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Valid from serial number: 364690AA-
Order number: 179574-040

Issued: 2000-06-01 ITS
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2000-06-01
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179574-040 2000-06-01
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7HFKQLFDOGDWD ................................................................ 7
4XDOLW\3DUWV .................................................................. 13
1 Issued Quality Parts ............................................... 13
6HWXSDQGPDLQWHQDQFHLQVWUXFWLRQV ............ 15
1 Setting up the new truck ........................................ 15
2 Introduction, maintenance .................................... 19
3 Safe lifting ................................................................. 22
0DLQWHQDQFHOXEULFDWLRQFKDUW........................... 23
1 Lubrication chart ..................................................... 29
2LODQGJUHDVHVSHFLILFDWLRQ ................................ 31
7RROV................................................................................... 33
1 Super Seal connector ............................................ 33
)RUNFDUULDJH ................................................................. 37
1 Component parts .................................................... 37
2 Dismantling the fork carriage ............................... 39
3 Replacing the rollers .............................................. 41
(OHFWULFGULYHPRWRU................................................... 43
1 Component parts .................................................... 43
2 Removing the motor from the truck .................... 45
3 Refitting the motor in the truck ............................. 46
4 Service and repairs ................................................ 47
5 Technical data ......................................................... 50
© BT Industries AB Service Manual Orion P24 Approved by: 3

&RQWHQWV
497 364690AA-
2000-06-01 179574-040
'ULYH7UDQVPLVVLRQDVVHPEO\ ............................ 51
1 Component parts .................................................... 52
2 Dismantling/Assembly
Leakage from the upper cover ............................. 53
3 Replacing the drive shaft gasket ......................... 54
4 Replacing wheel bolts ............................................ 56
(OHFWURPDJQHWLFEUDNH ............................................ 59
1 Component parts .................................................... 60
2 Dismantling .............................................................. 61
3 Assembling ............................................................... 61
4 Manual release of the brake ................................. 62
5 Adjustment ............................................................... 62
6WHHULQJV\VWHP ........................................................... 63
1 Component parts, mechanical steering ............. 63
2 Components parts, servo steering ...................... 66
3 Adjustment, steering .............................................. 71
4 Components parts, tiller arm ................................ 72
5 Adjustment, tiller arm ............................................. 73
6 Tiller arm handle ..................................................... 74
7 Dismantling/Assembly, buttons ........................... 76
(OHFWULFDOV\VWHPV ...................................................... 79
1 Electrical parts ......................................................... 79
2. Symbol list and electrical diagram ...................... 81
3. Functional description ............................................ 85
4. Hour meter ............................................................... 87
5. Fault codes ............................................................... 88
6. Parameters ............................................................... 92
7. Part numbers ......................................................... 100

&RQWHQWV
364690AA- 497
179574-040 2000-06-01
8. Transistor panel .................................................... 100

9. Diagnostic and troubleshooting ......................... 101
10 Technical specifications – Curtis 1243 ............ 103
+\GUDXOLFVSQHXPDWLFV ........................................ 105

1 Hydraulic diagram ................................................ 105
2 Adjustments ........................................................... 107
3 Cleaning the filter .................................................. 108
3RZHU7UDNF\OLQGHU ................................................. 109

1 Component parts .................................................. 109
2 Dismantling the PowerTrak cylinder ................ 110
3 Dismantling/assembling the ground
pressure springs ................................................... 112
© BT Industries AB Service Manual Orion P24 Approved by: 5

&RQWHQWV
497 364690AA-
2000-06-01 179574-040

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179574-040 1999-11-10 001
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Type TSL160 A DM4
Output, kW 2.5
Duty cycle S2, 60 min
Minimum carbon brush length, mm 11
Nominal commutator diameter, mm 71
Minimum commutator diameter, mm 68
Resistance, shunt field winding, Ω at 24 C° 0.346
Resistance armature winding, Ω 0.0098
at 24 °C
Insulation resistance between the windings >= 1 Mohm
and motor casing
Weight, kg 23
%UDNHV
Type 1EB46-11
Braking force, Nm 48
Output, W 44
Resistance coil, Ω 12
Nominal play in actuated position, mm 0.25-0.38
Minimum thickness brake disc, mm 7.7
Thickness of a new brake disc, mm 9.7
7UDQVPLVVLRQGULYHJHDU
Type 2-stage angle trans-
mission
Gear ratio 14.20:1
Oil volume, litre 1.75
Oil type Hypoid oil
at normal temperature SAE 80W/90
at temperature < -15oC SAE 75W
© BT Industries AB Service Manual Orion P24 Approved by: Fredrik Wigh 7

7HFKQLFDOGDWD
497 350497AA-
001 1999-11-10 179574-040
0RGHO 3
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Drive wheel, mm 250x75
Drive wheel for servo, mm 250x105
Axle pressure without load, kg 460
Axle pressure at rated load, kg 770
Wheel pressure at rated load, kg/cm 30
Tightening torque wheel bolts, Nm 130
Fork wheel, Bogie, mm 80x74
Axle pressure without load, kg 175-320
Axle pressure at rated load, kg 1800-2300
Wheel pressure at rated load, kg/cm 47-55
Swivel wheel, mm 150x50
Axle pressure without load 175-605
Axle pressure at rated load, kg 120-790
Wheel pressure at rated load, kg/cm 12-37
+\GUDXOLFV\VWHP
Output, kW 2.0
Duty cycle 10%
Pressure at rated load, bar 130
Overflow pressure, bar 145
Pump flow, cc/r 2.5
Tank volume, litre 1.2
Oil type:
at normal temperature ISO-L-HM32
at temperature < -15oC ISO-L-HV32
8 © BT Industries AB Service Manual Orion P24 Approved by: Fredrik Wigh

7HFKQLFDOGDWD
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179574-040 1999-11-10 001
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Type MET 3B 24 V
Output, W 160
Torque constant 0.6 Nm/A
Max current 55 A
Speed, rpm 2550
Minimum carbon brush length, mm -
Minimum commutator diameter, mm -
Resistance,Ω,armature 0.27
)XVHV
Control circuits, F50, F51 7.5 A
Drive motor 125 A
Pump motor 160 A
Servo steering (Option) 20 A
%DWWHU\FRPSDUWPHQW%DWWHULHV
Battery compartment
Dimensions LxWxH, mm
Short 212x790x775
Long 296x790x775
Capacity, Ah 292-600
Weight, kg 240-500
'ULYLQJVSHHG
Without load, m/s 3.33 + 5%
With rated load, m/s 2.63 + 5%
/LIWORZHULQJVSHHG
Lift to top with load, s 2.0
Lowering without load, s 2.3

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Driving without load, A -
Driving with rated load, A -
Lift without load, A -
Lift with rated load, A -
,QFOLQHFOLPELQJDELOLW\
Without load 15%, 8.5°
With rated load 8%, 4.5°
0HDVXUHPHQW
L2
Short 730 mm
Long 814 mm
Wa with 1170 mm forks and lift fork -
Wa with 1170 mm forks and lift fork, fixed -
side gates
Wa with 1170 mm forks and lift fork, fixed -
back rest
Lift height 225 mm
:HLJKW
Truck without battery, Max 600 kg
Fixed gates - kg
Fixed back rest - kg

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• Lift the truck from the marked lifting points when lifting using a
lifting device.
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497 364690AA-
001 2000-06-01 179574-040
• Lift at the truck's centre of gravity when lifting with another fork
lift truck.
L2
*/ */
/ $K Tp=460 Tp=770
/ $K Tp=480 Tp=690
Tp / $K Tp=480 Tp=800
/ $K Tp=520 Tp=700
0 460 770
• Secure the truck on the lifting truck's forks.

• Lift with greatest possible care.
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364690AA- 497
179574-040 2000-06-01 001
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Check that the battery cables are correctly connected to the bat-
tery.
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The battery can be replaced from both sides and from above.
Depending on which side you wish to dismantle the battery, the
battery lock (A) is fitted as illustrated. Also fit the fixed part (B) on
the opposite side.
Shims (C) are also supplied with the truck. These are used to
take up any play between the battery and battery compartment
wall. Fit these if necessary as illustrated.
6WDUWXS
The following points must be checked before the truck is used.
3RVLWLRQQR ,QVSHFWLRQSRLQWV $FWLRQ

1 Hydraulic function Check the function
2 Throttle Check the function, forwards/backwards
3 Safety switch against collisions Check the function
4 Horn Check the function
5 Steering Check the function
6 Gate switch Check the function
7 Platform Check the function (return to the top position)

497 364690AA-
001 2000-06-01 179574-040
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8 Hydraulic system Check the oil levels and check for oil leakage
9 Drive assembly Check for noise and oil leakage
10 Brakes Check the function
11 Platform/Brake switch Check the function
12 Chassis Inspect damage, remove dirt and the like.
13 Wheels Inspect damage, remove oil, metal chips and the
like
14 Lifting equipment Inspect damage, remove dirt and the like.
15 Battery Check the acid and charging level (see battery
maintenance)
16 Running time Carry out maintenance as set out in the table,
chapter Maintenance
• Also check that parameters are set to the correct values

- Maximum speed
- Acceleration
- Automatic speed reduction
- PIN-codes (Option).

