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Service Manual RRX35/45, RDX30, RSX40/50 Electric Electrical Stand-Up Rider Truck Effective Serial Number R_X0027135001

WARNING Read and observe all warnings on this unit before operating it. WARNING DO NOT operate this equipment unless all factory installed guards and shields are properly secured in place. Part no: 306756-000

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Date: April 20, 1998

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BT Standard Codes Version no

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000

BT Standard Codes B-Code

= Business area

F-Code

= Product family

T-Code

= Product type

C-Code

= Component function

Worksheet standard W-Code = Working code R-Code

= Reason code

SO-Code = Assortment C-Code List No Function Group

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Chassis

0000

Drive Motor

1000

Drive Gear / Transmission

2000

Brake / Wheel System

3000

Steering System

4000

Electrical System

5000

Hydraulic / Pneumatic System

6000

Operating Function-lifting Mast / Cylinders

7000

Peripheral / Installation Equipment

8000

Optionals / Attachments

9000

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Table of Contents BT Standard Codes ....................................................................................... 1 Warning Symbols .......................................................................................... 9 Warning Levels .......................................................................................... 9 Prohibitory Symbols .................................................................................... 10 Ordinance Symbols .................................................................................. 10 Introduction, Service Manual ...................................................................... 11 Contents, Section M ..................................................................................... 13 Machine Information ................................................................................. 13 General Product Information ...................................................................... 15 Presentation of the Rider Trucks RRX35/45, RDX30, and RSX40/50. ..... 15 Main Components ..................................................................................... 23 Grease Point Location .............................................................................. 25 Mast Adjustment Points ............................................................................ 26 Inch (SAE) and Metric Fasteners ................................................................ 27 Introduction ............................................................................................... 27 Nomenclature, Threads ............................................................................ 28 Strength Identification ............................................................................... 29 Conversion of Metric and English Units .................................................... 35 Technical Service Data ................................................................................ 37 Ordering Spare Parts ................................................................................... 41 Contents, Section P ..................................................................................... 43 Planned Maintenance ............................................................................... 43 Introduction, Maintenance .......................................................................... 45 Safe Jacking Procedure ............................................................................ 45 Service Schedule ......................................................................................... 47 Planned Maintenance Schedule ............................................................... 47 Planned Maintenance Procedures ............................................................ 50 Lubrication Chart ......................................................................................... 57 Oil and Grease Specifications .................................................................... 59 Approved Oils and Grease ....................................................................... 59 Contents, Section S ..................................................................................... 61

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Table of Contents Service Instructions .................................................................................. 61 Chassis ......................................................................................................... 63 General ..................................................................................................... 63 Door .......................................................................................................... 64 Left-Hand Side Panel ................................................................................ 65 Operator Compartment Panel ................................................................... 65 Main Card Access Panel .......................................................................... 66 Brake Pedal ................................................................................................... 67 Pedal Removal ......................................................................................... 68 Pedal Bearing Replacement ..................................................................... 69 Pedal Adjustment ...................................................................................... 69 Drive Motor ................................................................................................... 71 General Information .................................................................................. 71 Operating Conditions ................................................................................ 71 Troubleshooting ........................................................................................ 72 Drive Motor ................................................................................................... 79 Disassembly ............................................................................................. 81 Inspection and Troubleshooting ................................................................ 82 When Changing Brushes .......................................................................... 87 Caster Brake Assembly ............................................................................... 89 Removal .................................................................................................... 90 Electromagnetic Brake ................................................................................ 93 Installation ................................................................................................. 94 Adjustments .............................................................................................. 95 Coil Check On Brake ................................................................................ 95 Electromagnetic Brake, Armature and Magnetic Coil. .............................. 96 Drive Wheel ................................................................................................... 97 Removal .................................................................................................... 97 Installation ................................................................................................. 98 Support / Swivel Wheel ................................................................................ 99 Caster Pivot ............................................................................................. 100 Thrust Bearing ......................................................................................... 103 Caster Springs ......................................................................................... 105 Caster Spring ........................................................................................... 107 Caster Stops ............................................................................................ 108 Tandem Load Wheels ................................................................................. 111

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Table of Contents Removal ................................................................................................... 112 Single Load Wheels .................................................................................... 113 Removal ................................................................................................... 114 Installation ................................................................................................ 114 Caster Wheels ............................................................................................. 115 Removal ................................................................................................... 116 Installation ................................................................................................ 116 Caster Axle .............................................................................................. 117 Caster Wheels ............................................................................................. 119 Removal ................................................................................................... 120 Installation ................................................................................................ 121 Caster Axle .............................................................................................. 122 Steering Arm / Wheel / Lever ..................................................................... 123 Control Pod .............................................................................................. 124 Steering Wheel ........................................................................................ 125 Steering Tach .......................................................................................... 126 Steering Bearing ......................................................................................... 127 Removal ................................................................................................... 128 Installation ................................................................................................ 128 Electrical Functions .................................................................................... 129 Operating Description .............................................................................. 129 Start Up .................................................................................................... 131 Direction Selection ................................................................................... 133 Reverse Direction Selection .................................................................... 135 Forward Drive .......................................................................................... 137 Plug Braking ............................................................................................ 139 Steering Componets ................................................................................ 141 12-Volt Power Supply .............................................................................. 142 Driving speed reduction switch ................................................................ 143 Height Indicator and Preset Selector ....................................................... 145 Drive Motor Brush Indicator Switch ......................................................... 146 Pump Motor Brush Indicator Switch ........................................................ 147 Safety Check ........................................................................................... 148 Shunt Wire ............................................................................................... 149 Circuit Diagram 1(11) ............................................................................... 156 Circuit Diagram 2(11) ............................................................................... 157 Circuit Diagram 3(11) ............................................................................... 158 Circuit Diagram 4(11) ............................................................................... 159 Circuit Diagram 5(11) ............................................................................... 160

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Table of Contents Circuit Diagram 6(11) ............................................................................... 161 Circuit Diagram 7(11) ............................................................................... 162 Circuit Diagram 8(11) ............................................................................... 163 Circuit Diagram 9(11) ............................................................................... 164 Circuit Diagram 10(11) ............................................................................. 165 Circuit Diagram 11(11) ............................................................................. 166 Transistor Regulator ................................................................................... 167 Motor Connections ................................................................................... 168 Safety Control .......................................................................................... 169 Electronic Card ............................................................................................ 171 Display ..................................................................................................... 177 Time ......................................................................................................... 178 Warning Codes ........................................................................................ 179 Error Codes ............................................................................................. 181 Effect on the Truck ................................................................................... 183 Parameters .............................................................................................. 183 Running time ............................................................................................ 183 Programming Parameters ........................................................................ 184 Adjustment Procedures for Setting Brake Switch and Brake Transducer 187 Pump Motor ................................................................................................. 189 Component Repair ................................................................................... 190 Inspection and Troubleshooting ............................................................... 192 When Changing Brushes ......................................................................... 197 Hydraulic System ........................................................................................ 199 Operation ................................................................................................. 199 RRX35/45 Hydraulic Schematic .............................................................. 203 Hydraulic System ........................................................................................ 205 Operation ................................................................................................. 205 RRX35/45 Hydraulic Schematic .............................................................. 209 RDX30 Hydraulic Schematic ................................................................... 210 RSX40/50 Hydraulic Schematic ............................................................... 211 Mast, 3 Stage ............................................................................................... 213 Shimming Mast on Truck ......................................................................... 214 Three Stage Mast .................................................................................... 219 Sideshifter .................................................................................................... 225 Mounting Instructions ............................................................................... 227 Operation and Maintenance .................................................................... 228

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Table of Contents Reach, Single ............................................................................................... 231 Maintenance ............................................................................................ 231 Reach Repair ........................................................................................... 233 Freelift Cylinder, 3 Stage ............................................................................ 237 Freelift Cylinder Repair ............................................................................ 238 Staging Cylinder, 3 Stage ........................................................................... 241 Tilt Cylinder ................................................................................................. 245 Removal ................................................................................................... 246 Disassembly ............................................................................................ 246 Inspection ................................................................................................ 247 Assembly ................................................................................................. 247 Installation ................................................................................................ 248 Tilt Cylinder ................................................................................................. 251 Removal ................................................................................................... 252 Disassembly ............................................................................................ 253 Inspection ................................................................................................ 254 Assembly ................................................................................................. 254 Installation ................................................................................................ 256 Reach Cylinder ............................................................................................ 257 Removal ................................................................................................... 258 Disassembly ............................................................................................ 259 Inspection ................................................................................................ 260 Assembly ................................................................................................. 261 Installation ................................................................................................ 262 Height Indicator ........................................................................................... 263 Pulse sensor ............................................................................................ 264 Height Indication & Preset Height ............................................................. 265 General .................................................................................................... 266 Operation ................................................................................................. 266 Preset Height ........................................................................................... 267 Display ..................................................................................................... 268 Description of the display symbols. ......................................................... 269 Programming ........................................................................................... 270

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PS Warning Symbols Version no

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000

Warning Symbols Always follow the warnings given in this Instruction Manual and on the truck to avoid accidents and incidents from occurring.

1. Warning Levels Always follow the warnings given in this Instruction Manual and on the truck to avoid accidents from occurring.

Warning levels Warning texts are given in four levels and provide information on the risks, describe the consequences, and instruct how to avoid accidents. DANGER Warns that an accident will occur if you do not follow the instructions. The consequences are serious personal injury or possibly death, and/or extremely large material damage.

WARNING Warns that an accident can occur if the instructions are not followed. The consequences are serious personal injury or possibly death, and/or large material damage.

CAUTION Warns that an accident can occur if the instructions are not followed. The consequences are personal injury and/or material damage.

NOTE! Marks the risk of a crash/breakdown if the instructions are not followed.

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Prohibitory Symbols

NO SMOKING If smoking occurs in situations where a restriction agains smoking is stated, a serious accident can occur.

OPEN FLAMES PROHIBITED If open flames are used in situations where open flames are prohibited, a serious accident can occur.

GENERAL PROHIBITION If the prohibition is ignored, a serious accident can occur.

1. Ordinance Symbols

SAFETY SHOES When the directive for safety shoes is given, safety shoes shall always be worn to avoid personal injury.

PROTECTIVE GLASSES When the directive for protective glasses is given, protective glasses shall always be worn to avoid personal injury.

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M Introduction, Service Manual Version no

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001

395/396/397/398/399

Introduction, Service Manual The information in this Service Manual covers models RRX35, RRX45, RDX30, RSX40, and RSX50. Federal and State laws require that operators be completely trained in the safe operation of lift trucks. An Operator’s Manual is attached to every BT lift truck when it is manufactured. If the Operator’s Manual is missing from the truck, a new manual may be obtained by contacting: BT Prime-Mover, Inc. 3305 N Highway 38 Muscatine, Iowa

52761-8800

(319) 262-7700 This service manual is not a training manual. The information contained in this service manual is intended as a guide to help authorized technicians safely service this truck. The Service Manual is divided into four separate sections which cover different kinds of information needed for servicing these truck types. The main subject for each of these sections are as described below. SECTION

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SUBJECT

MACHINE INFORMATION

PLANNED MAINTENANCE

SERVICE INSTRUCTIONS

OPTIONS

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M Introduction, Service Manual Version no

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395/396/397/398/399

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M Contents, Section M Version no

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Contents, Section M 1. Machine Information

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M1.0

GENERAL PRODUCT INFORMATION

M2.0

TECHNICAL SERVICE DATA

M3.0

ORDERING SPARE PARTS

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M Contents, Section M Version no

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M1.0 General Product Information Version no

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395/396/397/398/399

General Product Information 1. Presentation of the Rider Trucks RRX35/45, RDX30, and RSX40/50. The RRX35/45 are battery powered reach trucks. The RDX30 is a battery powered deep reach truck. The RSX40/50 are battery powered straddle arm trucks. These trucks are intended solely to be operated handling pallets or similar load carriers indoors. In their standard design, the trucks are equipped with a steering wheel with all the controls for operating within easy access. The trucks have various maximum lifting capacities (review data plate on the truck to note the maximum lifting capacity). These trucks are equipped with a 24V or 36V electrical system and the speed is regulated by means of a transistor controller to provide infinite control of acceleration and speed while driving. The forks and auxiliary functions are controlled by means of a transistor controller. The control of the lift and auxiliary functions are done electrically with the levers on the control pod. Control of the speed and positioning of the forks when stacking is done by the position of the levers. The trucks can be fitted with different accessories including sideshifter, warning light, lights/fan package, travel alarm, and adjustable driving lights. The trucks can be specially equipped to work in cold conditions.

