potentiometers are deacti-
vated at the factory.
4.2. Connection for the hand terminal

For information on how to use the hand terminal, see chapter
“Curtis hand terminal”.
To change settings using the hand terminal the correspond-
ing potentiometer must be set to “off”.

PT S5 5460
Version no T-code
002 200,201,202,454
4.3. Status LED

The status LED shows flashing codes to indicate the status of
the regulator. These codes are listed with an explanation in
the chapter “Maintenance”.
5. Maintenance
There are no components in the transistor regulator that may
be repaired by the user.
NOTE!
Do not attempt to open the transistor regulator.
THE WARRANTY WILL CEASES TO BE VALID IF THE REG-
ULATOR IS OPENED!
It is recommended to clean the outside of the transistor regu-
lator regularly. When the regulator is cleaned this provides an
excellent opportunity to check the regulator’s diagnosis file
using the hand terminal, if available.
5.1. Safety
The regulator is a high power component. Requisite safety
precautions should be observed when working on the battery
powered vehicle. The safety instructions comprise, among
others, suitable training, protective glasses, appropriate cloth-
ing that must not hang loosely. Remove your watch and any
jewellery. Use insulated tools.
WARNING
Remove all watches and jewellery as well as always use
insulated tools.
5.2. Cleaning
The following minimum maintenance is recommended at
intervals of 250 hours, even though the transistor regulator
dose not require any real maintenance if installed correctly.
• Switch off the voltage by disconnecting the battery.
• Discharge the capacitors in the regulator by connecting a
load, for example, a contactor coil or horn across the regu-
lator terminal connections B+ and B- before work on the
regulator is carried out.

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• Remove all dirt and corrosion from around the busbars.

Wipe off the regulator with a damp cloth. Let it dry correctly
before reconnecting the battery.
• Make sure the connections to the busbars are tightened
correctly. Use two well insulated spanners to tighten the
connections so as not to load the bars.
6. Diagnosis and trouble shooting
During normal operations, without error indications, the status

LED flashes at a rate of approx. 1 flash/second. If the regula-
tor discovers a fault, a two digit code flashes continuously
until the fault has been rectified, see the table below.
If the hand terminal is used for diagnosis, set to the diagnosis
mode, then diagnosis information can be read off of the dis-
play, see the table below.
LED code Hand terminal Explanation Possible cause

LCD Display
1,2 ¤ ¤¤ HW FAILSAFE Hardware, 1. Regulator faulty
safety circuit
fault
1,3 ¤ ¤¤¤ M- FAULT M output short- 1. M output short-circuited to earth.
circuited 2. Direction contactors do not make.
3. Direction contactors do not make
quickly enough.
4. Internal motor short-circuiting to
earth.
1,4 ¤ ¤¤¤¤ SRO Switch 1. Wrong sequence of input signal for
sequence error KSI, brakes and travel direction
2. Brake or travel direction switch’s cir-
cuit broken.
2,1 ¤¤ ¤ THROTTLE 5 kOhm-0 or 1. Potentiometer input signal cable
FAULT 1 contact error broken.
2. Potentiometer input signal short-
circuited to earth or B+.
3. Potentiometer faulty
4. Wrong potentiometer type.

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LED code Hand terminal Explanation Possible cause

LCD Display
2,2 ¤¤ ¤¤ BB WIRING Safety revers- 1. Safety reversing, cable broken.
CHECK ing cable bro- 2. Safety reversing, control cable bro-
ken ken.
2,3 ¤¤ ¤¤¤ HPD HPD sequence 1. Wrong sequence of input signals for
error KSI, brakes and accelerator.
2. Incorrectly adjusted accelerator
2,4 ¤¤ ¤¤¤¤ THROTTLE Potentiometer 1. Potentiometer low cable broken.
FAULT 2 low, broken or 2. Potentiometer low cable short-
short-circuited. circuited.
3. Wrong potentiometer type.
3,1 ¤¤¤ ¤ CONT DRVR OC Contactor driv- 1. Coil, direction contactor short-
ing over cur- circuited.
rent 2. Shunt field short-circuited.
3,2 ¤¤¤ ¤¤ DIR CONT Welded direc- 1. Direction contactor lodged in made
WELDED tion contactor position.
3,4 ¤¤¤ ¤¤¤¤ MISSING CON- Missing con- 1. Direction contactor, break in coil.
TACTOR tactor or shunt 2. Direction contactor missing.
field 3. Shunt field broken.
4. Cable to shunt field or direction con-
tactor, broken.
4,1 ¤¤¤¤ ¤ LOW BATTERY Low battery 1. Battery voltage <16 volt.
VOLTAGE voltage 2. Corroded battery connection.
3. Loose battery or regulator connec-
tion.
4,2 ¤¤¤¤ ¤¤ OVERVOLTAGE Overvoltage 1. Battery voltage >45 volts
2. Vehicle operational with charger
connected.
4,3 ¤¤¤¤ ¤¤¤ THERMAL Over/under 1. Temperature >85oC or < 25 oC
CUTBACK temperature 2. Vehicle overloaded.
falling 3. Incorrect installation of the transistor
regulator
4. Operations in extreme environ-
ments.