364690AA- 497
179574-040 2000-06-01 001
,QWURGXFWLRQPDLQWHQDQFH
All points in the service program shall be included to attain the
highest safety and a least possible truck downtime. The service
intervals are only a guide and do not need to be followed strictly.
The truck driver must adapt these to local conditions, but it is
important that the intervals meet BT’s minimum demands.
The service intervals are based on operating times and can be
adapted to most normal 8 hour shifts. The following operating
hours have be used when calculating the interval.
Day time: 08.00-17.00 (20 hours/week)
2-shifts: 06.00-14.00, 14.00-22.00 (40 hours/week)
3-shifts: 06.00-14.00, 14.00-22.00, 22.00-06.00
(60 hours/week)
Ensure the truck is given regular maintenance services according
to the maintenance schedule. The truck’s safety, efficiency and
service life is dependent on the service and maintenance it is giv-
en.
Only use BT approved spare parts during service and repairs
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Only persons trained in servicing and the repair of this type of
truck are qualified to carry out service and repair work.
• Do not carry out any maintenance work on the truck if you do
not have the right qualifications and know how to carry out the
work.
• Keep the area where service work is done clean. Oil or water
will make the floor slippery.
• Never wear loose objects or jewellery when working on the
truck.
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• Always remove the battery plug when carrying out mainte-
nance on the truck, if the instructions in this service manual do
not say otherwise.
497 364690AA-
001 2000-06-01 179574-040
• Always switch off the truck's power supply before the hoods to
the drive assembly and the electrical system are opened.
• Offload the system pressure slowly before work on the truck's
hydraulic system is started.
• Use paper or rigid cardboard when checking a possible oil
leakage. 1HYHU use your hands.
• Bear in mind that the oil in the transmission and hydraulic sys-
tem can be hot.
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• Only new and clean oil may be used in the hydraulic system.
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• Store and transport changed oil according to applicable local
directions.
• Do not flush solvents and the like used for cleaning down
drains that are not intended for this purpose. Follow local di-
rections that apply for destruction.
• Disconnect the battery when welding on the truck.
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• Remove at least 100 mm of paint around the welding/grinding
area using sand blasting equipment or paint remover when
welding or grinding on painted surfaces.
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364690AA- 497
179574-040 2000-06-01 001
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Cleaning and washing the truck is a significant measure for the
reliability of the truck.
• Carry out general cleaning and washing each week.
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• Clean rubbish from the wheels each day.
• Use a well-known degreasing agent, diluted into an appropri-
ate concentration.
• Wash off loose dirt with tepid water.
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• Cover the electrical motors, connectors and valves before
washing.
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• Wash the motor component using a well-known degreasing
agent, diluted into an appropriate concentration.
• Wash off loose dirt with tepid water.
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• Blow electrical components clean using compressed air.
• Clean electrical panels, electronic cards, connectors, contac-
tors, solenoid valves, etc. with a moist cloth and a cleaning
agent.
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497 364690AA-
001 2000-06-01 179574-040
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All lifting must be carried out on a flat, anti-slip and firm surface.
Avoid newly laid asphalt or asphalt on a hot summer day.
• Always apply the parking brake to prevent the truck from mov-
ing while lifting. If the lift concerns the brake wheel, chock the
other wheels so that the truck stands still.
• Select the lifting points so that the lift is as easy as possible
(one corner at a time). If the truck has marked lifting points on
the lower part of the chassis, these should be used to give a
well-balanced lift.
• Ensure the area where you place the jack is clean and free of
oil and grease.
• Ensure there is no grease or oil on your hands or the jack lever.
• Use the lever belonging to the jack. A too short lever will re-
quire more effort than is necessary. If the lever is too long there
is a risk that the jack will be overloaded.
• Block up the truck.
- as close to the lifted part of the chassis as possible to re-
duce the falling height in the event of a collapse.
- so that the truck cannot roll.
- 1HYHU block up the jack to lift higher.
- 1HYHU work under a lifted truck without appropriate block-
ing.
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364690AA- 497
179574-040 2000-06-01 001
I: Inspect, correct and replace if necessary. T: Tighten C: Clean L: Lubricate

M: Measure, correct if necessary
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0000.1 Check all links and spiral pins I
0000.2 Check for damage to the platform. I
0000.3 Check the cover locks I
0000.4 Check the finger guard I
0000.5 Check signs and stickers I
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0380.1 Check for crack formation and damage I
0380.2 Check the play in bushings and links I
0380.3 Push in grease in the grease nipples I/L
(Option)
0380.4 Check the lift limit switch I
0RWRUV
1700.1 Check for loose connections I/T1 I/T
1700.2 Check the carbon brushes in the drive M
motor
1700.3 Clean the drive motor C
1700.4 Tighten the mounting bolts T2
1700.5 Check for abnormal noise in the bearings I
1700.6 Check the steering motor carbon brushes M
(Option)

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2550.1 Check for leakage I3 I
2550.2 Check oil level I
2550.3 Check for abnormal noise I
2550.4 Check mountings and play in the steering I
bearings
2550.5 Change the oil in the drive transmission L4 L
2550.6 Lubricate the gear ring (Servo, Option) L
%UDNHV
3100.1 Clean C
3100.2 Check for wear to the brake discs M
3100.3 Check for play in released position M
:KHHOV
3500.1 Remove string and other detritus I
3500.2 Check for wear on the drive wheel I
3500.3 Check that the swivel wheels rotate and I
swing freely
3500.4 Check for wear to the swivel wheels I
7LOOHUDUP
4110.1 Check for play on steering joints I
4110.2 Check the steering force I
4110.3 Check the gas cartridge’s force I
4110.4 Check the adjustment of the steering L/M
chain, lubricate

364690AA- 497
179574-040 2000-06-01 001

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5000.1 Check the operation of the brake micros- I I
witch
5000.2 Check the function of the safety switch I
against collision
5000.3 Check the operation of the gate switch I I
5000.4 Check the operation of the platform I I
switch
5000.5 Check the horn I I
5000.6 Check for wear to the cables I
5000.7 Check the operation of the driver’s con- I I
trols
5000.8 Check the error code log and operating- I I
times
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5110.1 Check electrolyte levels, 10-15 mm M
above the cell plates
5110.2 Check connections on the battery, truck I
and charger
5110.3 Check that the cell and pole guards are I
undamaged
5110.4 Check the fluid density and temperature M
5110.5 Remove overflow fluid from the battery C
trough
5110.6 Check the battery lock I

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5400.1 Clean and check the mountings C/T1 C/T
5400.2 Tighten the cable connections T1
5400.3 Check the contactor points on K10 and I
K30
5400.4 Check the contactor movement I
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5700.1 Clean the electrical panel C
5700.2 Check the connectors and cables TI I
5700.3 Check all segments on the display I
+\GUDXOLFV\VWHP
6100.1 Check for leakage from hoses and cou- I
plings
6100.2 Check for wear to the hoses I
6100.3 Check the tank I
6100.4 Check that the oil level is correct I
6100.5 Change the oil and clean the filter L5 L
/LIWF\OLQGHUV
6600.1 Check for leakage I
6600.2 Check the mountings I

364690AA- 497
179574-040 2000-06-01 001

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6680.1 Check for any damage, cracks on the I
PowerTrak springs
6680.2 Grease the ground pressure spring’s C/L
guides
= Connections are tightened for the first time after 80 hours and
then every 1000 hrs/ 12 months.
= Mounting bolts are tightened after 80 hrs/1 month to 45 Nm.
= Check for leakage in connection with the first oil change.
= The oil is changed for the first time after 80 hrs/1 month and
then every 3000 hrs/36 months.
= The oil is changed and the filter cleaned for the first time after
80 hrs/1 month and then every 1000 hrs/12 months.
When points with higher time intervals are addressed, the points
with shorter time intervals should also be addressed unless oth-
erwise stated above.