1.1. Intended Application of the Trucks The trucks are solely designed and manufactured to handle goods. The trucks should be fitted with the appropriate accessories relevant to the application.

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1.2. Forbidden Application of the Truck The trucks are designed for handling goods indoors. It is not permitted to use the trucks for other purposes including the following: -

As a towing tractor for trailers.

To tow other trucks.

To transport/lift passengers.

To drive on gravel or grass.

1.3. Truck Data The following table provides information regarding some technical data which is of value with daily use of the trucks.

Truck data

RRX35/45

RDX30

RSX40/50

Lifting capacity rated load, lb

3500 / 4500

3000

4000/5000

192-270 / 210-402

210-402

192-270 / 210-402

Operating speed without load, mph 24 Volt 36 Volt

6.0 mph 6.5 mph

6.5 mph

6.0 mph 6.5 mph

Operating speed with load, mph 24 Volt 36 Volt

5.5 mph 6.0 mph

6.0 mph

5.5 mph 6.0 mph

Service weight without battery, lb

5500 / 5800

6000

5100 / 5200

Service weight including battery, lb

Above + battery weight

Above + battery weight (2600 min)

Above + battery weight (2400 min)

Lift height, inches

The truck’s lifting capacity, lifting height, and weight can be found on the truck’s data plate.

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1.4. RRX35 Dimensions The following diagram shows external dimensions for the RRX35 truck in its standard design.

Fork length

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1.5. RRX45 Dimensions The following diagram shows external dimensions for the RRX45 truck in its standard design.

Fork length

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1.6. RDX30 Dimensions The following diagram shows external dimensions for the RDX30 truck in its standard design.

Fork length

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1.7. RSX40 Dimensions The following diagram shows external dimensions for the RSX40 truck in its standard design.

Fork length

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1.8. RSX50 Dimensions The following diagram shows external dimensions for the RSX50 truck in its standard design.

Fork length

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1.9. Data Plate The illustration below shows the data plate used on the truck.

Legend 1 Truck model number 2 Truck serial number 3 Weight less battery 4 Maximum battery weight 5 Minimum battery weight 6 Truck voltage DC 7 Battery type UL class 8 Battery maximum AMP hours 9 Truck type 10 Mast serial number 11 Attachment 12 Maximum degree rear tilt 13 Truck capacity

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2. Main Components 1

Hydraulic valve: The valves are located to provide easy access. 2 Battery: 24/36V with different capacities and weights. 3 Battery connector: The battery is charged through the battery connection. 4 Hydraulic unit: Pump motor and pump are an integrated unit. 5 Drive unit with brake: Drive motor, gears drive wheel and electrical brake combined in the drive unit. 6 Electrical steering: A servo steer motor drives a gear ring, enabling the drive unit to be rotated through 360 degree in either direction. 7 Data plate: Contains data designation, manufacturing number, year of manufacture, service weight, battery weight, classified lifting capacity, battery voltage, and manufacturer. 8 Cover: Removable to provide good access for servicing. 9 Pedal: Brake pedal. 10 Control console: The control console can be adjusted to a suitable height and angle to obtain a comfortable working position. The steering, hydraulic functions, horn, parking brake, preset height, travel direction, key switch, and any extra hydraulic functions are all controlled from this console. The position of the console maybe set in 1 of 3 positions. 11 Instrument panel: This provides information on the truck’s running hours, time display, error codes, travel direction, parking brake, steering angle and battery status. 12 Mast: The mast is a clear view model. 13 Electronics: The electronics are in a protected compartment.

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14 Control circuit fuse: 15A, BT part number 122308-150 15 Steering circuit fuse: 30A, BT part number 122308-300 16 Drive motor fuse: 500A, Two 250A fuses, BT part number 305656-003 17 Pump motor fuse: 425A, 24V BT part number 305656-002 355A, 36V BT part number 305656-001 18 Right foot pedal A red triangle (warning light) will be displayed on instrument panel if right foot pedal is not depressed. This safety feature is installed so operator keeps right foot within operator’s compartment. 19 Emergency stop The emergency stop switch will stop all control and power functions.

12 11 10

16 17 8

5 4 6 7 9 18

14 15

Main Components of Truck 24

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3. Grease Point Location

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4. Mast Adjustment Points

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Inch (SAE) and Metric Fasteners

1. Introduction Threaded fasteners such as bolts, nuts, cap screws, and studs are made to specifications that describe the mechanical strength and hardness of the fastener. A fastener used in a design application is selected in accordance with its specifications. Parts used on this truck are purchased from many countries. There are several standards used by these countries in the manufacture of threaded fasteners. Many of these fasteners are similar but cannot be used as direct replacements. Service persons must use replacement fasteners that have the same specifications. Fasteners made to each specification have identification marks for that specification. This specification is commonly called “grade” for SAE standards and “property” for metric standards. This section describes the identification of some common fasteners. The metric system used is described as SI (International System of Units, also called SI in all languages). The SI system of measurement is described in ISO Standard 1000, 1973.

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2. Nomenclature, Threads The thread design is specified by a series of numbers and letters for inch and metric fasteners (see figure below). The diameter of the shank of the fastener is shown first in the series, e.g. M12=12 mm, M20=20 mm (1/2=1/2 inch, 3/4=3/4 inch).

The number of threads per inch is normally not shown for inch nomenclature and only the UNC (Unified National Coarse) or UNF (Unified National Fine) is shown. This number of threads per inch is not shown because a UNC or UNF fastener has a standard number of threads per inch for a specific diameter. The length of a shank is often indicated as part of the description of a fastener. This length is shown in inches for inch fasteners and in millimeters for metric fasteners. A cap screw will have the following description: INCH

METRIC

1/2 x 13 UNC x 1-1/2 A B C D

M12 x 1.75 x 50 A B C

A = SHANK DIAMETER B = NUMBER OF THREADS PER UNIT OF LENGTH C = TYPE OF THREAD D = SHANK LENGTH

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A = THREAD SIZE B = PITCH C = LENGTH

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3. Strength Identification The most common property classes for metric fasteners are 8.8 and 10.9. The property class is marked with a number on the head of the cap screw or on a nut. Property classes less then 8.8 are often not marked. Grades for inch bolts go from 2 to 8. Grade 2 fasteners normally do not have marks. The following tables show the marks that identify the grades and property classes for different fasteners.

WARNING When fasteners must be replaced the new fasteners must be of the same strength or greater than the original fasteners. The new fasteners must also be the correct size. NOTE! Identification marks are according to bolt strength. The higher the number, or the increase in the number of marks, indicates increased bolt strength.

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Table 1. Bolt and Screw Designations

Types of Fasteners

Metric Fasteners

Inch Fasteners Strength Levels: SAE Grades

Strength Levels: Property Classes

* Markings Not Required 2

5.2

Hex Head Bolts & Cap Screws 5

4.6*

4.8*

5.8*

8.8

4.6

4.8

5.8

8.8

9.8

10.9

12.9

9.8

10.9

12.9

Markings for size M5 and Larger

Hex Head Flange Screws

Same As Above 5

12 Point Flange Screws

Hex Socket Head Cap Screws

Markings Not Required

5.1

8.8

12.9

8.8

12.9

4.8*

9.8

4.8

9.8

SEMS

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Table 2. Stud and Nut Designations

Types of Fasteners

Inch Fasteners

Metric Fasteners

Strength Levels: SAE Grades

Strength Levels: Property Classes

* Markings Not Required

5.2*

4.6*

4.8* 5.8*

8.8

4.6

4.8

8.8

9.8 9.8

5.8

10.9 12.9 Markings for size M5 and Larger

12.9

10.9

8.1 or

Studs

Optional Geometric Symbols for Size M5 through M11 ONLY.

Hex Nuts

Hex Slotted Nuts

Hex Flange Nuts

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8 or

Markings Not Required

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Table 3. Torque Nut Designations

Types of Fasteners

Inch Fasteners Strength Levels: SAE Grades

Metric Fasteners Strength Levels: Property Classes

or All Metal Prevailing Torque Nuts

G 9

or All Metal Prevailing Torque Flange Nuts or

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Table 4. Torque Nut with Nylon Insert Designations

Types of Fasteners

Metric Fasteners

Inch Fasteners

Strength Levels: Property Classes

Strength Levels: SAE Grades

or Nylon Insert Prevailing Torque Nuts

Markings Not Required

or or

Markings Not Required

Nylon Insert Prevailing Torque Flange Nuts

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Table 5. Fastener Torque Values

Size and Pitch

Property, Class 8.8*

Property, Class 10.9**

Property, Class 12.9***

N•m

in.-lb

N•m

in.-lb

N•m

in.-lb

5-6 8-10 20-25

44-53 71-88 177-221

7-8 12-14 30-35

62-71 106-124 ------------

8-10 14-16 ------------

71-88 124-142 -----------

N•m

ft-lb

N•m

ft-lb

N•m

ft-lb

M8 x 1.25 M10 x 1.5

-----------40-45

-----------30-33

----------60-65

22-26 44-48

34-40 70-75

26-30 52-55

M12 x 1.75 M14 x 2

70-80 110-125

30-33 52-59

100-110 155-180

74-81 114-133

115-130 180-210

85-96 133-155

M16 x 2 M20 x 2.5

170-190 340-380

125-140 251-280

240-270 450-500

177-199 332-369

280-320 550-600

207-236 406-443

M24 x 3

580-650

428-479

800-900

590-664

900-1050

664-774

M30 x 3.5

1150-1300

848-959

1600-1800

1180-1328

1850-2100

1364-1549

M36 x 4

2000-2250

1479-1660

2800-3150

2065-2323

3250-3700

2397-2729

M5 x 0.8 M6 x 1 M8 x 1.25

Property class 8.8, Protective Treatment CMHC Specification “H” (zinc phosphate), applies also to internally threaded fasteners made of property class 8 material.

** Property class 10.9, Protective Treatment CMHC Specification “H” (zinc phosphate), applies also to internally threaded fasteners made of property class 10 material. *** Property class 12.9, Protective Treatment CMHC Specification “H” (zinc phosphate), applies also to internally threaded fasteners of property class 12 material.

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4. Conversion of Metric and English Units AREA Multiply

To Get

Multiply

To Get

inches²

6.451

centimeters² (cm²)

centimeters²

0.155

inches² (in²)

feet²

0.093

meters² (m²)

meters²

10.764

feet² (ft²)

LINEAR Multiply

To Get

Multiply

To Get

inches

25.4

millimeters(mm)

millimeter

0.039

inches (in)

feet

0.305

meters (m)

meter

3.280

feet (ft)

yards

0.914

meters (m)

meter

1.094

yards (yd)

miles

1.609

kilometers (km)

kilometer

0.621

miles (mi)

MASS Multiply

To Get

Multiply

To Get

ounces (oz)

28.49

grams (g)

grams

0.035

ounces (oz)

pounds (lb)

0.454

kilograms (kg)

kilograms

2.205

pounds (lb)

tons (2000 lb)

907.18

kilograms (kg)

kilograms

0.001

tons (2000 lb)

0.907

metric ton (t)

metric ton

1.102

tons (2000 lb)

POWER Multiply

To Get

Multiply

To Get

horsepower

0.746

kilowatts (kW)

kilowatts

1.34

horsepower(hp)

PRESSURE Multiply

To Get

Multiply

To Get

pounds/in²

6.895

kilopascal (kPa)

kilopascals

0.145

pounds/in² (psi)

pounds/in²

0.007

megapascal (MPa)

megapascals

145.04

pounds/in² (psi)

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TEMPERATURE Multiply

To Get

Multiply

To Get

(Fahrenheit -32)

0.56

Celsius (C)

(Celsius x 1.8)

+32

Fahrenheit (F)

To Get

TORQUE Multiply

To Get

Multiply

inch pound

0.113

Newton meter (N•m) Newton meter

8.851

inch pounds in.-lb

feet pound

1.356

Newton meter (N•m) Newton meter

0.738

foot pounds ft-lb

VELOCITY Multiply

To Get

Multiply

To Get

miles/hour

1.609

kilometer/hour (km/h)

kilometer/hour

0.621

miles/hour (mph)

VOLUME

Multiply

To Get

Multiply

To Get

inches³

16.387

centimeters³ (cm³)

centimeters³

0.061

inches³ (in³)

inches³

0.016

liters

61.024

inches³ (in³)

quarts, U.S.