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7. Curtis 1307 hand terminal

Using the Curtis 1307 hand terminal you can program, test
and perform diagnostics on Curtis PMC 1207 regulators. It is
the 1207 regulator that drives the hand terminal through an
RJ11 modular connection located on the adjustment panel on
the top of the regulator.

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Pos Function Notes

1 LCD display 4 row LCD Display
2 PROGRAM MODE button Select this function to show and change the regu-
lator’s parameters.
3 TEST MODE button Select to show the status of the inputs/outputs, etc.
4 DIAGNOSTICS MODE Select to show the current active fault that the reg-
ulator has discovered.
5 SCROLL DISPLAY buttons Scroll the text rows up and down.
6 MORE INFO button Press to access more relevant information for the
current mode.
7 Key active LED’s Indicates whether the relevant CHANGE VALUE
button is active. When it dims no more adjustment
can be made.
8 CHANGE VALUE buttons Increase or decrease the value of the selected
object.
9 Operating mode LED’s Indicates which function mode is active.

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8. Using the hand terminal

• Connect the hand terminal to the regulator’s programming
output located on the top of the adjustment panel.
• Ensure the truck’s current is switched on.
When the hand terminal is connected for the first time the
brakes’ microswitch should be open, the brakes applied, until
the terminal has gathered all the regulator parameters. When
this is complete the terminal will display the regulator’s control
number, date of manufacture and the software’s revision
code. After this display, the terminal will present a prompt for
further instructions.
The terminal has three main functions: PROGRAM, TEST
and DIAGNOSTICS.
• PROGRAM mode is used to show the terminals parame-
ters. The presented parameters can also be replaced in
this mode.
• TEST mode shows real time information about the status
of the input/output signal and the regulator’s temperature.
In the TEST mode the current point does not need to be
the first on the list, it only needs to be among the first four
displayed in the window. The test mode is usable when you
test the function of the regulator during installation and for
trouble shooting if problems occur.
• DIAGNOSTICS mode shows the current fault found by the
regulator.
8.1. Test and adjust the parameters

• Press the PROGRAM mode button. The program mode
LED comes on.
The terminal now displays the first, four parameters. See the
diagram below.

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The parameters are shown four at a time. Each row repre-

sents one parameter. A indicates the name of the parameter.
The arrow B indicates the parameter that has been selected
for modification. C indicates the value of the current parame-
ter.
Press one of the SCROLL DISPLAY buttons to display more
parameters.
To adjust a specific parameter scroll the display up or down
so that the arrow B points at it.
• Increase the value by pressing the CHANGE VALUE - “up”
button, or lower the value using the CHANGE VALUE -
“down” button.
NOTE!
As soon as any of the parameters on the display have been
changed, the new value is transferred immediately to the
regulator.
See the relevant Service Manual for the actual regulator with
regard to information on standard parameter values and
adjustments.
8.2. Using the TEST mode

• Press the TEST mode button TEST mode LED comes on.
The terminal now shows the real time status of the different
input/output values. See the diagram below.
Values are shown on four rows at a time. Each row repre-

sents one input/output signal or value. A is the name and B is
the actual value.
Press on any of the SCROLL DISPLAY buttons to show more
values.
Example
The truck’s accelerator function can be tested by moving the
butterfly disc forwards or backwards. The value THROT-
TLE% will automatically be changed to show the requested
percentage value at full throttle. A value of 100% should be
possible in both travel directions.
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The table explains the TEST values.

.
Test value Description

THROTTLE% Accelerator input signal in per cent.
BATT VOLTAGE Current battery voltage.
HEATSINK °C Current regulator temperature.
BRAKE INPUT Status brake input signal, on/off.
SPEED IN Status pin 14 input to the regulator, on/off.
EMR REV INPUT Status safety reversing input, on/off.
FORWARD INPUT Status driving forward input, on/off.
REVERSE INPUT Status driving reversing input, on/off.
FWD CONTACT Status - connection driving in forward direction
output, on/off.
REV CONTACT Status - connection driving in reversing direction
output, on/off.
MAX TEMP °C The regulator’s registered maximum temperature
since DIAGNOSTIC HISTORY was last reset.
MIN TEMP °C Registered minimum temperature since DIAG-
NOSTIC HISTORY was last reset.
8.3. Use of diagnostic mode

• Press the DIAGNOSTICS mode button. DIAGNOSTICS
mode LED comes on.
The terminal now shows a list of the current faults discovered
by the regulator. The diagram shows the display when no
faults have been discovered.
NOTE!
Refer to the relevant service manual document covering the
controller itself for information about possible fault codes
displayed in DIAGNOSTICS mode.