497 364690AA-
001 2000-06-01 179574-040
5000
5000
5700
4110 4110
6680
5000 5000
5110
6600
0380
5400
3100
2550
1700
3500
0000
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6100
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5000

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0380 Grease nipples (Option) L F
2550 Drive transmission O4 I O C
2550 Gear ring L E
4110 Steering chain L D
6100 Hydraulic system O5 O B
6680 PowerTrak, ground pressure L F
spring
L= Lubricate I = Inspection O = Oil change

= The oil is changed for the first time after 80 hrs/1 month and
then every 3000 hrs/36 months.
= The oil is changed and the filter cleaned for the first time after
80 hrs/1 month and then every 1000 hrs/12 months.

497 364690AA-
001 2000-06-01 179574-040
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W\SH !& &
A Grease BT 26777 BT 26777 Bearings and bushings
(Spray) (Spray)
B Hydraulic oil ISO-L-HM32 ISO-VG32 Hydraulic system
C Transmission oil Hypoid oil Hypoid oil Gears
SAE 80W/90 SAE 75W
D Grease BT 26778 BT 26778 Chains
(Spray) (Spray)
E Grease Grafloscon Grafloscon Gear ring
A-G1 (Klüber) A-G1 (Klüber)
F Grease BT 73942XX5 BT 73942XX5 Grease nipples, Ground
TOTAL N3942 TOTAL N3942 pressure spring

497 364690AA-
001 2000-06-01 179574-040

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159232 Tools for fitting pins/sleeves
159229 Tools for loosening locks (1)
159230 Tools for fitting secondary locks

2 pole (2)
159231 Tools for fitting secondary locks

4 pole (2)
159228 Tools for removing pins/sleeves

(3)

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001 2000-06-01 179574-040
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31-151080 Tools for removing pins/sleeves
1=163787 Tools for fitting sleeves

2=163788
1
2
1=163789 Tools for fitting pins
2=163790 1: For 0.2–0.5 mm2
3=163791 2: For 0.5-1.0 mm2
3: For 1.5-2.5 mm2

7RROV
364690AA- 497
179574-040 2000-06-01 001
2WKHUWRROV
)LJXUH 1XPEHU 8VH
156263 Service instrument (CAN)
1=163793 Service instrument for

2=163792 program modifications
1=155619-001 1= Service instrument for Curtis

2=166161 transistor panel
3=166473 2= Cable for Curtis 1243 and
1207A
When ordering 3= Cable for Curtis 1207
155619-001 both
cables are sup-
plied

7RROV
497 364690AA-
001 2000-06-01 179574-040
)LJXUH 1XPEHU 8VH

08-13022 Puller, transmission
174006 Assembly tool, PowerTrak com-

pression spring

)RUNFDUULDJH
364690AA- 497 0380
179574-040 2000-06-01 001
)RUNFDUULDJH
&RPSRQHQWSDUWV
42
43
44,45,46
41
40
15 16 17 18 19
14
13
12
11
24
23
15
21
20
29
15
27
26
25
25 26 33 34 26 33 15 38 39

)RUNFDUULDJH
0380 497 364690AA-
001 2000-06-01 179574-040
3RV 'HVFULSWLRQ 1RWHV

11 Roller Initially lubricated
12 Circlip
13 Spring washer Minimum play with 2-4 spring
washer
14 Steering
15 Grease nipple Option
16 Wheel fork
17 Axle
18 Spiral pin
19 Bush
20 Axle
21 Spiral pin
23 Bush
24 Sleeve
25 Screw
26 Washer
27 Axle
29 Bush
33 Axle
34 Screw
38 Pivot pipe
39 Roller
40 Gas cartridge
41 Bracket
42 Screw
43 Switch
44 Screw
45 Nut
46 Washer

)RUNFDUULDJH
364690AA- 497 0380
179574-040 2000-06-01 001
'LVPDQWOLQJWKHIRUNFDUULDJH
• Remove the battery.
• Place supports under the chassis, as illustrated, on both sides

of the truck.
• Dismantle the battery hood.

)RUNFDUULDJH
0380 497 364690AA-
001 2000-06-01 179574-040
• Dismantle the gas dashpot.
• Release the hoses, loosen the screws (A) and lift out the lift
cylinders.

)RUNFDUULDJH
364690AA- 497 0380
179574-040 2000-06-01 001
• Lift out the fork carriage.
Assembly takes place in the reverse order.
5HSODFLQJWKHUROOHUV
• Remove the guide (14) and spring washers (13), remove the
circlip (12) and remove the roller (11).
11
12
13
14

• Minimise the play between the steering (14) and the cross
member with 2-4 spring washers (13).

)RUNFDUULDJH
0380 497 364690AA-
001 2000-06-01 179574-040

(OHFWULFGULYHPRWRU
364690AA- 497 1760
179574-040 2000-06-01 001
(OHFWULFGULYHPRWRU
&RPSRQHQWSDUWV
D
3
4
5
6
4 7
8
9
10
11
12
13
14
15
16
17
18
19
20 21
22
23
24
25
26

(OHFWULFGULYHPRWRU
1760 497 364690AA-
001 2000-06-01 179574-040

1 Screw M6x25
2 Screw M5
3 Bearing bracket N-side
4 Locking ring
5 Washer
6 Bearing 6205 HT24B
7 Protective ring
8 Carbon brush
9 Carbon bridge
10 Screw M5x20
11 Rotor
12 Wedge 4x6x16
13 Guard
14 Pole connection
15 Stator case
16 Bearing bracket D-side
17 Fan
18 Screw M5
19 Adjuster bush
20 Seal flange
21 O-ring
22 Seal
23 Bearing 6204 ZC3
24 Locking ring
25 Ring
26 Locking ring

(OHFWULFGULYHPRWRU
364690AA- 497 1760
179574-040 2000-06-01 001
5HPRYLQJWKHPRWRUIURPWKHWUXFN
• Switch off the truck and remove the battery plug.
• Remove the hood over the motor compartment.
• Loosen the four screws for the gate console and loosen the
connections for the ignition, emergency switch and the gate
switch and lift off the gate console. Loosen the four bolts for the
gate console bracket.
• Disconnect the motor cables.

• Dismantle the brakes
• Unscrew the five bolts holding the motor shield against the mo-
tor plate.
• Lift out the motor and place it on a clean surface. Cover the
drive transmission opening .
The necessary service and repairs can now be carried out on the
motor.

(OHFWULFGULYHPRWRU
1760 497 364690AA-
001 2000-06-01 179574-040
5HILWWLQJWKHPRWRULQWKHWUXFN
• Assembly takes place in the reverse order.
• Fit a new O-ring on the seal flange (22) on the drive shaft.
• Carefully lift the motor down in the drive transmission so that
the seals and gears are not damaged.
• Tighten the five bolts holding the motor shield on the motor
plate to 45 Nm.
• Connect the motor cables. Check that the polarities are cor-
rect. Connect the brake.
• Check the operation of the brake.

(OHFWULFGULYHPRWRU
364690AA- 497 1760
179574-040 2000-06-01 001
6HUYLFHDQGUHSDLUV
'LVPDQWOLQJWKHPRWRU
3
4
5
6
4 7
8
9
10
11
12
13
14
15
16
17
18
19
20 21
22
23
24
25
26

(OHFWULFGULYHPRWRU
1760 497 364690AA-
001 2000-06-01 179574-040
'LVPDQWOLQJ1VLGH
• Remove the carbon brushes (8).
• Loosen the screws (1).
• Dismantle the bearing bracket (3).
• Dismantle the locking rings (4).
• Dismantle the washers (5).
• Dismantle the bearing (6).
'LVPDQWOLQJ'VLGH
• Dismantle the locking ring (26).
• Dismantle the ring (25).
• Dismantle the seal flange (20).
• Dismantle the locking ring (24).
• Dismantle the bearing (23).
• Dismantle the seal (22).
• Dismantle the fan (17). Using a slide hammer, if necessary.
• Dismantle the adjuster bush (19).