0.946

liters

1.057

quarts, U.S. (qt)

quarts, U.S.

0.83

quarts, Imp. (qt)

quarts, Imp.

1.205

quarts, U.S. (qt)

gallons, U.S.

3.785

liters

0.264

gallons, U.S. (gal)

gallons, U.S.

0.83

gallons, Imp. (gal)

gallons, Imp.

1.205

gallons, U.S. (gal)

ounces

29.57

milliliters (ml)

milliliters

0.034

ounces (oz)

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Service Manual

1997-09-24

F-code

Section

C-code

M2.0 Technical Service Data

Version no

002

T-code

395/396/397/398/399

Technical Service Data MODEL RRX35 - RSX40

RDX30

RRX45 - RSX50

Series - DC

1 Hr. Continuous

Minimum brush length

.8 in. (20 mm)

Minimum commutator diameter

2.90 in. (74 mm)

Minimum brush spring tension

6.4 oz. (180 grams)

Part number

24 V - 305789-000 36 V - 305790-000

36 V - 305790-000

Vertical motor spiralbevel output

Gear ratio

17.57

Oil volume

1 gal.

SAE 80W90 SAE 80W/90 ATF

13.5” x 5.5” x 10.0”

95 ft-lb

5.0 in. x 3.6 in.

DRIVE MOTOR Type Power Duty factor

TRANSMISSION/GEAR Type

Normal temperature Above 23°F (-5°C) Below 23°F (-5°C) Below 5°F (-15°C) WHEELS Drive wheel Drive wheel weight without load with battery, lb Drive wheel weight with rated load and battery, lb Torque axle nut Load wheel Load wheel weight with rated load, lb

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6975 lb

Service Manual

1998-07-22

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PS M2.0 Technical Service Data Version no

T-code

002

395/396/397/398/399

MODEL RRX35 - RSX40

RDX30

RRX45 - RSX50

2200 rpm.

2550 rpm.

20% on 5 min. cycles

Minimum brush length

.8 in. (20 mm)

.62 in. (16 mm)

Minimum commutator diameter

2.90 in. (74 mm)

2.80 in. (72 mm)

Minimum brush spring tension

6.4 oz. (180 grams)

40 oz. (1120 grams

Part number

24 V - 307327-000 36 V - 307328-000

307282-000

2450 psi

2400 psi

2450 psi

24 V - 13 cc 36 V - 19 cc

36 V - 27 cc

5 gal - 19 Liters

Sunoco TH ATF Texaco 1

Sunoco TH ATF Texaco 15

Drive motor circuit

250 Amp

Pump motor circuit

24 V - 425 Amp 36 V - 355 Amp

500 (2 @ 250 Amp)

10 Amp

14.4” x 38.8” x 32.0” 16.4” x 38.8” x 32.0”

16.4” x 38.8” x 32.0” 21.0” x 38.8” x 32.0”

24 V - 1395 36 V - 1240

36 V - 1240

14.5 in. -1600 lb (2300 lb) 16.5 in. - 2000 lb (2300 lb)

16.5 in. -2000 lb (2300 lb) 21.0 in. - 2600 lb (2900 lb)

16.5 in. -2000 lb (2300 lb) 21.0 in. - 2400 lb (2900 lb)

HYDRAULIC UNIT Power Revolutions/minimum at work pressure Duty factor

Pressure at rated loa Pump flow Tank volume Normal temperature Above 23°F (-5°C) Below 23°F (-5°C) Below 5°F (-15°C)

24 V 36 V - 9.8 Kw 13.1 hp

FUSE

Control circuit BATTERIES Dimension W x L x H Capacity (Max. Amp-hrs.) Weight Minimum (Maximum)

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Service Manual

1998-07-22

F-code

PS Version no

002

Section

C-code

M2.0 Technical Service Data T-code

395/396/397/398/399

MODEL RRX35 - RSX40

RDX30

RRX45 - RSX50

24 V - 6.0 mph 36 V - 6.5 mph

36 V - 6.5 mph

24 V - 5.5 mph 36 V - 6.0 mph

36 V - 6.0 mph

24 V - 60 fpm 36 V - 80 fpm

36 V - 94 fpm

24 V - 40 fpm 36 V - 60 fpm

36 V - 60 fpm

Lower without load, electrical valve

75 fpm

90 fpm

Lower with rated load, electrical valve

80 fpm

95 fpm

Driving without load

24 V - 140 36 V - 140

36 V - 150

Driving with rated load

24 V - 160 36 V - 165

36 V - 170

Lifting without load

24 V 36 V - 240

36 V - 320

Lifting with rated load

24 V 36 V - 415

36 V - 570

DRIVING SPEEDS Without load With rated load LIFTING/LOWERING TIME Lift without load Lift with rated load

CURRENT CONSUMPTION

NOTE! Performance may vary up to ±10% due to motor and system efficiency tolerance. The performance shown represents nominal values obtained under typical operating conditions. NOTE! These products and specifications are subject to change without notice.

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Service Manual

1998-07-22

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Section

C-code

PS M2.0 Technical Service Data Version no

T-code

002

395/396/397/398/399

Return

Service Manual

1998-07-22

F-code

PS Version no

Section

C-code

M3.0 Ordering Spare Parts T-code

000

Ordering Spare Parts 1. Locate the fault on the truck. 2. Find out the machine model and serial number. 3. Locate the page with the exploded diagram and find the position number for the part you require. 4. Locate the position number in the table. Select the column for the actual machine model and serial number. 5. Note the part number. 6. Call the local BT dealer and state the part number. If you cannot find the machine model, serial number, or the article number, call the local BT dealer and he will help you.

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Service Manual

1997-07-15

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Section

C-code

PS M3.0 Ordering Spare Parts Version no

T-code

000

Return

Service Manual

1997-07-15

F-code

PS Version no

Section

C-code

P Contents, Section P T-code

000

Contents, Section P 1. Planned Maintenance

Return

P1.0

INTRODUCTION, MAINTENANCE

P2.0

SERVICE SCHEDULE

P3.0

LUBRICATION CHART

P4.0

OIL AND GREASE SPECIFICATIONS

Service Manual

1997-07-15

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Section

C-code

PS P Contents, Section P Version no

T-code

000

Return

Service Manual

1997-07-15

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Section

C-code

P1.0 Introduction, Maintenance

Version no

T-code

000

Introduction, Maintenance The schedules of maintenance and lubrication given in this section of the Service Manual cover up to one year’s operation of a truck. These schedules are based on hourly usage and can be adapted to suit most normal one shift patterns. The following hourly usage figures have been used when calculating the schedule: Single shift- 8 am-5 pm, 25 hours per week usage Double shift- 6 am-2 pm, 2 pm-10 pm, 50 hours per week usage Triple shift- 6 am-2 pm, 2 pm-10 pm, 10 pm-6 am, 75 hours per week usage The schedules are intended only as a guide, not as a rigid structure. Operators of trucks may wish to adapt them to local requirements; but it is emphasized that the schedules represent minimum manufacturer requirements, and all items should be included in a service program to ensure minimum downtime and a high safety status of the equipment. - Use only spare parts approved by BT. - Always clean the equipment and carry out a full safety check after service.

1. Safe Jacking Procedure 1. Disconnect battery. 2. Read and follow the correct operating procedures for your jack or hoist.

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Service Manual

1997-07-15

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Section

C-code

PS P1.0 Introduction, Maintenance Version no

T-code

000

Return

Service Manual

1997-07-15

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Section

P2.0 Service Schedule

Version no

C-code

T-code

001

395/396/397/398/399

Service Schedule 1. Planned Maintenance Schedule ITEM 0000 0000.1 0000.2 0000.3 0000.4 0640 0640.1 0640.2 0640.3 0840 0840.1 1700 1700.1 1700.2 1700.3 1700.4 1700.5 2550 2550.1 2550.2 2550.3 3100 3100.1 3100.2

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WORK REQUIRED Interval in Hours Interval in Days/Weeks/Months Chassis Check that the truck identification plate is legible Check for damage and cracks Retighten the truck body bolts (to the chassis) Check the cover screws Operator Controls Check that the travel direction/ speed selectors operational Check that the horn button is operational Check that the hydraulic levers are operational Driver’s Protection Check that the red emergency stop button is operational Drive Motor Check for arcing due to poor connections All connections tight Clean motor of dirt and dust Check torque of motor bolts Check for abnormal noise in motor bearings Drive Gear Check for oil leakage Clean motor of dirt and dust Check torque of motor bolts Brake Clean dust and debris Check brake shoes for wear

Service Manual

100

250

300

600

1200

3600

12 m

36 m

X X X X X X X

X X X X X

1997-11-07

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PS P2.0 Service Schedule Version no

T-code

001

395/396/397/398/399

ITEM 3100.3 3100.4 3500 3500.1 3500.2 3500.3 3500.4 4100 4100.1 4100.2 5110 5110.1 5110.2 5110.3 5110.4 5200 5200.1 5300 5300.1 5300.2 5300.3 5400 5400.1 5400.2 5400.3 5400.4 5400.5 5710 5710.1

Return

WORK REQUIRED Interval in Hours Interval in Days/Weeks/Months Check correct clearance of electrical brake and brake shoes Check brake operation Wheels Remove all string, wrapping and debris Check all wheels for wear Grease load wheel bearings Grease caster and caster wheels Steering Wheel Check fasteners Check ease of steering Battery Electrolyte level, ½ -e inch above cell plates All connections: battery, battery and charger plugs All cell and link covers intact Check battery specific gravity Instrument Panel Check battery indicator and hour meter for correct operation Electrical Control System Check key switch Check brake micro switch Check control wiring harness for proper routing Electrical Panel Cleaning and mounting to chassis Tightening of connections Check contactor tips Check contactor tips for free movements Check all cable insulation for damage Electronic Card Check for connections in harness connectors

100

250

300

600

1200

3600

12 m

36 m

X X X X X X X X X X X X X

Service Manual

X X

X X X X X

1997-11-07

F-code

Section

P2.0 Service Schedule

Version no

T-code

001

ITEM 6000 6000.1 6000.2 6000.3 6000.4 6000.5 7100 7100.1 7100.2 7100.3 7100.4 7100.5 7100.6 7100.7 7100.8 7100.9 7310 7310.1 7310.2 7400. 7400.1 7400.2 7400.3 7400.4 7400.5

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C-code

395/396/397/398/399

WORK REQUIRED Interval in Hours Interval in Days/Weeks/Months Hydraulic System Check hoses and connections for leakage Check hoses for wear and damage Check oil tank for cracks, leaks and mounting Check correct oil level Change the hydraulic oil Mast Check for damage and cracks Retighten the mast mounting bolts Check the clearance of the rollers Check the lateral play of the inner section Check for wear on the lift chains and chain rollers Check the adjustment of the lift chains Clean & lube lift chains Clean & lube mast rails Lube chain sheaves Lift Cylinder Check for leakage Check mounting Lifting Device Check the clearance of the fork carriage Check the fork carriage for damage and cracks Check the forks for wear and cracks Check the reach attachment for damage and cracks Lube all grease fittings on reach attachment

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100

250

300

600

1200

3600

12 m

36 m

X X X X X X X X X X X X X X X X X X X X X

1997-11-07

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PS P2.0 Service Schedule Version no

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001

395/396/397/398/399

2. Planned Maintenance Procedures This section describes how to perform the services listed in the Schedule of Planned Maintenance Operations. As with the “Schedule”, this section is subdivided into service intervals.

2.1. Services to be performed daily or at each 8 hour operating shift: The daily inspection is to be made by the operator prior to each operating shift. It is the operator's responsibility to report any defects to the proper authorities, and the truck should not be operated until it has been inspected and repaired by a qualified technician. The operator is ultimately responsible for the safe operation of the reach truck. 2.1.1. Battery Discharge Indicator with slow down The battery discharge indicator indicates the current charge status of the truck’s battery. 1

Full charge battery

1/2

Half charged battery

Discharged battery

The battery battery discharge indicator has an integrated cutout function that slows down the truck’s lift function when a predetermined charge level has been reached. This prevents overloading the battery and increases the operating economy of the truck. When the battery has reached a charge level equivalent to 70% discharge, a warning signal is given via flashing lights. A further 10% of the battery’s capacity can then be used before the battery discharge indicator slows down the lift function. 2.1.2. Hydraulic System Inspect the entire truck for leaks, especially around the hydraulic pump assembly and the lift cylinders. Any sign of oil on the floor under the truck is an indication that the truck may be leaking hydraulic oil or transmission fluid. Report any problems to the proper authorities, and DO NOT operate the truck until it has been inspected and repaired by a qualified technician.