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200 PPT 1400MX/MXC 319893AA-
201 PPT 2000MX 319893AA-
202 PPT 1600MX 319893AA-
454 PPL 2000MX 319893AA-
1 General
Curtis 1207A-4110 version 137197-006 is similar to Curtis
1207-1137. The difference being the potentiometers and con-
nections for the hand terminal under the sliding cover have
been removed. You must have a hand terminal to make
adjustments on 1207A. See the chapter “Curtis hand termi-
nal”.
1.1 Characteristics and functions

The model 1207A gives the driver excellent control of the drive
motor speed. The current fed to the motor is controlled by vary-
ing the pulse time, operating cycle, for the regulator’s power
semiconductors, MOSFET-transistors. This technique is called
pulse width modulation, PWM, and provides, silent, variable
speed control. Pulse width modulation also known as “chop-
ping”, is a technique that rapidly switches the battery voltage to
the motor on and off very quickly, so that the motor speed can
be controlled. Model 1207A uses high frequency PWM, 15
kHz.
During acceleration and operations at a reduced speed, the
regulator permits more current to flow to the motor than what
the battery delivers. The regulator then acts as a DC trans-
former, which takes in a low current at high voltage, full bat-
tery voltage, yet a high current strength and low voltage.
A microprocessor continuously monitors the regulator’s oper-
ation. If an error is detected a corresponding error code is dis-
played via LEDs, on top of the regulator. The diagnostic
codes shown by the LEDs are listed in the chapter “Diagnos-
tics and trouble shooting”. If the error is critical the regulator is
deactivated. Normally the error can be rectified and is only
temporary. A low voltage error e.g. disappears when the und-
ervoltage no longer exists.
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2 Connections
The transistor regulator has four connections for the high cur-
rent circuits, one control circuit connection and a connection
for a hand terminal as set out on the table below.
Connector Connection
1 Hand terminal connection
2 Low output logic connector with 16 pins
M- Output to the motor armature
B- Negative connection to the battery
B+ Positive connection to the battery/series
field
A Brake diode to the motor armature
1 2
Cables are secured on the busbar by M8 bolts. Two spanners
should be used when tightening the bolts and thereby avoid
the risk of bending the busbar and applying unnecessary
strain on the connections.
M- A2
B- B+

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2.1 Control circuit connections

The transistor regulator has an integrated connector with 16
pins for the low output connections. Pin configuration is as set
out in the table below.
Pin No. Connection

Control circuit contactor
P1 Shunt field output
P2 Output to the contactor for direction of forks
P3 Output to the contactor for direction of steering
wheel
P4 Not connected
Throttle connection
P5 Not connected
P6 Not connected
P7 Throttle, potentiometer low
P8 Throttle, 2-wire 5 kOhm-0-input
Basic control signals
P9 Not connected
P10 Output for check of safety reversing
P11 Input for driving in fork direction
P12 Input for driving in steering wheel direction
P13 Input for safety reversing
P14 Input for selection of mode 1 or 2, (PowerTrak)
P15 Input for brake switch
P16 Input for ignition switch, (KSI)

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3 Technical specification
The technical specification for the regulator is in accordance
with the table below.
Parameter Range Unit Description

Nominal input voltage 24 Volt
Maximum operating voltage 30 Volt
Overvoltage point 33 Volt
Minimum operating voltage 16 Volt Undervoltage point
Electrical insulation for heatsink 500 V AC Minimum
PWM-operating frequency 15 kHz
Output current* 250 A During 1 minute
200 A During 2 minutes
150 A During 5 minutes
100 A During 1 hour
Contactor voltage 24 Volt
Contactor current, maximum 1 A Current limit at 2 A
Shunt drive current 2 A Standard approx. 1 A
KSI-input voltage 16-30 Volt
KSI-input current 80 mA
Logic card, input current 10 mA at 24 V
Logic card, input threshold 8 Volt
Ambient operating temperature -25 to +50 °C
Reduction with over temperature 85 °C
Reduction with under temperature -25 °C
*Output current measured under specific test conditions.