(OHFWULFGULYHPRWRU
364690AA- 497 1760
179574-040 2000-06-01 001
&OHDQLQJ
For correct functioning, it is important that the motor be kept as
clean as possible. The motor and motor compartment must be
checked regularly for dust, oil and other contamination.
If the motor windings and interior are dry, use a vacuum cleaner
with a suitable nozzle to clean the motor. Compressed air can be
used in combination with a vacuum cleaner. If so, the com-
pressed air must be clean and dry.
If the windings have a coating, use a lint-free cloth, dampened if
necessary with an organic and volatile cleaning agent that can
dissolve grease but which will not damage the windings. Howev-
er, the cleaning agent must not be used in such quantities that it
enters motor parts.
Remnants of the cleaning agent must be removed with a suitable
solvent, if it leaves an oily surface.
If the motor parts are badly soiled, it may be necessary to spray
them with a solvent. It is especially important with the armature
that the solvent is applied in such a way that dissolved dirt, etc.
does not enter 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 ventila-
tion is necessary during drying which must continue until a
number of insulation measurements give similar and approved
results.

(OHFWULFGULYHPRWRU
1760 497 364690AA-
001 2000-06-01 179574-040
7HFKQLFDOGDWD
Type TSL 160 A-DM4

Output, kW 2.5
Duty cycle S2 60 min
Resistance, shunt field winding, Ω at 24 C° 0.346
Resistance, armature windingΩ at 24 C° 0.0098
Insulation resistance between the windings >= 1 Mohm
and motor casing
Weight, kg 23

'ULYH7UDQVPLVVLRQDVVHPEO\
364690AA- 497 2550
179574-040 2000-06-01 001
2
1 3
4
5
6
10
16 17 7
15 8
9
14
11
12
13

2550 497 364690AA-
001 2000-06-01 179574-040
&RPSRQHQWSDUWV

1 Motor gear
2 Lock nut Tightening torque 130 Nm
Lock using a centre punch.
3 Primary gear
4 Conical roller
bearing
5 Shim
6 Shim
7 Conical roller
bearing
8 Conical roller
bearing
9 Lock nut Tightening torque 400 Nm
Lock using a centre punch.
10 Cover
11 Screw Tightening torque 25 Nm
Lock using Loctite 242
12 Shim
13 Pinion/Crown Gear play 0.09-0.15 mm. Pretension
gear the bearing with 2-5/100. Stamped
measurement on pinion adjusted using
shims.
14 Drive shaft
15 Wheel bolt Tightening torque 90 Nm
Lock using Loctite 270
16 Sealing ring Fill the sealing ring with grease
Seal using Loctite 574
17 Conical roller
bearing

364690AA- 497 2550
179574-040 2000-06-01 001
7HFKQLFDOGDWD
7\SHRIWUXFN 25,21
Transmission type 2-stage angle transmission
Gear ratio 14,20:1
Oil volume, litre 1.75
Oil type Hypoid oil
Viscosity, normal tempera- SAE 80W/90
ture
Viscosity, <-15°C SAE 75W
'LVPDQWOLQJ$VVHPEO\
/HDNDJHIURPWKHXSSHUFRYHU
• Unscrew the platform.
• Lift up the truck and block it so it is stable.
• Unscrew the drive wheel.
• Unscrew the M8 bolts holding the transmission in the transmis-

sion cover using an 6 mm allen key. Support the transmission
so it does not fall.
$VVHPEO\WDNHVSODFHLQWKHUHYHUVHRUGHU
• Seal the transmission against the cover using Loctite 547.
• Tighten the M8 bolts to a torque of 27 Nm.

2550 497 364690AA-
001 2000-06-01 179574-040
5HSODFLQJWKHGULYHVKDIWJDVNHW
The drive shaft sealing ring can be replaced with the transmission
fitted in the truck.
Follow the instructions below if oil leaks from the drive shaft.
'LVPDQWOLQJ
7 6 5 2
4
• Remove the drive wheel from the transmission.
• Remove the lower transmission cowl and drain the oil (2).
• Loosen the drive shaft nut. Remove the nut and the spacer
ring (3).
• Carefully tap out the drive shaft using a hammer and brass drift
(4).
• Pull off the bearing from the drive shaft using tool 08-13022
(5).
• Check that the bearing discs are not damaged. If they have
been damaged by the puller, measure the spacer washers'
combined thickness and replace them before assembling (6).
• Remove the gasket ring from the drive shaft (7).

364690AA- 497 2550
179574-040 2000-06-01 001
$VVHPEOLQJ
Assembly of the transmission after replacing the drive shaft’s
sealing ring is carried out in the reverse order.
Bearing in mind the following when assembling.
• Fill the sealing ring with grease after fitting it on the drive shaft.
• Ensure only undamaged spacer washers with the same over-
all thickness as the original washers are placed on the drive
shaft.
• Press the bearing on the drive shaft and make sure the bear-
ing's spacer washers are not damaged.
• When the drive shaft with the bearing, spacer washers and
seal is fitted, ensure that the shaft keyways correspond with
the crown gear's keys and that the bearing and seal sit correct-
ly in the gear housing before the axle is fully pressed in.
• Place the distance ring on the end of the drive shaft, and fit the
shaft nut. AlwaysXVH a new nut. Tighten the axle nut to a
torque of 400 Nm and lock with a centre punch mark in the
centre. The drive shaft nut should be lubricated before it is
placed on the shaft.
• Replace the O-ring before installing the lower cowl. Make sure
it is not damaged. Mount the cowl and tighten the bolts to a
torque of 25 Nm. The bolts should be greased before assem-
bly. Fill with oil as set out in the instructions for refilling.
Mount the drive wheel and tighten the wheel bolts to a torque of
90 Nm. The bolts should be greased before assembly.

2550 497 364690AA-
001 2000-06-01 179574-040
5HSODFLQJZKHHOEROWV
The wheel bolts on the transmission are stud bolts. To replace the
wheel bolts, proceed as follows:
• Pull out the battery's emergency disconnector.

• Remove the platform.
• Lift the machine using a jack and put it on blocks.
• Remove the drive wheel.
• Wheel bolts with damaged threads are removed using the stud
bolt tool.
• Broken wheel bolts:
• 0HWKRG Drill a hole in the centre of the bolt and screw out
the bolt using a screw extractor for M14 bolts.
• 0HWKRG If the bolt will not come loose with a screw extractor,
the bolt must be drilled out.
- Drive a centre punch into the centre of the bolt. Be careful to
centre the centre punch.
- Drill a pilot hole through the bolt using a 5 mm bit.
Drill out the bolt using an 11.5 mm bit.
- Try to remove the remains of the bolt with pliers or the like. If
that does not work, remove the remains by clearing the
threads with a screw tap M14x1.5.

364690AA- 497 2550
179574-040 2000-06-01 001
• Apply LOCTITE 270 on the threads of the wheel bolts.

Mount the new wheel bolt with a stud bolt tool.
Tightening torque 90 Nm
Assemble the drive wheel. Tighten the wheel nuts to xx Nm.
• Remove the blocks and lower the truck.
• Assemble the platform.
• Connect the battery disconnector.

2550 497 364690AA-
001 2000-06-01 179574-040

(OHFWURPDJQHWLFEUDNH
364690AA- 497 3370
179574-040 2000-06-01 001
1
2
12 3
11 4
5
10
9 8 7 6
13
A A
A-A

3370 497 364690AA-
001 2000-06-01 179574-040
&RPSRQHQWSDUWV

1 Magnet housing
2 Screw 3
3 Pressure plate
4 Sleeve
5 Shims for adjusting the air 1 = 0.5 mm
gap 5 = 0.13 mm on each position
6 Friction disc, brake disc Nom. thickness: 9.7 mm
Min thickness: 7.7 mm
7 O-ring
8 Hub
9 Mounting plate
10 Screw 3
11 Spring 8
12 Cable with connector
13 Screw for manual release Not supplied
M6

364690AA- 497 3370
179574-040 2000-06-01 001
'LVPDQWOLQJ
• Lift off the brake from the motor axle.
• Place the brake on a clean surface.
• Unscrew the adjuster screws (2) gradually to reduce the spring
tension equally.
,QVSHFWLRQ
Check the parts for damage and/or wear:
• Check the brake disc (6) and the wear surfaces on the pres-
sure plate (3) extra carefully.
• Check the springs (11) and the spacers (4, 5) with regard to
damage.
• Check for signs of damage to the splines on the hub (8) and
friction disc (6).
• Check for signs of swelling/deformation or damage to the mag-
net (1) and pressure plate (3).
$VVHPEOLQJ
• Clean the parts carefully.
• Assemble the brake in the reverse order to dismantling.
• Bear in mind the following:
- That the hole in the pressure plate (3) aligns with the corre-
sponding hole in the magnet housing.
- That the right number of springs have been fitted.
- That the play 0.25-0.38 mm has been set correctly. Should
possibly be adjusted.
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3370 497 364690AA-
001 2000-06-01 179574-040
0DQXDOUHOHDVHRIWKHEUDNH
13
The brake can be released manually, for example, if the brake is
broken and the truck needs to be moved to the service area or in
A A
order to centre the brake disc easier during assembly. To release
the brake unscrew the two screws (13) equally and gradually.
A-A :$51,1*
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9,5 Nm
0,25-0,38 mm 4
5
• Measure the play in three places.