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P2.0 Service Schedule

Version no

001

C-code

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395/396/397/398/399

2.1.3. Frame/Sheet Metal Inspect the truck for loose, damaged or missing parts. All shields must be in place and functional. Report any problems to the proper authorities. DO NOT operate the truck until it has been inspected and repaired by a qualified technician. 2.1.4. Wheels/Tires Inspect wheels and tires for wear and damage. Trash that is wrapped around wheels and axles will cause premature tire wear and bearing damage. The floors should be kept clear of trash to prevent damage to the wheels and tires. 2.1.5. Functions/Operations Test the truck for the proper operation of all functions including the travel controls, lift and lower functions, the brakes, and the emergency disconnect button. Safety devices must be operational. Report any problems to the proper supervisors. DO NOT operate the truck until it has been inspected and repaired by a qualified technician.

2.2. Services to be performed monthly or every 250 operating hours: The monthly planned maintenance service should be performed by a qualified technician. 2.2.1. Inspection All of the services and inspections listed above for the daily inspection should be performed at this time. The inspection procedure should be more thorough, and minor deficiencies should be corrected. 2.2.2. Transmission Inspect for oil leakage. 2.2.3. Brakes The brakes should stop a fully loaded truck at full speed in approximately one truck length. 2.2.4. Battery Contact your battery dealer for specific instructions on care and maintenance of the battery. © BT Products

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1997-11-07

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PS P2.0 Service Schedule Version no

T-code

001

395/396/397/398/399

An average battery will have a specific gravity of 1.170 at the 80% discharged level. However, there are many different batteries on the market. Only the battery manufacturer can accurately determine the fully charged and 80% charged levels. Contact the battery manufacturer for this information. 2.2.5. Electrical Connections All electrical connections should be checked that they are clean and tight. Plug-in connectors should be unplugged and plugged back in to clean the terminals. If the truck is equipped with any of the cold-storage, freezer use, or corrosive environment application packages, the di-electric compound in the plug-in connectors should be renewed. 2.2.6. Contactor Tips (NOT Sealed) Inspect contactor tips for arcing, pitting, or burning. Minor pitting of the tips is not a problem. However, if the tips are pitted through the tip to the copper bar, the tips should be replaced. DO NOT file tips. Replace tips only in complete sets. Some contactors have concealed tips or are fully sealed so that tips cannot be replaced. 2.2.7. Motor Brushes The drive motor is equipped with a brush wear sensor which will indicate when the brushes need replacing. Minimum brush lengths are given in the specifications section of this manual. As a rule of thumb, the brushes should be replaced if the brush spring is within 1/16 in. of touching the brush holder. 2.2.8. Drive Motor Blow out the drive motor fan and vents. Check for any signs of oil on the drive motor fan and air vents. Check for any damage to the fan or air vents.

WARNING Compressed air used for cleaning MUST be reduced to less than 30 psi., and then only with effective chip-guarding and personal protective equipment worn.

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P2.0 Service Schedule

Version no

001

C-code

T-code

395/396/397/398/399

2.2.9. Hydraulic Reservoir Check the fluid level in the hydraulic reservoir. 2.2.10. Frame Lube (“Lubrication Chart” on page 55) The pressure type grease fittings (zerk fittings) should be lubricated with Texas Refineries #880 Crown and Chassis lubricating grease. The total number of grease fittings depends on the truck options when built. A truck with a coldstorage, freezer use, or corrosive environment application package will have more grease fittings than a standard truck. Look for flush-type grease fittings on the load wheel axles. Regular fittings may be found on the transmission mounting bearing and the mast chain sheave shafts. 2.2.11. Pivot Points There are some pivot points and other items that need to be lubricated but do not have grease fittings. Lubricate these non-greasable wear points with a drip oil can using 10 wt. machine oil.

2.3. Services to be performed annually or every 1200 operating hours. The annual planned maintenance service will take a longer period of time to complete than does the monthly service. This would be a good time to arrange other repairs that have been noted on the monthly service. 2.3.1. Inspection All of the services and inspections listed in sections 5.1 and 5.2 for the daily and monthly inspection should be performed at this time. The inspection procedure should be more thorough, and minor deficiencies should be corrected. 2.3.2. Transmission The transmission fluid should be drained once a year. The drain port is located on the lower portion of the side cover opposite the drive tire. Remove the bolt to drain the transmission fluid. Flush the transmission case with safety solvent. Pour clean safety solvent into the fill port accessed from battery compartment. With drive tire off the floor, allow solution to run out of drain port while transmission is running.

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Service Manual

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Stop flushing when the solution runs clean. Allow the solvent to drain well before replacing the drain plug bolt. Replace the drain plug bolt. Refill the transmission with the proper clean oil before operating truck. 2.3.3. Battery At approximately 1500 hours, contact an authorized battery dealer to determine the overall condition of the battery. Determine if the battery needs to be washed down. This can only be done by properly equipped and trained personnel. 2.3.4. Hydraulic System The hydraulic system should be drained, flushed and refilled, and the pressure relief valve setting should be checked and adjusted. This will maintain proper lubrication properties within the system.

WARNING Before siphoning oil from reservoir, make certain siphon is clean. To drain reservoir, remove reservoir filter assembly. Siphon oil from reservoir and purge oil out of hydraulic system. Fill reservoir with proper clean oil. Operate raise and lower function several times to purge air from system. Check oil level. Put rated truck capacity load on forks and adjust pressure relief valve, if necessary, so that truck will lift rated load. 2.3.5. Brakes Follow procedures for brake removal before inspecting. Remove brake assembly and inspect friction disc for wear. The friction disc should be replaced once thickness is 0.25 in. (6 mm) or less. The armature and magnetic coil should be adjusted if machine will not meet stopping and holding specifications. The air gap should not exceed 0.018 in. 0.46 mm) and should remain within 0.003 in. (0.076 mm) throughout the circumference. 2.3.6. Lift and Carriage Chains. Lift and carriage chains should be checked every 500 hours. A chain gauge should be used to check stretch of the links. To adjust inner rails, loosen jam nut and tighten chains 54

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Service Manual

1997-11-07

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Section

P2.0 Service Schedule

Version no

001

C-code

T-code

395/396/397/398/399

equally until the top of the rails are level in the fully lowered position. Retighten jam nut and torque. Carriage chains should be adjusted in the fully lowered position. Adjust chains until the heel of the forks are 1/2 in. (12.7 mm) off of the floor.

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Service Manual

1997-11-07

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Section

C-code

PS P2.0 Service Schedule Version no

T-code

001

395/396/397/398/399

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Service Manual

1997-11-07

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Section

P3.0 Lubrication Chart

Version no

C-code

T-code

000

395/396/397/398/399

Lubrication Chart Pos. No

Service Point

Interval/Running Hours 300 h

1 2 3 4 5 6

Wheel bearings Mast beam Lifting chains Hydraulic syste Steering bearings Drive gear

600 h

1200 h

Lubricant (See Chart in Section 6 for Code)

L L L C C L= Lubrication

C = Check

O L O

A A D B A C

O = Oil change

2 3

5 1 1 Truck Lubrication Points

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Service Manual

1997-07-15

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Section

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PS P3.0 Lubrication Chart Version no

T-code

000

395/396/397/398/399

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Service Manual

1997-07-15

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Section

C-code

PS P4.0 Oil and Grease Specifications Version no

000

T-code

395/396/397/398/399

Oil and Grease Specifications 1. Approved Oils and Grease Lubricant A

Grease

B C D E

Hydraulic oil Transmission oil Motor oil Grease

Grease

Return

Specification >14°F(-10°C) <14°F(-10°C) Tex. Ref. C Mobiltemp and C #880 SHC 32 Sunoco TH ATF SAE 80w/90 SAE 75w SAE 40 SAE5w-20 Molykote Molykote 200025 200025 49670-00 49670-00

Service Manual

1997-07-15

Application area <-13°F(-25°C) Mobiltemp SHC 32 Texaco 15 ATF SAE5w-20 Molykote 200025 49670-00

Bearings and bushings Hydraulic system Gears Chains Mast rails, Reach, Sideshifter Mast rails, Reach, Sideshifter

F-code

Section

C-code

PS P4.0 Oil and Grease Specifications Version no

T-code

000

395/396/397/398/399

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Service Manual

1997-07-15

F-code

PS Version no

Section

C-code

S Contents, Section S T-code

000

Contents, Section S 1. Service Instructions NO FUNCTION GROUP

C-CODE

CHASSIS

0000

DRIVE MOTOR

1000

DRIVE GEAR / TRANSMISSION

2000

BRAKE / WHEEL SYSTEM

3000

STEERING SYSTEM

4000

ELECTRICAL / PNEUMATIC SYSTEM

5000

HYDRAULIC SYSTEM

6000

LIFTING MAST / CYLINDERS

7000

PERIPHERAL / INSTALLATION

8000

EQUIPMENT 9

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OPTIONS / ATTACHMENTS

Service Manual

1997-04-15

9000

F-code

Section

C-code

PS S Contents, Section S Version no

T-code

000

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Service Manual

1997-04-15

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Section

C-code

S0.1

0000 Chassis

Version no

T-code

001

395/396/397/398/399

Chassis 1. General The chassis has several panels and covers that are removable. During operation of the truck, these panels and covers must be secured to the chassis. The purpose of bolton panels and covers is for access of components when servicing the truck. 13 12

14 1 16

9 8 7

6 5 15

Removal/Installation of Chassis Panels & Covers © BT Products

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Service Manual

1997-07-15

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PS Chassis

S0.1

0000

Version no

T-code

001

395/396/397/398/399

POS. NO

DESCRIPTION

POS. NO

DESCRIPTION

POS. NO

Panel, left hand

Latch

Plug, hole

Panel, side

Washer, flat

Screw

Grill, fan

Nut

Panel, cover

Screw

Door

Mount, control

Screw

Panel, right hand

Screw

Washer

Dash

Plate, heat sink

DESCRIPTION

2. Door 2.1. Removal 1. Turning screw (5) clockwise one quarter turn. 2. Open door (10) fully and lift door upward to release hinge pins.

2.2. Installation 1. Set door (10) in place so hinge pins are securely mounted in panel hinge. 2. Close door. Turn screw (5) counter clockwise one quarter turn.

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CAUTION

Do not force screw (5) past quarter turn or latch can become loose.

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S0.1

0000 Chassis

Version no

001

T-code

395/396/397/398/399

3. Left-Hand Side Panel 3.1. Removal 1. Park truck on level surface and block. 2. Disconnect battery at battery plug and remove.

Overhead guard post

3. Turning screw (5) clockwise one quarter turn. 4. Open door (10) fully and lift door upward to release hinge pins. 5. Remove console cover (12) by removing seven screws (14) and control pod.

Control Pod

6. Remove three flanged nuts. Two are located under control console by reservoir and the third flanged nut can be accessed through battery box left hand side or by removal of operator’s compartment side panel (2). 7. Remove bolt at rear of panel located by drive motor. 8. Remove four bolts securing overhead guard post. Disconnect harness at post if applicable. 9. Pull left-hand panel (1) outward and set aside.

CAUTION

Side panel is heavy. Help may be required to remove.

4. Operator Compartment Panel 4.1. Removal 1. Remove top bolt securing panel (2). 2. Loosen bottom bolt (5) while holding panel (2) in place. 3. Lift up and set aside.

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PS Chassis

S0.1

0000

Version no

T-code

001

395/396/397/398/399

5. Main Card Access Panel 5.1. Removal 1. Loosen two lower bolts. 2. Remove two top bolts and lift electrical cover panel (15) up and set aside.

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1997-07-15

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Section

C-code

S0.2

0640 Brake Pedal

Version no

T-code

000

395/396/397/398/399

Brake Pedal 12

2 1

2 5

8 4 3 8 9

13 14 POS. NO

DESCRIPTION

POS. NO

Pedal, brake

10 11

DESCRIPTION

POS. NO

Stop, pedal

Screw

Bearing, flanged

Plate

Mat, pedal

Bumper

Screw

Nut, twin

Bracket, brake

Screw

Switch, brake

Spring, return

Potentiometer

Screw

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Service Manual

1997-07-15

DESCRIPTION

F-code

Section

C-code

PS S0.2 Brake Pedal

0640

Version no

T-code

000

395/396/397/398/399

1. Pedal Removal 1. Park the truck on a flat surface. 2. Disconnect the battery at the battery connector. Check to make sure the battery retainer plates are in place. 3. Jack the rear of the truck so the drive and caster wheels are approximately 1 in. off the ground. Block the truck in this position. 4. Looking into the operator's compartment, remove the four screws from the right panel covering the logics card. Take panel out and set to the side.