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4 Parameters
The table below describes the parameters that can be
adjusted using the hand terminal. To set parameters using the
hand terminal see the chapter “Using the hand terminal”.
Parameter Range Std. value Unit Description

(1307 display)
Acceleration M1 0-3 1.0 s Time from zero to full
(M1 ACCEL RATE) throttle in operating
mode 1
Acceleration M2 0-3 1.0 s Time from zero to full
(M2 ACCEL RATE) throttle in operating
mode 2
Maximum speed M1 40-100 100 % Percentage of output
(M1 MAX SPEED) signal at max. speed
input signal in operating
mode 1
Maximum speed M2 40-100 70 % Percentage of output
(M2 MAX SPEED) signal at max. speed
input signal in operating
mode 2
Main current limit M1 100-150 150 A Maximum current in
(M1 MAIN C/L) operating mode 1
Main contact current 20-60 60 A Maximum contact cur-
limit M1 rent in operating mode 1
(M1 MAIN PLUG C/L)
Ramp start current 100-150 100 A Maximum contact cur-
limit M1 rent during ramp start in
(M1 RAMP C/L) operating mode 1
Main current limit M2 100-150 100 A Maximum current in
M2 MAIN C/L) operating mode 2
Main contact current 20-60 60 A Maximum contact cur-
limit M2 rent in operating mode 1
(M2 PLUG C/L)
Ramp start current 60-100 100 A Maximum contact cur-
limit M2 rent during ramp start in
(M2 RAMP C/L) operating mode 2
Neutral brake current 10-70 10 A Maximum contact cur-
limit rent during neutral brak-
(NEUT BRAKE C/L) ing

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Parameter Range Std. value Unit Description

(1307 display)
Neutral brake ON/OFF OFF Choice of braking or
(NEUT BRAKE) freewheeling when the
throttle returns to the
neutral position
Quick start 0-4 0 Defines how quickly the
output signal changes
when changing the
position of the throttle
Creep speed/min. 0-25 10 % The control unit’s out-
operating cycle put signal jumps to this
speed when you
change driving direction
The parameters for operating mode 1 respective operating

mode 2 are selected via the status on pin 14, Selection of
operating mode 1 or 2 (PowerTrak).
• Operating mode 1: These parameters are active when the
signal on pin 14 is low.
• Operating mode 2: These parameters are active when the
signal on pin 14 is high.
5 Diagnostics and trouble shooting

5.1 Trouble shooting
A microprocessor continuously monitors the regulator’s oper-
ation. If an error is detected a corresponding error code is dis-
played via LEDs, on top of the regulator. The diagnostic
codes shown by the LEDs are listed in the chapter “Error
codes”. If the error is critical the regulator is deactivated. Nor-
mally the error can be rectified and is only temporary. A low
voltage error e.g. disappears when the undervoltage no
longer exists.
The automatic system for error detection includes:
• Contactor coils open/ short-circuited drive circuit.
• Overcurrent, contactor drive circuit/ contactor coil short-
circuited.
• Contactor welded together.
• Control of function for safety reversing.
• M-output error.

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• Memory controlled during start-up.

• Cut-out with overvoltage.
• Current supply outside permitted range (internal).
• Throttle error.
• Reduction with undervoltage.
• Watchdog.
5.2 Error codes

During normal operations without any errors the STATUS
LEDs flashes approx. once per second. If the regulator
detects an error, a two digit code flashes continuously until
the error is rectified, see the table below.
If a hand terminal is used for error diagnostics, select the
DIAGNOSTIC mode; diagnostic information can then be
read-off on the display, see table below.
5.2.1 LED indications
Only one error at a time is shown. Errors are not queued.
LED code Programming Explanation Probable cause

unit’s LCD dis-
play
LED dimmed No current or defec- Fuse has tripped, bad con-
tive regulator nection, no connection
LED on Defective regulator Regulator defective
1,2 ¤ ¤¤ HW FAILSAFE Failsafe function 1. Regulator defective
error
1,3 ¤ ¤¤¤ M- SHORTED M- output short- 1. M-output short-circuited to
circuited earth
2. Direction contactor does
not make
3. Direction contactor does
not make quickly enough
4. Internally short-circuit to
earth in motor
1,4 ¤ ¤¤¤¤ SRO SRO-error 1. Incorrect sequence in KSI,
braking and direction input
2. Switching circuit for brak-
ing or direction open

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unit’s LCD dis-
play
2,1 ¤¤ ¤ THROTTLE 5 kOhm-0 or lever 1. Throttle input cable open.
FAULT 1 error 2. Cable for throttle input
short-circuited to earth or B+
3. Throttle potentiometer
defective
2,2 ¤¤ ¤¤ BB WIRING Function for safety 1. Function for safety revers-
CHECK reversing connec- ing-cable open
tion error 2. Function for safety revers-
ing-Check open cable
2,3 ¤¤ ¤¤¤ HPD HPD-sequence 1. Incorrect sequence on KSI,
error brake/throttle inputs
2. Incorrectly adjusted throttle
2,4 ¤¤ ¤¤¤¤ THROTTLE Potentiometer low 1. Potentiometer low, cable
FAULT 2 cut-off or short- open
circuited 2. Potentiometer low, cable
short-circuited
3,1 ¤¤¤ ¤ CONT DRVR OC Overcurrent in drive 1. Direction contactor’s coil
circuit output short-circuited
2. Shunt field short-circuited
3,2 ¤¤¤ ¤¤ DIR CONT Welded direction 1. Direction contactor locked
WELDED contactors in made position
3,4 ¤¤¤ ¤¤¤¤ MISSING Contactor or shunt 1. Direction contactor’s coil
CONTACTOR missing open
2. Direction contactor missing
3. Shunt field open
4. Cable to shunt or direction
contactor open
4,1 ¤¤¤¤ ¤ LOW BATTERY Low battery voltage 1. Battery voltage <16 volts
VOLTAGE 2. Corrosion on battery
terminals
3. Loose connection on the
battery or regulator
4,2 ¤¤¤¤ ¤¤ OVERVOLTAGE Overvoltage 1. Battery voltage >33 V
2. Truck used with charger
connected