• Adjust the play by removing the shims (5).

6WHHULQJV\VWHP
364690AA- 497 4000
179574-040 2000-06-01 001
6WHHULQJV\VWHP
&RPSRQHQWSDUWVPHFKDQLFDO
VWHHULQJ
C F
B B
C 2
A
4
3

6WHHULQJV\VWHP
4000 497 364690AA-
1 001 2000-06-01 179574-040
2
E
7
3
8
A-A
E
D
10
9
18, 19
26, 27
12
11
13
25
6
24
D
B-B
17
16
13
14
15
G
22
23
C
G
19
18
21
20

6WHHULQJV\VWHP
364690AA- 497 4000
179574-040 2000-06-01 001
4 3
5
10
10
18 6
19 9
24 7 27
8
25 26
15
23
22
21
20
14
13
11
12
17
16
17

6WHHULQJV\VWHP
4000 497 364690AA-
001 2000-06-01 179574-040
&RPSRQHQWVSDUWVVHUYRVWHHULQJ
28
29
31
30
4 3
5 32
10
10 33
34
18 6
19 9
24 7 27
8
25 26
15
23
22
21
20
14
13
11
12
17
16
17

6WHHULQJV\VWHP
364690AA- 497 4000
179574-040 2000-06-01 001
6WHHULQJD[OHVHUYRVWHHULQJ
35
36
49
37 B
50
38
51 39
52 40
53 41
42 B
B-B 43
44
45
46
47
48
A-A A

6WHHULQJV\VWHP
4000 497 364690AA-
001 2000-06-01 179574-040
35
37
36
38
38 53
39 52
51
49
49 50
51 40
47
41
43
44
42
45
46
48

6WHHULQJV\VWHP
364690AA- 497 4000
179574-040 2000-06-01 001

1 Steering rod Mechanical steering
2 Gear ring
3 Sleeve
4 Locking screw
5 Sleeve
6 Steering joint with
sprocket
7 Bearing
8 Locking ring
9 Locking ring
10 Pin
11 Screw M8x35 23.0 Nm
12 Steering
13 Sprocket
14 Screw M6x20 9.5Nm
15 Screw M8x35 23.0 Nm
16 Steering bearings
17 Nilos ring
18 Lock nut Tightened so there is no
axial play on the tension
arm.
19 Stud bolt
20 Lock nut
21 Sleeve
22 Dashpot
23 Washer
24 Adjustment screw
25 Tension arm
26 Chain
27 Chain lock

6WHHULQJV\VWHP
4000 497 364690AA-
001 2000-06-01 179574-040

3RZHUVWHHULQJ
28 Steering unit
29 Steering axle
30 Axle
31 Steering motor
32 Gear
33 Washer
34 Screw
6WHHULQJD[OH 3RZHU6WHHULQJ2SWLRQ
35 Steering column
36 Circlip
37 Circlip
38 Sliding bearing
39 Washer
40 Axle
41 Spacer
42 Ring
43 Circlip
44 Bearing
45 Circlip
46 Sleeve
47 Wedge
48 Screw
50 Pin
51 Dashpot
52 Stop screw
53 Nut

6WHHULQJV\VWHP
364690AA- 497 4000
179574-040 2000-06-01 001
$GMXVWPHQWVWHHULQJ
$GMXVWLQJWKHVWHHULQJVHUYR
• Switch off the voltage using the ignition.
• Lift up the truck so that the drive wheel is free of the ground
• Loosen the two screws (A), so that the servo can be easily ad-
justed laterally.
• Switch on the voltage.
• Hold your hand lightly on the servo when the voltage is
switched on. Press the servo lightly against the steering col-
A umn.
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• Now adjust the servo laterally until the steering stands still.
The servo is pressed lightly against the steering column when
adjusting.
• When the steering stands still the screws (A) are tightened
again.
• Now test the servo setting by steering to the left and right, then
release the steering and make sure the steering stands still, it
should not drift in any direction. If the steering drifts the adjust-
ment must be restarted from the point "Switch on the voltage"
above.
• Lower the truck to the floor and test drive.
The distance between the servo unit and the steering column
directly affects the gain on the servo. With 4.5° turning of the tiller
arm relative to the drive wheel, you can measure 95% of the bat-
tery voltage across the steering motor.
$GMXVWLQJWKHVWHHULQJFKDLQ
• Check the measurement between the sleeve (21) and the
8-10 mm fixed bracket on the drive unit.
• Adjust using nut (20).
21
20

6WHHULQJV\VWHP
4000 497 364690AA-
001 2000-06-01 179574-040
&RPSRQHQWVSDUWVWLOOHUDUP
1
8
9
10 11
12
14 13
16
15
18 17
19
20
21
22
23

6WHHULQJV\VWHP
364690AA- 497 4000
179574-040 2000-06-01 001

1 Screw 4
2 Washer
3 Handle
4 Screw 4
5 Washer 2
6 Cable holder
7 Nut
8 Gas dashpot
9 Bracket
10 Stop screw
11 Screw 4
12 Ball joint
13 Screw
14 Spacer
15 Bush 2
16 Dashpot 2
17 Axle
18 Ridge
19 Spacer
20 Screw
21 Spacer
22 Spacer
23 Switch S 10
$GMXVWPHQWWLOOHUDUP
$GMXVWLQJWKHEUDNHPLFURVZLWFK
The switch (23) is always adjusted to its lowest position.
• Loosen the screws (13, 20) holding the switch and spacer.
• Press down the switch and tighten the screws.
• Check that the switch is actuated by the ridge (18) in the arm's
upper and lower positions.
6WHHULQJV\VWHP
4000 497 364690AA-
001 2000-06-01 179574-040
1 7LOOHUDUPKDQGOH
14
15
14
14
13
14
12
11 10
8
9
17
18
7
19
6
20
4
21
23 22
24
25
3
27 26
28
29
32
31
33
30
34
35

6WHHULQJV\VWHP
364690AA- 497 4000
179574-040 2000-06-01 001

1 Screw
2 Cover Keyboard option
3 Handle
4 Electronic card
5 Screw
6 Display card
7 Upper cover
8 Pushbutton Option
9 Signal switch
10 Signal button
11 Display glass
12 Arm
13 Pushbutton Lift/Lower
14 Sign
15 Spring
16 Pushbutton Not used
17 Arm
18 Holder
19 Spring
20 Control rocker
21 Axle
22 Sliding bearing
23 Control stop
24 Arm
25 Spring holder
26 Spring
27 Spring holder
28 Sliding bearing
29 Control rocker

6WHHULQJV\VWHP
4000 497 364690AA-
001 2000-06-01 179574-040

30 Button for safety reversing
31 Arm
32 Spring
33 Lower cover
34 Screw M4x40
35 Screw 2xM5x45
2xM5x60
'LVPDQWOLQJ$VVHPEO\EXWWRQV
• Dismantle the cover (2), (keyboard option).
• Dismantle the screws (35), hold against the upper cover (7).
• Disconnect the cable connected to the electronic card (4).
• Remove the screws (34).
• Carefully lift off the lower cover (33), place a finger between
lower cover (33) and button (30) to hold the button (30) in posi-
tion.
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6WHHULQJV\VWHP
364690AA- 497 4000
179574-040 2000-06-01 001
5HSODFLQJWKHVLJQDOEXWWRQVZLWFK

• Dismantle the button as illustrated.
• Disconnect the connections for the switch on the electronic

card (4).
• Press out the switch from its bracket.
5HSODFLQJWKHOLIWORZHUEXWWRQ
• Remove the button by placing a screwdriver in hole (A) as il-
lustrated below.
A A
• Unscrew the holder (18) so that the arm (12) becomes loose.

6WHHULQJV\VWHP
4000 497 364690AA-
001 2000-06-01 179574-040
5HSODFHWKHSXVKEXWWRQ
• Press the button, by hand, sideways.
• Place a screwdriver as illustrated and carefully pry out the but-
ton.
• Unscrew the button's holder and arm.