CAUTION

Pinch point, keep fingers clear of floor board cutout while holding down left foot brake pedal.

CAUTION Disconnect wire connections to right foot pedal switch prior to removal of floor board. 5. Push down on the left foot brake pedal (1) with one hand and remove the floor board by pulling up and pivoting the plate (7) toward the motor compartment. Release the left foot brake pedal as the floor board pivots up. 6. Remove floor board and set to the side. 7. Remove the screws (11) holding the transducer switch (10) and remove wires from the brake switch (12). 8. Loosen the four mounting bolts holding brake pedal assembly to the frame. Remove brake pedal assembly from truck to service.

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Service Manual

1997-07-15

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Section

C-code

S0.2

0640 Brake Pedal

Version no

000

T-code

395/396/397/398/399

2. Pedal Bearing Replacement 1. To replace bearing assemblies on brake pedal (1), remove the brake pedal return spring (5). 2. Remove the flange bearing mounting screws (8) on both bearings. 3. Loosen the set screws on bearing collars and slide bearing assemblies back. 4. Remove brake pedal assembly from bracket (4) and remove bearings (2). Reverse procedure for reassembly.

3. Pedal Adjustment 1. See “Adjustment Procedures for Setting Brake Switch and Brake Transducer” on p age187. When replacing the pedal stop (6) it should be threaded down until the stop makes contact with the bracket (4).

Return

Service Manual

1997-07-15

F-code

Section

C-code

PS S0.2 Brake Pedal

0640

Version no

T-code

000

395/396/397/398/399

Return

Service Manual

1997-07-15

F-code

Section

C-code

S1.0

1700 Drive Motor

Version no

000

T-code

395/396/397/398/399

Drive Motor 1. General Information Routine maintenance schedule with recorded findings is the best way to reduce costly shut-downs and repair of equipment during operating hours. The goal of any maintenance program -- long-life and troublefree operations -- is related to the time spent making inspections and correcting minor problems as they occur. The drive motor is equipped with brush sensors. When brushes are in need of replacement, a warning code C-17 will show on the dash display.

2. Operating Conditions Operating environment of lift truck motors varies widely: The following recommendations should be applied as actual conditions dictate. Normal Service:

Basically an eight hour day of indoor material handling.

Severe Service:

Extended operating hours, or constant usage.

Extreme Service:

Chemical Processing Freezer operation Processing plants (poultry, meat)

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Service Manual

1997-07-15

F-code

Section

C-code

PS S1.0 Drive Motor

1700

Version no

T-code

000

395/396/397/398/399

3. Troubleshooting When a motor has trouble in operation, a reasonable decision has to be made as to the proper corrective course of action. We have reviewed many troubleshooting guides and have reduced them to a few which seem to be the most effective Symptom/Cause relationships.

Return

Table 1

Indications, causes, and correction of unsatisfactory brush performance.

Table 2

Primary sources of unsatisfactory brush performance.

Service Manual

1997-07-15

F-code

Section

C-code

S1.0

1700 Drive Motor

Version no

000

T-code

395/396/397/398/399

TABLE 1.

Indications, Causes, and Correction of Unsatisfactory Brush Performance Indications

Immediate Causes

Primary Faults

Sparking

Commutator surface condition Overcommutation Undercommutation Too rapid reversal of current Faulty machine adjustment Mechanical fault in machine Electrical fault in machine Bad load condition Poor equalized parallel operation Vibration Chattering of brushes Wrong brush grade Fluctuating contact drop

1-2-3-43-44-45-46-49-59-60 7-12-31-33 7-12-30-32 7-12-30-32 8-9-11 6-14-15-16-17-18-19-20-21-28-29 25-27-28-29-38-39-40-41-42

Etched or burned bands on brush face

Overcommutation Undercommutation Too rapid reversal of current

7-12-31-33 7-12-30-32 7-12-30-32

Pitting of Brush Face

Glowing Embedded copper

See “Glowing at brush face” See “Copper in brush face”

Rapid Brush Wear

Commutator surface condition

See specific surface fault in evidence. Also see 50. See “Sparking”

Severe sparking Imperfect contact with commutator Wrong brush grade

7-13-23-34 51-52 See “Chattering or Noisy Brushes” 55-57-59 50

11-14-15-16-51-52 54-58

Glowing at Brush Face

Embedded copper Faulty machine adjustment Severe load condition Bad service condition Wrong brush grade

See “Copper in brush face” 7-12 38-39-41-42 46-47 57-61-62

Copper in Brush Face

Commutator surface condition Bad service condition Wrong brush grade

2-3 43-46-47-48-49 59-61

Flashover at Brushes

Machine condition Bad load condition Lack of attention

14-35 38-39-41-53 5-11

Chattering or Noisy

Commutator surface condition Looseness in machine Faulty machine adjust High friction Wrong brush grade

See specific surface in evidence 15-16-17 10-11 6-43-45-49-52-58-59 55-58-59

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Service Manual

1997-07-15

F-code

Section

C-code

PS S1.0 Drive Motor

1700

Version no

T-code

000

395/396/397/398/399

TABLE 1. Continued Indications Appearing at Commutator Surface Indications

Immediate Causes

Primary Faults

Brush Chipping or Breakage

Commutator surface condition Looseness in machine Vibration Chattering

See specific surface fault in evidence 15-16-17 52 See “Chattering or Noisy Brushes 14

Sluggish brush movement Rough or Uneven Surface

1-2-3-4-17

Dull or Dirty Surface

5-44-60

Eccentric Surface

1-19-22-52

High Commutator Bar

Sparking

Low Commutator Bar Streaking or Threading of Surface

Sparking Copper or foreign material in brush face Glowing

2-25 43-44-45-46-49-59 2-3-46-47-48-61 See “Glowing at Brush Face”

Bar Etching or Burning

Sparking Flashover

2-3-7-12-30-31-32-33 5-11-14-35-38-39-41-53

Bar Marking at Pole Pitch Spacing

Sparking

25-37

Bar Marking at Slot Pitch Spacing

Sparking

7-12-30-57-60

Flat Spot

Sparking Flashover Lack of attention

19-23-25-41-53 5-11-14-35-38-39-41-53 1-5-11

Discoloration of Surface

High temperature Atmospheric condition Wrong brush grade

See “Heating at Commutator” 44-46 60

Raw Copper Surface

Embedded coppe Bad service condition Wrong brush grade

See “Copper in Brush Face” 43-45-47-49 59-61

Rapid Commutator Wear with Blackened Surface

Burning Severe sparking

2-3-11-14 See “Sparking”

Rapid Commutator Wear with Bright Surface Copper Dragging

Foreign material in brush face Wrong brush grade Brush vibration

43-45-47-49 61 39-52-58-59

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Service Manual

1997-07-15

F-code

Section

C-code

S1.0

1700 Drive Motor

Version no

000

T-code

395/396/397/398/399

TABLE 1. Continued Indications Appearing at Commutator Surface Indications

Immediate Causes

Primary Faults

Heating in Windings

Severe load condition Unbalanced magnetic field Unbalanced armature currents Poorly equalized parallel operation Lack of ventilation

38-41-42-53 18-19-20-21-27-28-29

Severe load condition Severe sparking High friction Poor commutator surface Depreciation High contact resistance

38-41-42 7-8-9-12-20-33-45-57 10-11-36-43-45-49-58-59 See specific surface fault in evidence 6-24 56

Severe load condition Faulty machine adjustment Severe sparking Raw streaks on commutator surface Embedded coppe Wrong brush grade

38-41-42 7-10-11-12-26 See “Sparking” See “Streaking or Threading of Surface” See “Copper in Brush Face” 57-58-59-61-62

Heating at Commutato

Heating at Brushes

Return

Service Manual

1997-07-15

8-19-22-25-27-28-29-37 7-13-23-24

F-code

Section

C-code

PS S1.0 Drive Motor

1700

Version no

T-code

000

395/396/397/398/399

TABLE 2. Primary Sources of Unsatisfactory Brush Performance Preparation and Care of Machine 20. 21. 22. 23. 24. 25.

Poor preparation of commutator surface High mica Feather-edge mica Bar edges not chamfered after undercutting Need for periodic cleaning Clogged ventilating ducts

Machine Adjustment 26. 27. 28. 29. 30. 31. 32.

Brushes in wrong position Unequal brush spacing Poor alignment of brush holders Incorrect brush angle Incorrect spring tension Interpoles improperly adjusted Series field improperly adjusted

Mechanical Fault in Machine 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43.

Brushes tight in holders Brushes too loose in holders Brush holders loose at mounting Commutator loose Loose pole pieces or pole-face shoes Loose or worn bearings Unequal air gaps Unequal pole spacing Dynamic unbalance Variable angular velocity Commutator too small

Electrical Fault in Machine 44. 45. 46. 47. 48. 76

Return

Open or high resistance connection at commutator Poor connection at shunt terminal Short circuit in field or armature winding Ground in field or armature winding Reversed polarity on main pole or interpole Service Manual

1997-07-15

F-code

Section

C-code

S1.0

1700 Drive Motor

Version no

000

T-code

395/396/397/398/399

TABLE 2. Continued Machine Design 49. 50. 51. 52. 53. 54. 55. 56.

Commutating zone too narrow Commutating zone too wide Brushes too thin Brushes too thick Magnetic saturation of interpoles High bar-to-bar voltage High ratio of brush contact to commutator surface area Insufficient cross connection of armature coils

Load or Service Condition 57. 58. 59. 60. 61. 62. 63. 64. 65. 66. 67. 68. 69.

Overload Rapid change of load Reversing operation of non-interpole machine Plugging Dynamic braking Low average current density in brushes Contaminated atmosphere “Contact poisons” Oil on commutator or oil mist in air Abrasive dust in air Humidity too high Humidity too low Silicone contamination

Disturbing External Condition 70. 71. 72. 73. 74. 75. 76. 77. 78. 79. 80. 81.

Return

Loose or unstable foundation External source of vibration External short circuit or very heavy load surge “Commutation factor” too high “Commutation factor” too low Contact drop of brushes too high Contact drop of brushes too low Coefficient of friction too high Lack of film forming properties in brush Lack of polishing action in brush Brushes too abrasive Lack of carrying capacity

Service Manual

1997-07-15

F-code

Section

C-code

PS S1.0 Drive Motor

1700

Version no

T-code

000

395/396/397/398/399

Return

Service Manual

1997-07-15

F-code

Section

C-code

S1.1

1700 Drive Motor

Version no

000

T-code

395/396/397/398/399

Drive Motor 1 3 2

4 13 7 14

8 9

5 16

11 12

25 16 26 27

28 29 30

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Service Manual

1997-07-15

F-code

Section

C-code

PS S1.1 Drive Motor

1700

Version no

T-code

000

395/396/397/398/399

Pos. No

Return

Description

Pos. No

Description

Pos. No

Description

Screw

Brush

Endhead, drive

Band, head

Spring

Screw

Fan unit

Bearing

Ring, seal

Guard, fan

Retainer

O ring

Field coil

Retainer and seal

Sleeve

Screw, pole shoe

Stud, terminal

Bearing

Endhead, commutator

Armature

Ring, retainer

Plate, brush

Key, woodruff

Ring, retainer

Service Manual

1997-07-15

F-code

Section

C-code

S1.1

1700 Drive Motor

Version no

000

T-code

395/396/397/398/399

1. Disassembly 1. Remove the cover band (23) from the commutator end of the motor. 2. Use a brush hook to reach into the motor and lift the brush springs (19). Pull the brushes (2) out of the brush holders. Either position the brushes outside the motor or remove the brush retaining screws and remove the brushes from the motor. 3. Scribe or center punch locating marks in the end head and the frame. Although locating marks are not always necessary because of locating pins in some motors, they can save a lot of time when the motor does not have locating pins. 4. Remove the commutator end head retaining screws. Most motors have a slip fit bearing at the commutator end, and the end head can be removed with very little trouble. 5. Remove the drive end head retaining screws, if necessary. Separate the armature (9) and drive end head (11) as an assembly from the frame and field coil assembly. 6. Separate the armature (9) from the drive end head (11). This operation is usually done by pressing the armature out of the drive end bearing. Remove with a puller. When a puller is used, protect the end of the armature shaft with a nut or a thick flat washer.

