Standard SmartPTO V3 Operation Manual (Rev 4.0)

WorkForce Power Take-Off · formerly SmartPTO · Document OPS-003-B01, Rev 4.0 (April 2024)

This is the complete operation manual for the WorkForce Power Take-Off. Use the quick reference below to find key information fast, or download the full manual for step-by-step procedures, control diagrams, and safety detail.

 

Download the full manual:

Standard WorkForce Power Take-Off Operation Manual, Rev 4.0 (PDF)

 

 

What this manual covers

• System overview and specifications
• Notes, cautions, and warnings
• Safety: high-voltage, hydraulic, and emergency shutdown
• Pre-use activities and operating precautions
• Controls: Pump Toggle switch, Emergency Stop, Touch Encoder
• Touch Encoder data screens (Home, Use, Temps, Faults, Info)
• State-of-charge alarm and LED array interpretation
• Operation: power on at the work site, functional checks, shutdown
• Charging (Level 1 and optional Level 2 J1772)
• Charging, storage, cold and hot weather guidelines, and environmental limits
• Fully electric, universal power take-off; eliminates truck idling. Powers a truck-mounted hydraulic boom and optional electric cab AC.
• DC energy storage and distribution, typically 120 volts. IPM-AC motor. Li-NMC (lithium-nickel-manganese-cobalt) battery.
• Hydraulic system capable of up to 3,988 psi, adjusted down to the truck's maximum operating pressure. Compatible with open- and closed-center hydraulics.
• Mounts in the rear bed, cabinet, or chassis.
• Treat every circuit as live. Test before you touch. Never work high-voltage alone; keep a safety observer present.
• Always shut the unit off and relieve hydraulic pressure before disconnecting hoses or servicing. Lower all hydraulic components to the ground first.
• Disconnect the charger after 24 hours. The pack self-discharges very slowly. Top off for a few hours before use if needed.
• After 30 days unused, the powertrain enters Long Term Storage Mode and discharges to 60 percent while balancing cells. Connecting a charger exits this mode and restarts the 30-day timer.
• For installed units, check SOC monthly. If it falls below 50 percent, charge to at least 80 percent.
• For long-term storage over 30 days, charge to 80 to 90 percent first and do not leave it plugged in. Recheck about every 90 days; if below 50 percent, recharge to 80 to 90 percent.
• Coming out of storage, charge 24 hours to restore battery balance. Keep firmware current.

Specifications

Full current specifications are maintained on the product page at viatec.us. Core system characteristics from this manual:

Safety highlights

The unit carries high-voltage, arc-flash, and fire hazards, plus high-pressure hydraulic hazards. Only trained, qualified personnel with proper PPE should access or service it. Full safety detail is in Section 3 of the manual.

WARNING Do not attempt to extinguish a lithium-containing fire without correct PPE. Hot metals may be ejected from the battery module. Battery fires release hydrogen fluoride, carbon oxides, and hydrocarbons.

WARNING Never search for a hydraulic leak by hand. High-pressure oil can inject into tissue and require major surgery. Use cardboard or wood to locate pinhole leaks.

Emergency shutdown

Press the Emergency Stop button on the Control Panel to immediately disable all hydraulics and electronics. To reset, twist clockwise and pull outward.

Controls

Pump Toggle switch

Turns the hydraulic system on or off. When powered and ready, the switch is illuminated. Press and hold two seconds to activate the pump; press and hold two seconds again to deactivate.

Emergency Stop pushbutton

Press to immediately shut down the system. Twist clockwise and pull outward to reset.

Touch Encoder

The display defaults to the Pump Status screen during operation. Requested shows blue, running shows green, fault shows red, pump off shows gray. When plugged in, the display switches to the Charging screen with estimated time to full. The selector ring cycles five data screens: Home, Use, Temps, Faults, Info.

Reading the screens

Home

Battery state-of-charge percentage, plus status indicators (gray to green when active): Truck Key On, Truck Engine Off, Truck in P or N, Park Brake Set.