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unit’s LCD dis-
play
4,3 ¤¤¤¤ ¤¤¤ THERMAL Reduction with 1. Temperature >85o C or
CUTBACK over-/under temper- <-25o C
ature 2. Truck overloaded
3. Incorrect fitting of regulator
4. Extreme operating
environment
The BT version of regulator 1207A has SRO-type “3”. This
means that the regulator is made operational through all
inputs for KSI, brakes and forward must be made in the men-
tioned order. However, operations are permitted if a reverse
input precedes the brake input. This can be used with start of
the truck on an incline. It is this that is called “Starting on
incline”.
5.3 Testing the error detection circuits

Special materials handling directives such as nprEN1175,
demand regular testing of the transistor regulator’s error detec-
tion function. It is therefore recommended that the detection cir-
cuits are checked each time the truck is serviced as follows:
• Support the truck so that the drive wheel is free from the
ground, disconnect the battery and ensure that the ignition
switch is Off.
• Use a suspended fuse holder with a 10 A-fuse and croco-
dile clips, connected to the regulator’s M- and B connec-
tions.
• Switch On the ignition switch, release the brake and press
the throttle. The motor should not be running and the direc-
tion contactors should not be switched.
• Let the ignition switch remain On and disconnect the sus-
pended fuse. The truck’s should still not start.
• Switch the ignition on and off a few times, release the
brake and press the throttle. The truck should now work
normally.

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6 Maintenance
There are no parts inside of the transistor regulator that the
user can service.
NOTE!
Do not attempt to open the transistor regulator.
IF THE REGULATOR IS OPENED THE WARRANTY CAN
CEASES TO BE VALID!
However, the outside of the transistor regulator should be
cleaned regularly. Cleaning provides an excellent opportunity to
check the regulator’s diagnostic history using the hand terminal.
6.1 Safety
High power components can be found in the regulator. Appro-
priate safety precautions must always be taken when working
on a battery powered vehicle. Safety precautions include, but
are not limited to, training, the use of protective glasses, not
wearing loosely hanging clothes. Remove watches and jewel-
lery and always use insulated tools.
WARNING
Remove watches or jewellery and always use insulated
tools.
6.2 Cleaning
Despite the regulator not requiring any maintenance if
installed correctly, it is however recommended that the follow-
ing minimum care should be carried out regularly after every
250 hours.
• Cut the voltage by disconnecting the battery.
• Discharge the capacitors in the transistor regulator by con-
necting a load for example, a contactor coil or the horn
across the regulator’s B+ and B- connections before carry-
ing out any work on the regulator.
• Remove all dirt and corrosion from around the busbars.The
regulator should be wiped clean with a damp cloth. Allow it
to dry before reconnecting the battery.
Cables are secured on the busbar by M8 bolts. Two spanners
should be used when tightening the bolts and thereby avoid
the risk of bending the busbar and applying unnecessary
strain on the connections.

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7 Hand terminal Curtis 1307

The hand terminal Curtis 1307 makes it possible to program,
test and trouble shoot regulators of the type Curtis PMC
1207/1207A. The hand terminal is controlled by the host proc-
essor 1207/1207A via a modular connector RJ11 located on
the adjustment panel above the regulator 1207, or a 4 way
Molex connector located on the front of regulator 1207A.
Curtis 1207 connection
Curtis 1207A connection
M- A2
B- B+

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Pos. Function Notes

1 Display 4 row LCD-display.
2 PROGRAM MODE key Select this mode to show and change the regula-
tor’s parameters.
3 TEST MODE key Select this mode to show the status of the inputs/
outputs, etc.
4 DIAGNOSTICS MODE Select this mode to show the current error condi-
key tion detected by the regulator.
5 SCROLL DISPLAY keys Scroll the displayed rows of text up and down.
6 MORE INFO keys Press this key to receive more information about
the current status.
7 LED for active keys Indicates whether the relevant CHANGE VALUE
key is active. When the LED is dimmed no further
adjustment can be made.
8 CHANGE VALUE keys Increase or decrease the value of the selected
parameter
9 LED for operating mode States which operating mode is currently active.