CAUTION If the shaft, coupling, or spline is damaged when removing the end head, the armature or the drive spline usually has to be replaced. Use caution, and DO NOT damage the armature. 7. Remove snap ring from the end head. Then press the bearing (17) out of the end head (21). 8. After the motor has been separated into all its major subassemblies, the components should be cleaned and inspected for wear or damage. © BT Products

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Service Manual

1997-07-15

F-code

Section

C-code

PS S1.1 Drive Motor

1700

Version no

T-code

000

395/396/397/398/399

2. Inspection and Troubleshooting After the motor components have been thoroughly cleaned and dried, they should be inspected for the following:

2.1. Drive End Head 1. Check bearing recess for any signs of wear. 2. Check mounting holes for any stripped or crossed threads or broken studs.

2.2. Commutator End Head 1. Check bearing recess for any signs of wear. 2. Check brush holder insulation for cracks or any signs of burning. 3. Check brush holders and springs for wear.

2.3. Bearings 1. Check bearings by turning them with your fingers. Feel for binding or gritty effects and excessive looseness or wobble. A good bearing should also have a small amount of drag or stiffness caused by the lubrication but should turn smoothly. If the bearing turns very freely, it should be replaced. Bearings should also be changed if worn out, damaged, or removed from armature shaft. Ball bearings that have been pulled off shafts, pressed out of end heads, or side loaded in such a way as to apply pressure on the balls and races must be replaced.

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Service Manual

1997-07-15

F-code

Section

C-code

S1.1

1700 Drive Motor

Version no

000

T-code

395/396/397/398/399

2.4. Brush and Commutator The brushes and commutator should be inspected for even wear and good commutation. Good Commutation: A dark uniform coloring pattern at the brush wearing surface. Poor Commutation: The surface of the commutator appearing rough, pitted, or scored, or showing signs of burning or heavy arcing between bars. The color pattern will be: Streaky film with commutator wear. Bar edge burning. Uneven film. Carbon dust bridging between bars. Brushes should be inspected for uneven wear and signs of overheating, i.e.: Discolored brush shunts. Discolored brush springs. Refer to the Brush Chart at the end of this section.

2.5. Armature 1. Check for loose commutator bars. Loose commutator bars will usually be indicated by excessive wear or burning on one bar. The commutator can be checked for loose bars by lightly tapping all of the bars with the handle of a plastic or wooden handled screwdriver. A contrasting dull thud or vibration will indicate a loose bar. Replace the armature if the commutator bars are loose. 2. Check for grounded circuits using a test light. Most commercial growlers incorporate a test light. Check the armature for grounded circuits by placing one test lead of the test lamp on the commutator and the other test lead on the armature shaft. If the test light lights, the armature is grounded.

Grounded Circuit Test

3. Standard Winding Armatures are tested on a growler using a steel strip or hacksaw blade to locate any shorted windings. © BT Products

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Service Manual

1997-07-15

F-code

Section

C-code

PS S1.1 Drive Motor

1700

Version no

T-code

000

395/396/397/398/399

Check for shorted windings by slowly rotating the armature in the growler while holding the strip or blade so that it passes over each armature core slot. If a winding is shorted, the strip or blade will vibrate and the blade will get hot.

Test for Shorted Windings on Armature

NOTE! If the armature has been turned and undercut prior to testing, check for and remove any copper buildup or filings between commutator bars and at the commutator riser. This condition will cause an armature to check shorted and usually results from a dull undercutting tool. 4. Check commutator bars for any signs of burning. If deep burned sections are evident, either in the brush track or on the riser ends of the commutator bars, an open or short circuit in the armature windings is indicated.

2.6. Frame and Field Assembly Check the condition of all insulation. If the insulation on the field coils appears blackened or charred, the serviceability of the coils is questionable. Burned or charred insulation is a result of coil overheating due to overloading conditions, grounded or shorted coil windings. Check the condition of all other insulation such as brush rigging, under coil connections and around terminal studs.

Test for Shorted Windings on Armature

2.6.1. Testing After thorough inspection, the Frame and Field Assembly should be checked for grounded, open, or shorted circuits. Grounded and open circuits can be checked using a test light. Most commercial growlers incorporate a test light as shown in opposite illustration.

Grounded Circuit Touch one test lead to a clean bare metal spot on the frame and check all terminals with the other lead. If a grounded condition exists, the test light will light.

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Service Manual

1997-07-15

F-code

Section

C-code

S1.1

1700 Drive Motor

Version no

000

T-code

395/396/397/398/399

Open Circuit Check between all connecting terminals with test leads. If the bulb fails to light, an open circuit is indicated.

Shorted Circuit Shorted windings in series coils are very difficult to detect. Generally, if the coil insulation is sound and these are no signs of overheating, the coil can be presumed good.

2.6.2. Frame and Field Service Notes If the inside of the motor is exceptionally dirty and there is evidence of a grounding condition caused by the dirt, the inside of the motor can be given an additional coat of insulating varnish. Red glyptol can be used if a better material is not available, however, we recommend using a class H Polyurethane air drying insulating varnish. This is readily available under various brand names from electrical repair or parts houses in aerosol type dispensers. Before spraying field coils, make sure they are absolutely clean and dry. Protect brush rigging, pole shoe faces, and end head seats to keep varnish off.

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Service Manual

1997-07-15

F-code

Section

C-code

PS S1.1 Drive Motor

1700

Version no

T-code

000

395/396/397/398/399

2.7. Assembly 2.7.1. Field Coil Installation Good solder connections are important due to the vibration characteristics encountered by these motors which can cause cold or poorly soldered connections to break. 1. Prior to installing the field coils, the connections which require soldering should be buffed or wire brushed clean to remove any oxidation. The connections should then be tinned with a soldering iron. NOTE! We do not recommend using a soldering gun or torch. A soldering gun cannot provide the heat concentration required, and a soldering torch can damage the insulation. 2. After field coil installation, connect the solder joint, making sure the solder is flowing properly to avoid a cold soldered joint.

Pole Shoe Screw Removal & Installation (Field Coil Removal & Installation) Continue assembly in the reverse of disassembly, paying particular attention to the following points. 2.7.2. Bearing Installation 1. Whenever ball bearings are pressed into an end head or onto a shaft, always press against the race that is absorbing the pressure.

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Service Manual

1997-07-15

F-code

Section

C-code

S1.1

1700 Drive Motor

Version no

000

T-code

395/396/397/398/399

Press on the outer race when installing into end heads. Press against the inner race when installing onto a shaft. 2. End heads having slip-fit bearings are normally retained by a snap ring. Always install new snap ring(s). 2.7.3. After Assembly 1. The motor should be connected as specified in Troubleshooting, and tested to the specifications. 2. When testing motors, the voltmeter connections must be made at the motor terminals.

3. When Changing Brushes When changing brushes, the commutator must be serviced as follows: Resurface the commutator by taking only light cuts each time, 0.005 in. (0.12 mm). If reslotting/undercutting is necessary, the final operation is to lightly sand the commutator with a fine sandpaper to remove any burrs left from the undercutting operation.

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Service Manual

1997-07-15

F-code

Section

C-code

PS S1.1 Drive Motor

1700

Version no

T-code

000

395/396/397/398/399

Return

Service Manual

1997-07-15

F-code

PS Version no

001

Section

C-code

S3.0 3540 Caster Brake Assembly T-code

396/397/398

Caster Brake Assembly 1

2 3 5 25

4 6

24 23

7 9 17

10 11 12

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Service Manual

1997-07-15

F-code

Section

C-code

PS S3.0 3540 Caster Brake Assembly Version no

T-code

001

396/397/398

POS. NO

DESCRIPTION

POS. NO

Lock, nut

Nut

Washer

Lockwasher

Screw, cap

Ring, Nilos

Nut

Shaft

Bearing

Pivot, caster

Bracket

Screw, cap

Bearing, thrust

Bearing, flanged

Nut

Caster assembly

Pin, roll

Guide, spring

Block

Pivot

Spring

Fitting, grease

Screw, cap

Screw, set

Bushing

DESCRIPTION

POS. NO

DESCRIPTION

1. Removal NOTE! For models with brake on caster wheels.

1.1. Caster Brake Adjustment 1. Park the truck on a flat surface. 2. Disconnect the battery at the battery connector. Check to make sure the battery retainer plates are in place. 3. Jack the rear of the truck so the drive and caster wheels are approximately 1 in. off the ground. Block the truck in this position. 4. Looking into the operator's compartment, remove the four screws from the right-hand panel covering the logics card. Take panel out and set to the side.

CAUTION

Return

Service Manual

Pinch point. Keep fingers clear of floor board cutout while holding down left foot brake pedal.

1997-07-15

F-code

Section

C-code

S3.0 3540 Caster Brake Assembly

Version no

001

T-code

396/397/398

CAUTION Disconnect wire connections to right foot pedal switch prior to removal of floor board.

5. Push down on the left foot brake pedal with one hand and remove the floor board by pulling up and pivoting the plate toward the motor compartment. Release the left foot brake pedal as the floor board pivots up. 6. Remove floor board and set to the side. 7. Total travel of the left foot brake pedal from up to down is 3.5 in. The pedal setpoint is 50 percent down or 1.8 in. This can be felt by a change in force at the pedal by the spring tension.

Adjuster nuts

8. Loosen the adjuster nuts of the cable end at the caster assembly bell crank. Adjust the cable threaded end to allow for more engagement required by a worn brake. At the 50 percent pedal up position, the caster wheels should stop rotating due to the brakes making contact with the caster wheel drums. Rod

9. When the cable can no longer be adjusted for caster braking, the brake must be adjusted at the caster wheels.

Spring

10. Run the cable adjustment back to the original position. Full threads toward the caster assembly. 11. Remove only one caster wheel. Refer to caster wheel removal, section 3560. 12. Remove brake assembly for the caster wheel. 13. Adjust double nuts at the brake rod up or down by tightening brake arm. Check brake at 50 percent pedal up position. The caster wheel should stop rotating due to the brake starting to make contact with the drums.

Adjusting nuts

14. Lock the double nuts together. 15 Reassemble and test truck for braking. © BT Products

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Service Manual

1997-07-15

F-code

Section

C-code

PS S3.0 3540 Caster Brake Assembly Version no

T-code

001

396/397/398

Return

Service Manual

1997-07-15

F-code

Section

C-code

S3.1 3370 Electromagnetic Brake

Version no

T-code

000

395/396/397/398/399

Electromagnetic Brake 13

07 Air Gap 06

03 04 11 10

POS. NO

DESCRIPTION

POS. NO

DESCRIPTION

Brake assembly

Plate, mounting

Screw, socket head

Coil

Spacer

Screw

Armature

Spring

Nut, jam

Hub

Screw, socket head

Plate, friction

Washer

Return

Service Manual

DESCRIPTION

1997-07-15

F-code

Section

C-code

PS S3.1 3370 Electromagnetic Brake Version no

T-code

000

395/396/397/398/399

WARNING Magnetic coil and armature are under pressure. DO NOT remove retaining screws without manual release screws in place.

1. Installation 1. Park truck on level surface and block securely. 2. Disconnect the battery. 3. Fully tighten two manual release screws (11). WARNING Two manual release screws must be fully tightened before removing three brake retaining screws. 4. Remove the three screws (09) which hold brake parts and set aside, ensuring all parts are clean and dry. Avoid moving adjustable spacers (07) if possible, thus maintaining correct axial air gap when reassembled. 5. Secure the mounting plate (06) to the electric drive motor taking care to make sure the head of the screws (12) are recessed and do not protrude above the counter bore. 6. Secure the brake hub (04) to the motor shaft. It should not interfere with the mounting plate (06). 7. Slide friction plate (05) onto the hub spline and up to the mounting plate (06). 8. Hold the main body of the brake up to the mounting plate (06) and line up the screws (09). Carefully secure in place. 9. Once the brake is fully secured in position, remove and set aside the manual release screws (11). 10. Check the air gap and adjust if necessary (See adjustments instructions). 11. After making adjustments, check that brake will release when power is applied.