Use

Hours system on, hours idle eliminated, kWh used, estimated gallons saved, hours pump running.

Temps (degrees Celsius)

Motor, Controller, Battery lowest, Battery highest, System ECU, Hydraulic oil.

Faults

PT Err Code (powertrain error number), Battery Fault Module 1, Battery Fault Module 2, SmartPTO Fault. These are the primary on-unit fault indicators for the V3 platform.

Info

Serial number, software version, IQAN Connect key (for the telematics gateway), and Viatec contact information.

State-of-charge alarm

During normal operation the buzzer warns of low charge. Below 10 percent SOC it sounds for two seconds, then pauses for a number of seconds roughly equal to the current SOC percentage. As charge drops the alarm sounds more often, reaching two seconds on and one second off near 1 percent.

LED array

Two LED arrays (front and rear, visible from ground or bucket) show the same status: all green with pump off, one blue segment for pump requested, all green for pump running, red for a fault. When charging, each segment is 10 percent; the flashing segment is the level currently filling, solid segments are complete.

Operating sequence

Power on at the work site

1. Turn the engine off, then turn the ignition key back to ON without starting the engine. This keeps accessories (strobes, work lights) running.
2. Enable the vehicle PTO switch before leaving the cab. Some installs use the dash display: press PTO, and the logo changes from Detected to Allowed with engine off, indicating the system is ready.
3. Reset the Emergency Stop on the Control Panel (twist and pull).
4. Press and hold the Pump Toggle two seconds to start the pump. Verify GPM and pressure on the Touch Encoder.
5. Rotate to the Home screen and verify battery state-of-charge.
6. Deploy outriggers per normal sequence.
7. Switch to and operate the overhead boom per normal sequence. From the bucket, the ENGINE START STOP plunger switches between the unit and the diesel engine.
8. Stow the boom, then stow the outriggers.
9. Press and hold the Pump Toggle two seconds to turn the hydraulic system off. Confirm GPM reads zero.
10. Disable the cab PTO switch if desired, then operate the vehicle normally.

Turning off

CAUTION Shut the pump off as soon as possible after retracting outriggers. Running the powertrain 10 minutes after operations can waste 10 percent or more of available energy.

Charging

Standard (Level 1, 120V)

Plug the charge connection into a properly rated 120-volt outlet using a cord rated for at least 15 amps continuous. The unit draws roughly 10 to 11 amps for the charge cycle.

Optional (Level 2, J1772 EVSE, 240V)

Requires a Level 2 charger with a J1772 connector to communicate with the optional internal fast charger. Plug in, press and hold the Fast Charge Start button, then confirm charging on the Touch Encoder or LED array.

WARNING Using an improperly rated cord or cable can cause it to heat up, melt, or start a fire.

Charging and storage rules

CAUTION Never store the unit below 30 percent state of charge. Prolonged low charge can damage the pack and void the warranty.

Temperature and environmental limits

Cold weather (below 10C / 50F)

No permanent battery impact, but expect temporary reduction in power and runtime. Cold hydraulic fluid also increases energy draw.

Hot weather (above 35C / 95F)

Generally no noticeable change, but high pack temperature can temporarily reduce power. Above 43C (109F) the charger reduces charge current, lengthening charge time. The BMS blocks operation and discharge above a pack temperature of 60C (140F).

Environmental conditions

Condition	Range
Full performance range	+10C (+50F) to +40C (+104F) ambient
All operation functionality maintained	-20C (-4F) to +50C (+122F) battery pack temp
All charging functionality maintained	0C (+32F) to +50C (+122F) battery pack temp
Operation prevented	Below -20C (-4F) and above +60C (140F) pack temp
Recommended storage range	-20C (-4F) to +35C (95F) ambient

 

Support

Viatec Customer Care: 833-4-VIATEC · viatec.us/support

 

ViaTec WorkForce Power Take-Off (formerly SmartPTO) · Operation Manual reference · full document: OPS-003-B01 Rev 4.0