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8 Using the hand terminal

• Connect the hand terminal to the regulator’s programmer
socket located above the adjustment panel.
• Make sure the current to the truck is on.
The first time the hand terminal is connected to the regulator
the brake switch must be open, brakes applied, until the hand
terminal has read in all the regulator parameters. The hand
terminal then displays the regulator’s model number, date of
manufacture and the software’s version number. The hand
terminal then prompts for further instruction.
The hand terminal has three primary operating modes: PRO-
GRAM, TEST and DIAGNOSTICS.
• PROGRAM mode used to show, and change the regula-
tor’s parameters. The shown parameters can also be
changed in this mode.
• TEST mode shows real time information on the status of
the inputs, outputs and the regulator temperature. In the
TEST mode the points of interest are not always at the top
of the list. They only need to be shown among the four
rows displayed in the window. The TEST mode can be
used to check the operation of the regulator during initial
installation and for trouble shooting.
• DIAGNOSTICS mode shows the active error detected by
the regulator.
Two other operating modes can be activated SPECIAL PRO-
GRAM and SPECIAL DIAGNOSTIC.
• The SPECIAL PROGRAM mode allows a number of differ-
ent tasks including: erasing the diagnostic history file,
adjusting the display contrast, language selection, saving
settings, etc.
• In the SPECIAL DIAGNOSTICS mode the regulator’s diag-
nostic history is shown. This file contains a list of all faults
observed and saved by the regulator since the file was last
cleared.

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8.1 Using the PROGRAM mode to check

and adjust parameters
• Press on the PROGRAM mode key. The corresponding
LED for PROGRAM operating mode comes on.
The hand terminal now shows the first four parameters.
PROGRAM See illustration below.
Parameters are shown four at a time. Each row represents

one parameter. A indicates the name of the parameter. The
arrow B indicates the parameter currently selected for adjust-
ment. C indicates the current parameter value.
Press on one of the SCROLL DISPLAY keys to show other
parameters.
Scroll the display up or down to adjust a specific parameter
so that the arrow (B) points on the actual parameter.
• Increase the value by pressing the key CHANGE VALUE
“up” or decrease it by pressing on the key
CHANGE VALUE “down”. The LEDs on these keys indi-
cate whether there is still room for adjustment, i.e. that
when the upper limit for a parameter range has been
reached, the LED on the “up” key does not come on
thereby indicating that the value cannot be further
increased. When the lower limit has been reached the LED
on the “down” key goes out.
NOTE!
As soon as a displayed parameter is modified, the new
value is transferred directly to the regulator.
See the appropriate service manual for the regulator in ques-
tion for information on parameters, standard parameter val-
ues and adjustments.

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8.1.1 Using the key MORE INFO in PROGRAM mode

The MORE INFO key in PROGRAM mode shows a bar chart
together with the min. and max. values for the selected
parameters. The parameters can either be changed from the
PROGRAM main menu or after the key MORE INFO has
been pressed to show extra information, see the example
below.
MODE 1 ACCELERATION
RATE; SECS
MIN 0.2
1.3
MAX 3.0
8.2 Using SPECIAL PROGRAM mode

SPECIAL PROGRAM makes it possible to perform a number

of different tasks of which most are self-explaining. Via the
SPECIAL PROGRAM you can return to previous settings,
save regulator settings in the hand terminal’s memory, load
MORE INFO PROGRAM
regulator settings from the hand terminal to a regulator, erase
the diagnostics history file, adjust the contrast on the pro-
grammer’s LCD display, select the display language on the
hand terminal and show basic information about the regulator
and hand terminal.
SPECIAL PROGRAM is accessed by first pressing the
MORE INFO key. Keep the MORE INFO key held down and
press the PROGRAM key. The LED on the PROGRAM key
comes on, exactly as when the hand terminal is in the PRO-
GRAM mode. The key MORE INFO is first used to reach the
SPECIAL PROGRAM mode, and once the mode is active,
used to execute the different measures. For example, to
adjust the contrast on the display, you select “Contrast
Adjustment” by scrolling the screen until the option is shown
at the top of the window and then press the MORE INFO key
to find out how to make the adjustment.
8.3 Using TEST mode

• Press on the TEST key. The corresponding LED comes
on.
The hand terminal’s display shows the real time status of the
TEST different inputs, outputs and values. See the illustration
below.