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Service Manual

1997-07-15

F-code

Section

C-code

S3.1 3370 Electromagnetic Brake

Version no

000

T-code

395/396/397/398/399

2. Adjustments 1. Adjustment is carried out by using a 14 mm open end wrench and a 6 mm socket key. 2. Loosen three retaining screws (09) to release the threaded spacers (07). NOTE! Do Not remove retaining screws. 3. Using the 14 mm open end wrench, the threaded spacers (07) can now be threaded in or out of the magnet which changes the relative position of the armature and end plate, thus changing the air gap. 4. The air gap should be set to 0.008 in. to 0.014 in. and be within 0.003 in. throughout entire circumference.

3. Coil Check On Brake

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Service Manual

•

24V coil at 70°F (20°C) should be 9 ohms

•

36V coil at 70°F (20°C) should be 22 ohms

1997-07-15

F-code

Section

C-code

PS S3.1 3370 Electromagnetic Brake Version no

T-code

000

395/396/397/398/399

4. Electromagnetic Brake, Armature and Magnetic Coil. 4.1. Removal WARNING Magnetic coil and armature are under pressure. Do not remove retaining screws without manual release screws in place. 1. Park truck on level surface and block securely. 2. Disconnect the battery. 3. Fully tighten two manual release screws (11). 4. Remove three brake retaining screws (09). 5. Electrically disconnect brake assembly and lift upwards to remove.

4.2. Installation 1. Make certain brake friction plate (05) and armature (03) are clean and free of oil. 2. Set armature (03) and magnetic coil (02) on base plate (06). 3. Align and tighten three brake retaining screws (09). 4. Remove two manual release screws (11) and electrically connect brake. 5. The air gap should be set to 0.008 in. to 0.014 in. and be within 0.003 in. throughout entire circumference. 6. Test operation of brake by connecting battery, turn key switch ON, and depress brake foot pedal. This will allow truck to operate.

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Service Manual

1997-07-15

F-code

Section

C-code

S3.2

3530 Drive Wheel

Version no

000

T-code

395/396/397/398/399

Drive Wheel 3 4

POS. NO

DESCRIPTION

POS. NO

DESCRIPTION

Tire

Nut

Wheel, drive

Washer, spherical

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Service Manual

1997-07-15

F-code

Section

C-code

PS S3.2 Drive Wheel

3530

Version no

T-code

000

395/396/397/398/399

2. Installation 1. Press drive tire on wheel hub. This is usually done while pressing off old tire. Press hub to center of tire (1). 2. Install drive tire assembly on transmission axle hub. The seven drive tire retaining nuts should be torqued to 95 ft-lb (130 N•m).

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Service Manual

1997-07-15

F-code

PS Version no

001

Section

C-code

S3.3 3540 Support / Swivel Wheel T-code

395/396/397/398/399

Support / Swivel Wheel 1

3 6 4 7 8 9

10 11 12 19 20

14 17 15 16

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Service Manual

1998-03-05

F-code

Section

C-code

PS S3.3 3540 Support / Swivel Wheel Version no

T-code

001

395/396/397/398/399

POS. NO

DESCRIPTION

POS. NO

DESCRIPTION

POS. NO

DESCRIPTION

Lock, nut

Spring

Caster assembly

Lockwasher

Screw, set

Block

Ring, Nilos

Nut

Fitting, grease

Bearing

Screw, cap

Bushing

Screw, cap

Nut

Washer

Nut

Pivot, caster

Screw, cap

Guide, spring

Bearing, thrust

1. Caster Pivot 1.1. Removal 1. Park the truck on a flat surface. 2. Disconnect the battery at the battery connector. Check to make sure the battery retainer plates are in place. 3. Jack the rear of the truck so the drive and caster wheels are approximately 1 in. [25.4 mm] off the ground. Block the truck in this position. 4. Looking into the operator's compartment remove the four screws from the right-hand panel covering the logics card. Take panel out and set to the side.

CAUTION

Pinch point. Keep fingers clear of floor board cutout while holding down left foot brake pedal.

CAUTION Disconnect wire connections to right foot pedal switch prior to removal of floor board. 5. Push down on the left foot brake pedal with one 100

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Section

C-code

S3.3 3540 Support / Swivel Wheel

Version no

001

T-code

395/396/397/398/399

hand and remove the floor board by pulling up and pivoting the plate toward the motor compartment. Release the left foot brake pedal as the floor board pivots up. 6. Remove floor plate and disconnect wires from right foot switch setting floor plate to one side. WARNING Secure transmission before removing mounting bolts (20). Serious injury could occur. 7. Turn and secure transmission so that you can access mounting bolts (20). NOTE! For models with brake on caster wheels, the cable linkage must be disconnected before removal of foot pedal. 12. Remove four bolts securing brake pedal assembly. 13. Remove foot pedal. 14. Bend lockwasher (2) tab down and remove lock nut (1). 15. Remove Nilos ring (3) and bearing (4). 16. Remove caster assembly. 17. Remove mounting bolts (20). 18. Remove caster pivot (13). Inspect and replace bushings and bearings as needed.

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PS S3.3 3540 Support / Swivel Wheel Version no

T-code

001

395/396/397/398/399

1.2. Installation 1. Install pivot block compartment first.

(16)

closest

battery

2. Install rear pivot block (16) on caster pivot (13). 3. Maneuver caster pivot (13) in place between frame . 4. Install caster assembly in caster pivot (13). NOTE! Make certain nilos ring and lockwasher are in correct position. 5. Torque locknut (1). 6. Bend tab on lock washer (2) up to secure lock nut (1). 7. Install foot pedal. NOTE! For models with brake on caster wheels, the cable linkage must be installed. 8. Set spring tension and stops. Refer to section 3540. 9. Install shielding and test truck operation.

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2. Thrust Bearing 2.1. Removal 1. Park the truck on a flat surface. 2. Disconnect the battery at the battery connector. Check to make sure the battery retainer plates are in place. 3. Jack the rear of the truck so the drive and caster wheels are approximately 1 in. [25.4 mm] off the ground. Block the truck in this position. 4. Look into the operator's compartment, remove four screws from the right-hand panel covering the logics card. Take panel out and set to the side. CAUTION Pinch point. Keep fingers clear of floor board cutout while holding down left foot brake pedal. CAUTION Disconnect wire connections to right foot pedal switch prior to removal of floor board. 5. Push down on the left foot brake pedal with one hand and remove the floor board by pulling up and pivoting the plate toward the motor compartment. Release the left foot brake pedal as the floor board pivots up. 6. Remove floor board and set to the side. NOTE! For models with brake on caster wheels, remove brake arm. 7. Bend tab down on lock washer (2). 8. Remove lock nut (1), lock washer (2) and Nilos ring (3). 9. Inspect and replace bearings as needed.

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PS S3.3 3540 Support / Swivel Wheel Version no

T-code

001

395/396/397/398/399

2.2. Installation 1. The truck must be properly blocked at this time. 2. Install race (4) in caster pivot and thrust bearing (14) on caster assembly. 3. Install caster assembly in caster pivot (13). 4. Install bearing (4), Nilos ring (3), lock washer (2) and lock nut (1). 5. Tighten lock nut (1) while turning caster wheel assembly until tight, then back off 1/4 in. [6.35 mm] turn. 6. Bend lock washer tab (2) up to secure lock nut (1). NOTE! For models with brake on caster wheels, install brake arm. 7. Test caster operation.

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3. Caster Springs 3.1. Removal 1. Park the truck on a flat surface. 2. Disconnect the battery at the battery connector. Check to make sure the battery retainer plates are in place. 3. Jack the rear of the truck so the drive and caster wheels are approximately 1 in. [25.4 mm] off the ground. Block the truck in this position. New Free Length is 7 in. [178 mm]

4. Look into the operator's compartment, remove four screws from the right-hand panel covering the logics card. Take panel out and set to the side. CAUTION Pinch point. Keep fingers clear of floor board cutout while holding down left foot brake pedal. CAUTION Disconnect wire connections to right foot pedal switch prior to removal of floor board.

Worn Free Length is 6.5 in. [165 mm] or Less.

5. Push down on the left foot brake pedal with one hand and remove the floor board by pulling up and pivoting the plate toward the motor compartment. Release the left foot brake pedal as the floor board pivots up. 6. Remove floor board and set to the side. 7. Remove right-hand side electronics panel cover. 8. Loosen jam nuts (6) and release all spring tension with adjusting bolts (5). Remove bolts (5). 9. Remove jam nut (10) and loosen stop bolt (9) to allow caster pivot to rest on frame stop. 10. Springs must be removed from the side.

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PS S3.3 3540 Support / Swivel Wheel Version no

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001

395/396/397/398/399

3.2. Installation 1. Install adjusting bolts (5). 2. Lower truck to the floor and remove hoist. 5-3/8 in.

3. Tighten adjusting bolts (5) until you have 5-3/8 in. [136.5 mm] from top of cap and bottom of spring. 4. Adjust stops bolts (11) and (9) to 1/8 in. [3 mm] clearance on each stop. CAUTION Pinch point. Keep fingers clear of floor board cutout while holding down left foot brake pedal. CAUTION Disconnect wire connections to right foot pedal switch prior to removal of floor board. 5. Push down on the brake pedal with one hand and install the floor board by pushing down and pivoting the plate toward the motor compartment. Release the brake pedal as the floor board pivots down. 6. Test truck operation.

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S3.3 3540 Support / Swivel Wheel

Version no

001

T-code

395/396/397/398/399

4. Caster Spring 4.1. Adjustments 1. Park truck on level surface. 5-3/8 in.

2. Disconnect battery and securely block truck. 3. Remove right-hand side electronics panel cover. 4. Measure from top of springs to the caster pivot plate. The measurement should be 5-3/8 in. [136.5 mm]. 5. To change adjustment, loosen jam nuts (6) and tighten or loosen bolts (5).

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PS S3.3 3540 Support / Swivel Wheel Version no

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001

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5. Caster Stops 5-3/8 in.

5.1. Adjustment 1. Park truck on level surface and disconnect battery. 2. Remove four cap screws securing right side A5 logic card panel cover. 3. Remove floor plate, and disconnect wiring harness to right side foot pedal switch. 4. Spring compression from caster pivot plate to top of spring spacer must measure 5-3/8 in. [136.5 mm]. If not adjust spring bolts accordingly. NOTE! Spring compression measurement must be taken when stop bolts are not touching stop blocks. Stop Bolt

5. Factory recommended dimension between upper stop bolt (11) and upper stop block is 1/4 in. [6.35 mm], however it is possible to increase this dimension to 3/8 in. [9.5 mm] on some models. See chart to determine maximum dimension between upper stop bolt (11) and upper stop block for your particular truck. CAUTION

Verify battery compartment size, battery weight, and mast height. Failure to do so could result in serious injury.

Mast Height Battery Compartment 14 in. [356 mm] Minimum 1600 lb battery 16 in. [406 mm] Minimum 2000 lb battery 21 in. [533 mm] Minimum 2400 lb battery 21 in. [533 mm] Minimum 2600 lb battery

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192

210

240

270

300

330

3/8 in.

1/4 in.

3/8 in.

1/4 in. 1/4 in.

Service Manual

360

402

1/4 in.

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S3.3 3540 Support / Swivel Wheel T-code

395/396/397/398/399

6. Dimension between bottom stop bolt (9) and bottom stop block must be 1/8 in. [3 mm]. 7. Install floor plate and connect wiring harness to right side foot pedal switch. 8. Install A5 logic card panel cover. 9. Connect battery and test truck operation.

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001

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110

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S3.4 3550 Tandem Load Wheels

Version no

000

T-code

395/396/397/398/399

Tandem Load Wheels

POS. NO

Return

DESCRIPTION

POS. NO

DESCRIPTION

Axle

Washer, 16 gauge

Toe box

Bearing

Plate, rocker

Wheel, load

Ring, retainer

Nut

Fitting, grease

Bolt, shoulder

Washer, 10 gauge

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PS S3.4 Tandem Load Wheels

C-code

3550

Version no

T-code

000

395/396/397/398/399

1. Removal 1. Park the truck on a flat surface. 2. Disconnect the battery at the battery connector. Check to make sure the battery retainer plates are in place. 3. Hoist machine so load wheels are approximately 2 in. off the floor, and securely block. 4. Remove retainer ring (4) from axles. 5. Remove axle (1) and load wheel assembly from toe box (2). 6. Inspect bearings (8). 7. Install new load wheel (9) and bearings (8) as needed.