(OHFWULFDOV\VWHPV
364690AA- 497 5000
179574-040 2000-06-01 001
(OHFWULFDOV\VWHPV
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© BT Industries AB Service Manual Orion P24 Approved by: Joakim Carleborn 79

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5000 497 364690AA-
001 2000-06-01 179574-040
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80 © BT Industries AB Service Manual Orion P24 Approved by: Joakim Carleborn

(OHFWULFDOV\VWHPV
364690AA- 497 5000
179574-040 2000-06-01 001
6\PEROOLVWDQGHOHFWULFDOGLDJUDP
6\PERO 'HVFULSWLRQ )XQFWLRQ 1RWHV

A1 Transistor regulator
A5 Electronic card
A6 Display
A7 Keypad PIN-number login Option
F1 Fuse Drive motor circuit 125 A

F3 Fuse Pump motor circuit 160 A
F 50 Fuse Operating circuit A5 7,5A
F 51 Fuse Operating circuit A1 7,5 A
F 52 Fuse Optional equipment Option
F64 Fuse Steering motor 20 A Option
G1 Battery 24 V
H1 Horn
K10 Contactor Main contactor

K30 Contactor Pump motor
M1 Motor Drive motor

M3 Motor Pump motor
M6 Motor Steering motor option
P1 Potentiometer Load sensor
R1 PTC-resistor Power supply 15 Ohm

(OHFWULFDOV\VWHPV
5000 497 364690AA-
001 2000-06-01 179574-040

S1 Switch Option
S2 Switch Option
S3 Switch Option
S4 Switch Option
S5 Switch Option
S6 Switch Option
S10 Switch Travel brake Brake lever
S17 Switch Key
S18 Switch Horn button
S19 Switch Man on platform
S20 Switch Switch for safety reversing
S21 Switch Emergency switch off
S31 Switch Lift height limiter
S34 Switch Fork lifting
S41 Switch Fork lowering
S53 Switch Gates
S59 Switch Platform in upper position
Y1 Brake
Y41 Magnetic valve Fork lowering
X1 Connector Battery
X41 Connection point CAN communication

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• Battery connector plugged in.
• S21 closed.
• S17 on.
'ULYLQJZLWKRXWXVLQJSODWIRUPDQGJDWHV
VSHHG≤ NPK
A1
B-
S1
Ish S2
T1
• S59 open.
- M-
+
A2 • S10 closed.
Shunt
A
Ia A1 • L1 activated in any direction.
T2
K10 B+
'ULYLQJIURPSODWIRUPZLWKRXWXVLQJ
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• S 19 closed.
• S10 closed.
• L1 activated in any direction.
'ULYLQJIURPSODWIRUPDQGXVLQJJDWHV
VSHHG≥ NPK
• S 19 closed.
• S 53 closed.
• S10 closed.
• L1 activated in any direction.

(OHFWULFDOV\VWHPV
5000 497 364690AA-
001 2000-06-01 179574-040
1HXWUDOVSHHGUHGXFWLRQ
• L1 to neutral position, motor starts to work as generator. Brake
energy comes back to battery.
• Load sensor P1 determines speed reduction force.
• Y1 will be applied when the truck comes to a stand still even if
the tiller arm is in drive position.
3LFWXUH
Energy back to the battery.
The transistors (T2) for the generated brake current are not
live.
A1
B-
S1
T1
Ish S2
- M-
A2
+
Shunt
A
Ia A1
T2
K10 B+
1HXWUDOVSHHGUHGXFWLRQRQVORSHV
If the driver release the speed leaver (L1) on a slope and the truck
doesn’t come to a stop within a certain time the electrical brake
will be applied.
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The brake is always applied when the truck is started with the till-
er arm in it’s upper or lower position (S10 open). The brake is re-
leased in the same moment as the conditions for driving are
fulfilled and the truck starts to move.
Conditions to brake the truck:
• S10 open or S19 open.

(OHFWULFDOV\VWHPV
364690AA- 497 5000
179574-040 2000-06-01 001
/LIWLQJWKHIRUNV
• S34 activated.
• S31 closed.
• Battery status ok (if battery capacity >20% left).
/RZHULQJWKHIRUNV
• S41activated.
+RUQ
• S18 activated.
+RXUPHWHU
A • Press S18 and turn S17 to on at the same time.
• Press S18 until you read the H= hour meters.
• You have now choosen H=hourmeters the symbol “B” will be
highlighted.
E D C B • You can now choose type of hourmeter by pressing L1.

A= Key time.
b= Drive motor time.
c= Pump motor time.
d= Activity time.
s= Time left to make service.

(OHFWULFDOV\VWHPV
5000 497 364690AA-
001 2000-06-01 179574-040
)DXOWFRGHV
• Press S18 and turn S17 to on at the same time.
• Press S18 until you read E= fault codes
A
• By choose E the symbol “E” will be highlighted to indicate
what’s currently shown on display.
• The last 50 fault codes will be stored.The latest fault will be
shown first. The display first show the error code and then
wich hour the fault occured.
E D C B
• The fault codes are devided into two groups C = caution and
E = error.
• The C will not be stored. It’s only a caution and will be high-
lighted on display as long as the fault exists.
• If you for example only have one fault registerd in memory the
second empty place will be shown like this: Fault : E - - - and
time : - - - - .
&RGH &
Description Default parameter warning.
Possible fault Parameter area is probably corrupt.
reason Default values have been down loaded, i.e special
parameter settings must be restored.
&RGH &
Description Butterfly warning
Possible fault Problem with butterfly sensor.
reason Butterfly may have been activated during start up
or faulty sensor.
&RGH &
Description Emergency switch warning
Possible fault Emergency switch activated
reason No voltage supply to motor controller.
Harness problem.

(OHFWULFDOV\VWHPV
364690AA- 497 5000
179574-040 2000-06-01 001
&RGH &
Description Service time warning
Possible fault Time to make service
reason Service counter not reset after latest service
&RGH &
Description Battery undervoltage warning
Possible fault Battery voltage < 17 volt
reason Battery parameter not correct adjusted
Time to charge battery
&RGH &
Description Battery overvoltage warning
Possible fault Battery voltage > 33 volt
reason Fully charged battery and regenerative braking.
&RGH &
Description Power amplifier thermal cutback
Possible fault Too intensive driving
reason Defect motor controller
&RGH (
Description Brake switch transistor shorted
Possible fault Defect motor controller
reason

(OHFWULFDOV\VWHPV
5000 497 364690AA-
001 2000-06-01 179574-040
&RGH (
Description Digital output or field over current
Possible fault Attempt to drive more current than specified from
reason outputs.
Problem to regulate field currrent.
Internal controller fault.
&RGH (
Description Contactor off
Possible fault Problem with main contactor tips or cabling (open
reason circuit).
Contactor control wire not connected.
Contactor drive output in controller faulty (off).
&RGH (
Description Contactor welded
Possible fault Main contactor tips welded.
reason Contactor drive output in controller faulty (on).
&RGH (
Description Checksum error
Possible fault Internal microcontroller fault (tiller head), faulty
reason software or pcb.
&RGH (
Description Software problem
Possible fault Internal microcontroller fault (tiller head),faulty
reason software or pcb.

(OHFWULFDOV\VWHPV
364690AA- 497 5000
179574-040 2000-06-01 001
&RGH (
Description Drive communication error
Possible fault Broken CAN-wire.
reason Motor controller not working
&RGH (
Description Drive communication Tx error
Possible fault Motor controller does not answer, bad connec-
reason tions or faulty motor controller.
&RGH (
Description Bus off error
Possible fault CAN-bus problem, harness or hardware problem.
reason
&RGH (
Description Over run error
Possible fault CAN-bus problem, harness or hardware problem.
reason
&RGH (
Description Error in Safety reversing
Possible fault Critical sensor element faulty
reason
&RGH (
Description Field open
Possible fault Shuntfield open, harness broken, motor controller
reason defect.