PT S5 5460
Version no T-code
003 200,201,202,454
Parameters are shown four at a time. Each row represents

one input, one output or one value. A is the name and B is the
current value. In TEST mode the test value does not need to
be at the top of the display. It only needs to be among the four
visible rows in the window. The TEST mode can be used with
the installation of the regulator, and with later trouble shoot-
ing.
Show other values by pressing the SCROLL DISPLAY keys.
Example
The operation of the truck’s throttle can be controlled by mov-
ing the toggle switch forwards or backwards. The value
THROTTLE % should changed with the movement of the
throttle to show the speed’s set value in per cent of the value
for maximum speed. It should be possible to set a value of
100% in both travel directions.
The table shows the meaning of the TEST values.
Test value Description

THROTTLE % The throttle’s input signal in per cent.
BATT VOLTAGE Current battery voltage
HEATSINK °C Current regulator temperature
BRAKE INPUT Status of brake input, on/off
SPEED IN Status of pin 14, the input signal to the regulator on/
off
EMR REV INPUT Status of the safety reversing input, on/off
FORWARD INPUT Status of the input for driving forwards, on/off
REVERSE INPUT Status of the input for reversing, on/off
FWD CONTACT Status of contactor input for direction forwards,
on/off
REV CONTACT Status of contactor input for direction reversing,
on/off
MAX TEMP °C Highest recorded regulator temperature since
DIAGNOSTIC HISTORY was last cleared
MIN TEMP °C Lowest recorded regulator temperature since
DIAGNOSTIC HISTORY was last cleared

PT S5 5460
Version no T-code
003 200,201,202,454
8.4 Using DIAGNOSTICS mode

• Press the DIAGNOSTICS key. The corresponding LED
comes on.
The hand terminal’s display shows a list of the active errors
detected by the regulator. The illustration below shows the
DIAGNOSTICS display when no errors have been detected.
NOTE!
See the appropriate service manual for the regulator in ques-
tion for information on possible error codes shown in the
DIAGNOSTICS mode.
8.5 Using SPECIAL DIAGNOSTICS mode

The regulator file with diagnostic history is shown in SPECIAL

DIAGNOSTICS mode. This file is a list of all the regulator’s
detected and recorded errors since the file was last cleared.
Each error is only recorded once in the file diagnostic history
MORE INFO DIAGNOSTICS
irrespective of how many times the error has occurred.
SPECIAL DIAGNOSTICS is accessed by first pressing on the
MORE INFO key. Keep the MORE INFO held down and then
press the DIAGNOSTICS key. The LED on the DIAGNOS-
TICS key comes on, exactly as when the hand terminal is in
the DIAGNOSTICS mode.
To clear the diagnostic history file, switch to SPECIAL PRO-
GRAM mode, and select “Clear Diagnostic History” and then
press the MORE INFO key for instruction. Clearing the diag-
nostic history file also resets the max. and min. temperatures
in the TEST mode.

PT S5 5460
Version no T-code
003 200,201,202,454

PT S5 5710
Electronic card
SSD K Hallman 001 200,201,202
Electronic card
Resistance Control

200 PPT 1400MX/MXC 237000AA-
201 PPT 2000MX 237000AA-
202 PPT 1600MX 237000AA-
1 Controller
The BT PPT 1400MX/1600MX/2000MX controller contains a
logic-unit (micro processor) which detects signals from micro-
switches, armature voltage, etc. The controller’s inputs and
outputs are equiped with connectors for connection/discon-
nection of cables.
The controller is equipped with a green LED (labelled PWR/
ERROR), which indicates correct main voltage. The LED for
PWR/ERROR also indicates faults in the emergency stop cir-
cuit or in the contactor circuits.
The inputs are suited for the 24 V voltage level and will draw a
certain current in order to clean the opening contacts and,
also, to indicate input signals with green LED’s.
The contactor outputs are electronically short circuit proof and
indicate output signals with red LED’s. The drive contactor
outputs are controlled by transistors and will receive the full
main voltage when the current is turned on, i.e. 24 V and after
the contactors have closed, the voltage will drop to half this
value, i.e. 12 V.

PT S5 5710
Electronic card
Version no T-code
001 200,201,202
In addition to signals from switches, the drive motor’s arma-

ture voltage is monitored, so that speed step 3 will be
engaged at a pre-determined voltage level or, alternatively,
after a fixed time lapse.
1
4 2
Connection contacts
Position Connection
1 Shunt field
2 Battery +, armaturevoltage, contactors, horn
3 Key switch(S17), battery -, instrument, magnetic valve (Y41)
4 Micro switches
I = Input, green LED

O = Output, red LED
Terminal No LED No Connection Function

Pwr/Error On = OK (green) Flashes =
Error
101 101 I Driving, fork direction
102 102 I Driving, steer wheel direction
103 103 I Driving, speed 2
104 104 I Driving, speed 3

PT S5 5710
Electronic card
Version no T-code
001 200,201,202

105 105 I Fork lift
106 106 I Fork lower
107 107 I Horn
108 O 24 V (+)
109 109 I Brake
110 I Safety reversing (S20)
201 I Battery controller

202 I 24 V (+)
203 O Battery controller
204 O Magnetic valvel
205 O 24 V (+)
206 O Hour meter
207 I (-)
301 O Shunt field (+)

302 O Shunt field (-)
401 401 O Contactor, fork direction

402 402 O Contactor, steer wheel direction
403 403 O Contactor, speed 2
404 404 O Contactor, speed 3
405 405 O Contactor, pump motor
406 O Horn
407 I 24 V (+)
408 I Armature voltage
409 O (-)

PT S5 5710
Electronic card
Version no T-code
001 200,201,202

PT S5 5710
Electronic card
SSD K Hallman 002 200,201,202
Electronic card
Transistor Control

200 PPT 1400MX/MXC 243537AA-
201 PPT 2000MX 243537AA-
202 PPT 1600MX 243537AA-
1 General
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.
5
2
3
4

PT S5 5710
Electronic card
Version no T-code
002 200,201,202
1.1 Connection/adjustments
Position Connection/Adjustment
1 Key switch (S17), battery -, instrument, magnetic valve (Y41)
2 Battery +, armature voltage, contactors, horn
3 Shunt field
4 RV1, adjustment of maximum speed
5 Micro switches
I = Input, green LED

O = Output, red LED

101 101 I Driving, fork direction
102 102 I Driving, steer wheel direction
103 103 O Speed control
104 104 I Referens value, speed
105 105 I Fork lift
106 106 I Fork lower
107 107 I Horn
108 O 24 V (+)
109 109 I Brake

PT S5 5710
Electronic card
Version no T-code
002 200,201,202

201 I Battery controller

202 I 24 V (+)
203 O Battery controller
204 O Magnetic valve
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
403 403 U 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 (+)
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 (S20)
417 I Shunt field(-)

PT S5 5710
Electronic card
Version no T-code
002 200,201,202

Master Service Manual Product Family PT: BT PPT 1400C BT PPT 1400 MX BT PPT 1400Mxc BT PPT 1600Mx BT PPT 2000Mx

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Master Service Manual Product Family PT: BT PPT 1400C BT PPT 1400 MX BT PPT 1400Mxc BT PPT 1600Mx BT PPT 2000Mx

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Master Service Manual

© BT Industries AB Part number: 147637-040

Valid from serial number:

T-code Model Serial No Notes

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

Section C-code T-code Document Issued

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

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

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

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

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

T-code Model Serial No Notes

1.1 Issued operator’s manuals

One of these Operator’s Manuals is supplied with the Manual

2 (2) Service Manual 1999-04-14 English

General product information

T-code Model Serial No Notes

1 Presentation of the truck

© BT Industries AB Service Manual 1999-06-02 English 1 (8)

1.1 Intended application of the truck

1.2 Forbidden application of the truck

2 (8) Service Manual 1999-06-02 English

Truck type PPT PPT PPT PPT

* Deviations may occur on trucks adapted to specific applica-

PPT 1400, 1600 & 2000MX

PPT PPT PPT PPT

4 (8) Service Manual 1999-06-02 English

G D WEIGHT WITHOUT BATTERY kg

© BT Industries AB Service Manual 1999-06-02 English 5 (8)

6 (8) Service Manual 1999-06-02 English

© BT Industries AB Service Manual 1999-06-02 English 7 (8)

7 Warning and information plates and

8 (8) Service Manual 1999-06-02 English

General product information

T-code Model Serial No. Notes

1 Presentation of the truck

2 Intended use of the truck

3 Forbidden use of the truck

Truck type PPL 2000MX

2 (8) Service Manual 1998-09-02 English

PPL 2000MX 240 Ah PPL 2000MX 320 Ah

© BT Industries AB Service Manual 1998-09-02 English 3 (8)

4 (8) Service Manual 1998-09-02 English

© BT Industries AB Service Manual 1998-09-02 English 5 (8)

6 (8) Service Manual 1998-09-02 English

9 Warning and information plates

© BT Industries AB Service Manual 1998-09-02 English 7 (8)

8 (8) Service Manual 1998-09-02 English

T-kod Modell Maskinnr Anm.

Model PPT 1400MX PPT 1600MX PPT 2000MX

© BT Industries AB Service Manual 1994-03-24 English 1 (4)

Model PPT 1400MX PPT 1600MX PPT 2000MX

2 (4) Service Manual 1994-03-24 English

Model PPT 1400MX PPT 1600MX PPT 2000MX

© BT Industries AB Service Manual 1994-03-24 English 3 (4)

4 (4) Service Manual 1994-03-24 English

T-code Model Serial No. Notes

MODEL PPL 2000MX

© BT Industries AB Service Manual 1998-06-12 English 1 (4)