(OHFWULFDOV\VWHPV
5000 497 364690AA-
001 2000-06-01 179574-040
&RGH (
Description M minus error
Possible fault Problem with switch transistor in armature circuit
reason inside motor controller.
&RGH (
Description Power amplifier sensor error
Possible fault Armature current sensor fault in motor controller.
reason
&RGH (
Description Power amplifier CAN-timeout
Possible fault Motor controller reports unexpected loss of data
reason flow from tiller head.
3DUDPHWHUV
A
• Press S18 and turn S17 to on at the same time.
• Press S18 until you read P= parameters.
• You have now choosen P=parameters the symbol “C” on dis-
play will be highlighted to indicate what’s currently shown on
E D C B display.
• Scroll to the parameter you want to change or look at by pres-
sing the L1 up or down.
• Press S18 ones to get access to the parameter.
• Set parameter value by pressing L1 up or down.
• Press S18 ones to confirm change.
• Turn S17 to off.
You have now completed a parameter change and the next time
you start the truck the new parameter setting will be valid.
127(
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(OHFWULFDOV\VWHPV
364690AA- 497 5000
179574-040 2000-06-01 001
'ULYHUSDUDPHWHUV
3DUDPHWHU 1DPH 8QLW 0LQ 0D[ 6WHS 6WG 'HVFULSWLRQ
02 Speed % 10 100 5 100 10:low Speed
100:full Speed
03 Acceleration 10 100 5 75 10:low acceleration
100:full acceleration
04 Neutral speed 5 100 5 80 Defines motor speed
reduction reduction force when lever
goes to neutral position.
5: low reduction force
100: full reduction force
05 Logg off 1min 0 20 1 0 The time until the truck will
be switched off when a
key pad is used. Time is
counted from when the
latest power consumer is
used.
10 PIN-code 0 9999 1 0 Possibility to set up to 10
PIN - codes (10 different
drivers)
6HUYLFHSDUDPHWHUV
• Connect CAN-key in X41
• Choose parameter
KKK

14 Creep speed -10 10 1 0 This defines how much out-
put the controller gives
when you reach the first
speed sensor.
-10 : low speed when reach-
ing first speed sensor.
10:high speed when reach-
ing first speed sensor.
18 Main contac- 1 min 1 20 1 5 The number of minutes the
tor off main contactor will be
closed after the latest power
consumer has been used.
20 Hour meter 1 5 1 2 Select hour meter
selection

(OHFWULFDOV\VWHPV
5000 497 364690AA-
001 2000-06-01 179574-040

21 Battery size 1 20 1 9 Battery size selection
25 Service inter- 1h 0 2000 50 100 Possible to set servicetimer.
val
39 Access code 1 4 1 1 Defines what access level
service personnel will have
to parameters.
40 Display code 0 1 1 0 Defines what should be
shown on display.
3DUDPHWHUGHVFULSWLRQ
3DUDPHWHU
The maximum speed can be adjusted.
3DUDPHWHU
The lower value of the parameter the longer time it takes to ac-
celerate the truck to top speed.
3DUDPHWHU
Defines motor brake force when lever (L1) goes to neutral posi-
tion.The lower value of parameter the longer time to reduce
speed.
3DUDPHWHU
The time until the truck will be switched off when a key pad is
used. Time is counted from when the latest power consumer is
used.
3DUDPHWHU
10 drivers can have it’s own PIN-code to get access to the truck.
Each driver have possibility to set all the driver parameters indi-
vidual.
The PIN-code must consist of four digits.
If you choose PIN-code 10 for example you must dial 0010.
To start the truck press your four digit code and the green
no. 1 button.
To turn the truck to off press the red no.0 button.
When you have the CAN-key connected you can turn the truck
on by just pressing the green no. 1 button. You turn it to off by
pressing the red no. 0 button.
(OHFWULFDOV\VWHPV
364690AA- 497 5000
179574-040 2000-06-01 001
3DUDPHWHU
Defines the speed you will get when you reach the first speed
sensor.
3DUDPHWHU
The number of minutes the main contactor will be closed after the
latest power consumer has been used.
3DUDPHWHU
You choose wich hour meter you want to display.
1(A) = Key time
2(b) =Activity time
3(c) = Drive motor time
4(d = Pump motor time
5(s) = Time to service
3DUDPHWHU
You must give data about wich battery the truck is equipped with.
To adjust the disconnection point of the battery discharge indica-
tor meassure according to :
• Acid concentration when fully charged battery. To check qua-
lity of battery. Shall be between 1,27-1,29.
• When you get lift cut out (80 % discharged of battery capa-
city) you shall have close to 1,14 not less.

(OHFWULFDOV\VWHPV
5000 497 364690AA-
001 2000-06-01 179574-040
The acid concentration can vary depending of battery brand.
9DOXH )XQFWLRQ %DWWHU\$K

1
2
3
4
5
6
7 600
8
9 320
10 ↑
11 Less discharged
12
13 More discharged
14 ↓
15
16
17
18
19
20
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With this parameter you can set a time limit to next service from 0
to 2000 hours in step of 50 hours. When it’s time for service you
will get caution 29 (C29) on the display.

(OHFWULFDOV\VWHPV
364690AA- 497 5000
179574-040 2000-06-01 001
3DUDPHWHU
This parameter can be adjusted like:
• Key connected, driver parameters open.
• Key connected, driver parameters must be opened with can-
key.
• Key pad connected, driver parameters open.
• Key pad connected, driver parameters must be opened with
can-key.
_
3DUDPHWHU
A • Set parameter to value 1.

• Turn S17 to off and then on again.
• Press S18 to choose display mode.
See table below.
E D C B
6\PEROKLJK 'LVSOD\HGGDWD
OLJKWHG
B Speed reference value sent to Curtis.
C Digital inputs to Curtis and hallelements. * See
explanation below
BC Battery voltage (V)
D Armature current (A)
BD Field current (A)
CD PWM Armature in %
BCD Status Curtis
*They are displayed by high lighting segments of three of the fig-

ures (A).

(OHFWULFDOV\VWHPV
5000 497 364690AA-
001 2000-06-01 179574-040
• The most significant figure active (marked with arrow).

• Power amplifier inputs.
A T
6HJPHQW )XQFWLRQ
A S59 , input A1:13
B S53 , input A1:14
E D C B
C S31 , input A1:15
D S10 , input A1:12
$ E
) % F S19 , input A1:11

*
G S10 , input A1:5
( & DP
'3
'
• The second most significant figure active (marked with

arrow).
A
• Power amplifier outputs.
6HJPHQW )XQFWLRQ
A
E D C B
B
C Y41, output A1:2
D
$
E K10, output A1:4
) % F H1 , output A1:7
*
G Y1 , output A1:5
( & DP K30 , output A1:6
'3
'

(OHFWULFDOV\VWHPV
364690AA- 497 5000
179574-040 2000-06-01 001
• The third most significant figure active (marked with arrow).

• Digital input from control sensors.
A
6HJPHQW )XQFWLRQ
A
E D C B B
C
D Fork up
$
E Fork down
) % F Support arms up
*
G Support arms down
( & DP
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'
• The fourth most significant figure active (marked with arrow).
6HJPHQW )XQFWLRQ
A Extra function 6
E D C B
B Extra function 5
C Extra function 4
D Extra function 3
E Extra function 2
F Extra function 1
G
DP

(OHFWULFDOV\VWHPV
5000 497 364690AA-
001 2000-06-01 179574-040
3DUWQXPEHUV
A • Press S18 and turn S17 to on at the same time.
• Press S18 until you read Pn= partnumbers.
• You have now choosen Pn= part numbers the symbol “D” on
display will be highlighted to indicate what’s currently shown
E D C B on display. In the start the Pn = part number complete unit will
be shown.
• By scrolling with the L1 you can get the following information:
• SPn= Software part number.
• HPn= Hardware part number.
• HSn= Hardware serial number.
7UDQVLVWRUSDQHO
STATUS
MODEL VOLTAGE
SERIAL CURRENT
B+ M-
*HQHUDO
Curtis 1243 is a regulator for controlling shunt motors. Varying
M the voltage applied through the armature primarily controls the
A1 A2 speed. The voltage is varied through use of pulse-width modula-
tion (PWM). This involves varying the “on” time of the MOS-FET
transistors regulating the armature current.
Switching of the rotational direction is achieved by switching the
polarity on the field winding (S1-S2). The regulator is fitted with a
four-quadrant transistor bridge for the field winding and a single-
S1 S2 quadrant transistor bridge for the armature winding.
(OHFWULFDOV\VWHPV
364690AA- 497 5000
179574-040 2000-06-01 001
'LDJQRVWLFDQGWURXEOHVKRRWLQJ
(UURUFRGHVDQGWURXEOHVKRRWLQJ
STATUS
MODEL VOLTAGE
SERIAL CURRENT
The table below depicts the error codes that may be shown by the
STATUS LED or read using the handheld terminal.
67$786/(' +DQGKHOGWHU ([SODQDWLRQ 3RVVLEOHFDXVH

PLQDOGLVSOD\
LED off - No voltage or Burnt fuse, bad contact, not con-
defective regulator nected, defective regulator
LED on - Defective regulator Defective regulator
1,1 ¤¤ CURRENT Built-in current Armature current sensor fault in motor
SHUNT FAULT shunt defective controller.
1,2 ¤ ¤¤ HW FAILSAFE Power amplifier Motor controller reports unexpected
CAN-timeout loss of data flow from tiller head
1,3 ¤ ¤¤¤ M- SHORTED Internal M- short to Problem with switch transistor in arma-
B- ture circuit inside motor controller
3,1 ¤¤¤ ¤ CONT COIL/FLD Too high current Attempt to drive more current than
SHORT for contactor feed- specified from outputs.
ing or shorted field Problem to regulate field currrent.
winding Internal controller fault.
3,3 ¤¤¤ ¤¤¤ FIELD OPEN Open field winding Shuntfield open, harness broken,
motor controller defect.
4,1 ¤¤¤¤ ¤ LOW BATTERY Low battery volt- 1. Battery voltage <17 volts
VOLTAGE age 2. Corroded battery terminals
3. Loose battery or regulator connec-
tions
4,2 ¤¤¤¤ ¤¤ OVERVOLTAGE Overvoltage 1. Battery voltage > 33 volts
4,3 ¤¤¤¤ ¤¤¤ THERMAL Over-/under-tem- 1. Temp. >85oC or < - 25oC
CUTBACK perature reduction 2. Truck overloaded
3. Wrong installation of transistor regu-
lator
4. Operation under extreme conditions
(OHFWULFDOV\VWHPV
5000 497 364690AA-
001 2000-06-01 179574-040
5HVHWWLQJHUURUV
To reset an error turn S17 to off and then on again.
(UURU 5HVHWZKHQ
OVERVOLTAGE Battery voltage falls below 33 V
THERMAL CUTBACK The temperature is within allowed range
THROTTLE FAULT 1, 2 Error has been fixed
LOW BATTERY VOLTAGE When battery voltage exceeds 16 V
6DIHW\
The regulator is a high-power component. When working on a
battery operated vehicle, necessary precautions should be taken.
This includes, but is not limited to, correct training, use of eye pro-
tectors, avoiding use of lose-fitting clothes, removal of watches
and jewellery, and use of insulated tools only.
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RQO\
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364690AA- 497 5000
179574-040 2000-06-01 001
7HFKQLFDOVSHFLILFDWLRQV±
&XUWLV
9DOXH 8QLW ([SODQDWLRQ

Rated operating voltage 24 Volts
Overvoltage limit 33 Volts
Undervoltage limit 16 Volts Minimum operating voltage
Electrical insulation towards cold 500 V AC Minimum
body
PWM frequency 16 kHz
Max. current of armature winding * 300 Amps for 2 minutes
100 Amps for 1 hour
Max. current of field winding 35 Amps for 2 minutes
20 for 1 hour
Contactor voltage 24 Volts Same as battery voltage
Contactor current 2 Amps Max (current limit at 2.5 amps)
KSI input voltage, Min. 16.8 Volts
KSI input current 50 mA
Logic input voltage >7.5; High Volts
<1; Low
Logic input current 15 mA
Operating temperature -40 to +50 °C
Overtemperature, reduction 85 °C
Undertemperature, reduction -25 °C
* During specific test conditions.
(OHFWULFDOV\VWHPV
5000 497 364690AA-
001 2000-06-01 179574-040
+\GUDXOLFVSQHXPDWLFV
364690AA- 497 6000
179574-040 2000-06-01 001
+\GUDXOLFGLDJUDP
Y41
7 6
P M3
5 5
T
6000 497 364690AA-
001 2000-06-01 179574-040
6\PEROOLVW

1 Lift cylinders Fork lift
2 PowerTrak cylinder Increases the pulling capacity with a
loaded machine
3 Pressure sensor Input signal to transistor panel that a
flow limit change is to be made
4 Flow valve
5 Filter One filter on the pump’s suction side
and one on the return
6 Pressure relief valve
7 Non-return valve
M3 Motor Pump motor
P Pump 2.5 ccpr
T Tank 1.2 litre
Y41 Valve Lowering valve for forks
M3
5
T P
6 4 3
Y41
364690AA- 497 6000
179574-040 2000-06-01 001
$GMXVWPHQWV
$GMXVWPHQWRIWKHSUHVVXUHOLPLWYDOYH
The pressure limit valve is set to the correct value at the factory,
but may need to be adjusted if the valve or complete hydraulic
unit is replaced.
The truck should be able to lift a load of between 2250-2300 kg.

1 Cover nut
2 Adjuster screw, pressure Adjustment clockwise results
limit in increased pressure
Adjustment anticlockwise
results in reduced pressure
• Unscrew the cover nut (1) with a spanner, 13 mm.

• Place a load, 2200 kg, on the forks and check that the machine
lifts this.
• If the machine can lift 2200 kg, place a further 100 kg on the
forks. Check whether machine can lift the load.
• If the machine can lift 2300 kg, adjust the pressure limit valve
by screwing the adjuster screw (2) anticlockwise using a 4 mm
allen key until the machine cannot lift the load.
6000 497 364690AA-
001 2000-06-01 179574-040
&OHDQLQJWKHILOWHU
3
1
2 4
5
• Dismantle the hydraulic unit from the machine.
• Empty the oil from the tank.
• Loosen and remove the hose clip (1).
• Loosen and remove the two tank holders (2).
• Loosen the suction filter (5) and the return filter (3).
• Clean the filter in an environment friendly cleaning agent.
3RZHU7UDNF\OLQGHU
364690AA- 497 6680
179574-040 2000-06-01 001
3RZHU7UDNF\OLQGHU
&RPSRQHQWSDUWV
1 2

1 PowerTrak cylinder
2 Compression spring Secured with immense force!
3 Drive unit
3RZHU7UDNF\OLQGHU
6680 497 364690AA-
001 2000-06-01 179574-040
1 'LVPDQWOLQJWKH3RZHU7UDNF\OLQGHU
2 Make sure the truck is unloaded and the forks lowered.
4 • Switch off the truck and remove the battery plug.

• Dismantle the gate console and drive motor.
3 • Loosen the hydraulic hose using a 19 mm spanner (1).
• Unscrew the hydraulic connection from the cylinder with a 27
mm spanner (2). Counter hold the cylinder's piston with a 22
mm spanner.
• Unscrew both guide screws with a 6 mm allen key and a 13
mm spanner (3).
• Remove the circlip (4).
• Lift up the truck so that the drive wheel is free from the ground
using a jack or the like. Block up the truck so that it is stable.
• Press down the cylinder so that the PowerTrak cylinder and
spring can be removed.
When the piston is pressed down oil can squirt out from the
piston.
Measurement between the washer and bolt head, 100 mm.
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364690AA- 497 6680
179574-040 2000-06-01 001
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• Pull out the piston from the PowerTrak cylinder.
• Remove the gaskets by using a screwdriver or other appropri-
ate tool.
• Fit the new gaskets. This is easiest if you heat the gaskets a lit-
tle, preferably in oil, so they become soft. Fit them using pliers.
• Oil the gaskets after assembly.
• Carefully press in the piston.
If the cylinder or piston are scratched, they should be replaced.
3RZHU7UDNF\OLQGHU
6680 497 364690AA-
001 2000-06-01 179574-040
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2 4
5
3

1 Screw
2 Spring support
3 Compression spring
4 Sliding seal Lubricated during assembly
5 Spring tube Lubricated during assembly
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364690AA- 497 6680
179574-040 2000-06-01 001
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1
Make sure the truck is unloaded and the forks lowered.
• Switch off the truck and remove the battery plug.
• Dismantle the gate console and drive motor.
• Unscrew the allen screw (1) and position the washer 174006
as illustrated.
• Screw in the allen key (1) as far as possible.
• Lift up the truck so that the drive wheel is free from the ground
using a jack or the like. Block up the truck so that it is stable.
• Fold out the compression spring through the slot in the drive
unit.
174006
• Secure the compression spring in a vice.
• Loosen the screw (1) completely.
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Assembly takes place in the reverse order. Ensure you grease
the sliding seals and spring tube before assembling.
3RZHU7UDNF\OLQGHU
6680 497 364690AA-
001 2000-06-01 179574-040

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Order number: 179574-040

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I: Inspect, correct and replace if necessary. T: Tighten C: Clean L: Lubricate

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I: Inspect, correct and replace if necessary. T: Tighten C: Clean L: Lubricate

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