WARNING Install bearing shield and 10 gauge spacer properly. 8. Install load wheel assembly in toe box (2). Install axle (1) and rocker plate (3). 9. Install retainer rings (4) to axle (1).

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S3.5 3551 Single Load Wheels

Version no

000

T-code

395/396/397/398/399

Single Load Wheels

POS. NO

Return

DESCRIPTION

POS. NO

DESCRIPTION

Toe box, right

Toe box, left

washer, 10 gauge

Fitting, grease

Washer, 18 gauge

Nut

Bearing

Bolt, shoulder

Tire, load

Nut

Wheel

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PS S3.5 Single Load Wheels

C-code

3551

Version no

T-code

000

395/396/397/398/399

1. Removal 1. Park the truck on a flat surface. 2. Disconnect the battery at the battery connector. Check to make sure the battery retainer plates are in place. 2. Hoist machine so load wheels are approximately 2 in. off the floor, and securely block. 3. Remove toe box retaining nuts (9) and bolts (10). 4. Remove axle nut (11). 5. Remove right toe box (1) and load wheel (6). 6. Press load tire (5) from wheel (6).

WARNING

Install bearing shield and 10 gauge spacer properly.

2. Installation 1. Inspect and replace bearing (4) as needed. 2. Press load tire (5) on wheel (6). 3. Install load tire assembly on toe box axle. 4. Install right toe box (1). 5. Install axle nut (11). 6. Install toe box assembly on support arm. Apply loctite #242 to nuts (11) and bolts (10). 7. Test operation of load wheel and truck.

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S3.6 3560 Caster Wheels

Version no

C-code

T-code

000

395/398

Caster Wheels 1

4 1

5 6

6 5

7 8

10 9

POS. NO

Return

DESCRIPTION

POS. NO

DESCRIPTION

Wheel, caster

Bearing

Bracket, caster

Lockwasher

Screw, set

Locknut

Axle, caster

Fitting, grease

Ring, Nilos

Cap, wheel

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C-code

PS S3.6 Caster Wheels

3560

Version no

T-code

000

395/398

2. Installation 1. Install Nilos ring (5) on axle. 2. Install caster wheel assembly. 3. Install Nilos ring (5), lockwasher (7) and axle nut (8). 4. Tighten axle nut (8) while turning caster wheel until wheel becomes tight. 5. Back off axle nut (8) until caster wheel turns freely. Axle nut (8) and lockwasher (7) tab are aligned. 6. Bend lockwasher (7) tab to secure axle nut (8). 7. Grease as needed. 8. Replace wheel cap (10).

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S3.6 3560 Caster Wheels

Version no

000

C-code

T-code

395/398

3. Caster Axle 3.1. Removal 1. Remove caster wheels. 2. Remove two set screws (3). One set screw locks the other in place. 3. Tap axle (4) out of caster bracket (2).

3.2. Installation 1. Install caster axle (4) in caster bracket (2). 2. Align setscrew holes. 3. Install set screws (3). 4. Install caster wheels.

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C-code

PS S3.6 Caster Wheels

3560

Version no

T-code

000

395/398

118

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Section

S3.7 3560 Caster Wheels

Version no

C-code

T-code

000

396/397/399

Caster Wheels 18

15 11

12 15 14 3 4

11 12 13

1 6 6

8 9

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PS S3.7 Caster Wheels

3560

Version no

T-code

000

396/397/399

POS. NO

DESCRIPTION

POS. NO

DESCRIPTION

POS. NO

DESCRIPTION

Wheel, caster

Lockwasher

Screw, cap

Bracket, caster

Locknut

Nut

Screw, set

Fitting, grease

Washer

Axle, caster

Cap, wheel

Pivot, brake

Ring, Nilos

Ring, E

Spring

Bearing

Brake assembly

Plunger, brake

1. Removal 1. Park the truck on a flat surface. 2. Disconnect the battery at the battery connector. Check to make sure the battery retainer plates are in place. 3. Jack the rear of the truck so the drive and caster wheels are approximately 1 in. off the ground. Block the truck in this position. 4. Remove wheel cap (10) 5. Bend lockwasher (7) tab down and remove axle nut (8). 6. Remove caster wheel assembly 7. Inspect and replace race and bearing (6) as needed 8. Remove E ring (11) and remove cap screws (13) if brake assembly is to be replaced otherwise replace brake shoes. 9. Remove nuts (14), washer (15), and slide brake plunger (18) up to remove brake pivot (16) and other washer (15). 10. Remove brake plunger (18) and spring (17).

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2. Installation 1. Slide spring (17) in caster bracket (2) and install brake plunger (18). 2. Install washer (15) on brake plunger (18) and slide brake pivot (16) on brake plunger (18) against washer (15). 3. Install second washer (15) on brake plunger against brake pivot (16). Secure assembly together with nut (14) and install a second nut (14) to lock in place. 4. Install brake assembly (12) with cap screws (13). 5. Move brake pivot (16) around to install E ring (11) on both brake assembles (12). 6. Install Nilos ring (5) on axle. 7. Install caster wheel assembly. 8. Install Nilos ring (5), lockwasher (7) and axle nut (8). 9. Tighten axle nut (8) while turning caster wheel until wheel becomes tight. 10. Back off axle nut (8) until caster wheel turns freely. Axle nut (8) and lockwasher (7) tab are aligned. 11. Bend lockwasher (7) tab to secure axle nut (8). 12. Grease as needed. 13. Replace wheel cap (10).

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PS S3.7 Caster Wheels

3560

Version no

T-code

000

396/397/399

3. Caster Axle 3.1. Removal 1. Remove caster wheels. 2. Remove two set screws (3). One set screw locks the other in place. 3. Tap axle (4) out of caster bracket (2).

3.2. Installation 1. Install caster axle (4) in caster bracket (2). 2. Align setscrew holes. 3. Install set screws (3). 4. Install caster wheels.

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PS S4.0 4110 Steering Arm / Wheel / Lever Version no

000

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Steering Arm / Wheel / Lever

POS. NO

DESCRIPTION

POS. NO

DESCRIPTION

POS. NO

Panel, lower pod

Ring, retainer

Console

Panel, upper pod

O ring

Arm

Screw

Spacer / bearing

Lever, adjusting

Washer, spring

Housing, bearing

O ring

Nut

Ring

Screw, set

Cap, spinner

Screw

Coupler

Nut

Motor, tach

Washer

Bolt, carriage

Screw / wave washer

Spinner

Washer

Grip, hand

Steering wheel

Lever assembly

Cushion

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DESCRIPTION

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PS S4.0 4110 Steering Arm / Wheel / Lever Version no

T-code

000

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1. Control Pod 1.1. Removal 1. Park truck on level surface. 2. Disconnect battery and block truck. 3. Remove adjusting lever (33) and washer (49). 4. Remove console cover. 5. Lift console (31) approximately 6 in. to access controls pod's wiring harness connectors. 6. Disconnect harness and remove control pod.

1.2. Installation 1. Route control pod wiring harness through console (31). 2. Connect control pod harness to truck’s main wiring harness. 3. Install console (31) cover. 4. Install adjusting lever (33) and washer (49).

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2. Steering Wheel 2.1. Removal 1. Park truck on level surface. 2. Disconnect battery and securely block truck. 3. Remove control pod. Refer to Control Pod 1.1 Removal. 4. Remove sixteen screws (53) on lower control pod panel (11) and remove lower panel (11). 5. Remove four screws (26). 6. Remove steering wheel (20). Inspect and replace bearing as needed.

2.2. Installation 1. Install steering wheel (20) in upper control pod panel (12). 2. Align holes on steering wheel mount and install four screws (26). Check steering wheel for ease of turning. 3. Install lower control pod panel (11) and install sixteen screws (53). 4. Install control pod. Refer to Control Pod 1.2 Installation. 5. Test operation of steering wheel (20) and truck.

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3. Steering Tach 3.1. Removal 1. Park truck on level surface 2. Disconnect battery and securely block truck. 3. Remove control pod. Refer to Control Pod 1.1 Removal. 4. Remove sixteen screws (53) and remove lower control pod panel (11). 5. Remove steering wheel (20). Refer to Control Pod 1.2 Installation. 6. Loose setscrew (47) and remove coupler (48). 7. Remove four screws (26) holding tach motor (27) and electrically disconnect steering tach motor (27) wires from wiring harness.

3.2. Installation 1. Connect steering tach motor (27) wires from wiring harness. 2. Install steering tach motor (27) and secure with four screws (26). 3. Install coupler (48) and tighten set screw (47). 4. Install steering wheel (20). Refer to Steering Wheel 2.2 Installation. 5. Install lower control pod panel (11) and tighten sixteen screws (53). 6. Install control pod. Refer to Control Pod 1.2 Installation.

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S4.1 4180 Steering Bearing

Version no

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000

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Steering Bearing 12 11 1

POS. NO

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Bearing

Screw

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4180

Version no

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1. Removal NOTE! Transmission and drive motor must be removed from truck to access bearing.

1. Park the truck on a flat surface. 2. Disconnect the battery at the battery connector. Check to make sure the battery retainer plates are in place. 3. Jack the rear of the truck so the drive and caster wheels are approximately 1 in. off the ground. Block the truck in this position. 4. Remove door and left-side panel to access motor compartment. Refer to Section S0.1. 5. Disconnect all electrical connections on drive motor and brake assembly. 6. Remove drive motor. 7. Secure transmission and remove six mounting bolts. 8. Remove mounting ring. 9. Remove fivteen bolt (11) retaining 360 degree bearing (1).

2. Installation 1. Install new steer bearing (1). 2. Install transmission mounting plate and transmission in truck and torque six mounting bolts. 3. Install drive motor. 4 Connect all electrical connections. 5. Refill transmission as needed. 6. Test steering and truck operation.

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S5.0 5000 Electrical Functions T-code

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Electrical Functions 1. Operating Description The main electronic card (A5) contains a microprocessor. This microprocessor monitors the state of switches, sensors, joysticks (mast and fork functions), and other input devices. A5 The microprocessor makes decisions based on this information. Output devices that the microprocessor controls are solenoids, contactors, drives, and optional equipment to customize the truck. The microprocessor’s programming parameters can be customized for each application. Two of the parameters that can be customized are the clock and calendar. The microprocessor has an internal battery with a ten year life span that can store the customized parameters in memory when the truck’s battery is disconnected. The microprocessor performs a diagnostic test at start up and during truck operation. The diagnostic test assists in repair by identifying problems and minimizing truck downtime. For any identified problems, the operator is alerted by a visible tool bar icon displaying error code numbers and an audible alarm. A history log records error codes by the time and day, using the clock and calender information stored in the microprocessor. The controller card is connected to the truck circuitry by eight connectors. To remove the controller card’s eight connections depress the connector’s latch and disconnect or simply pushing the connectors back together. The eight connectors are grouped functionally from the top down: digital inputs, communications, analog inputs, analog outputs, digital outputs and power output. The controller card’s eight connectors and light emitting diodes (LEDs) are clearly identified by numbers. When the controller card is connected correctly to the truck’s battery, the digital input LEDs light green and battery voltage is present at input pins. The digital output LEDs light red and battery voltage is present at output pins. The communications and analog voltage inputs and outputs do not have LEDs.

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PS S5.0 Electrical Functions

5000

Version no

T-code

001

395/396/397/398/399

K10

A1 F01

B+

2 A1 K13 M1 K13

44 S21 101

902

K11 K11 8

M 1

805

Y01

802

K11

803

K13

1 F50

S48

808 501 111

S23

102

36V only 21

S21

S17

22 22

809 40

Legend Battery negative Battery positive LED OFF (Not lit) LED input (lit) LED output (lit)

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S5.0 5000 Electrical Functions T-code

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2. Start Up Electricity from truck’s battery flows to drive motor transistor regulator (A1, terminal B-), and also to main electronic card (A5, terminal 902) through wire #40. By closing the emergency disconnect switch (S21) and key switch (S17), electricity can flow through control circuit fuse (F50) and to main electronic card (A5, terminal 809). Electricity is also supplied to main electronic card (A5, terminal 808). Trucks with a 36-volt electrical system have a jumper from terminal 808 to terminal 501 on main electronic card (A5), lighting the LED. Electricity flows through wire #22 to drive motor transistor regulator (A1, terminal 1) starting the internal safety test. Output from drive motor transistor regulator (A1, terminal 7) is sent through wire #34 to main electronic card (A5, terminal 101), lighting the LED. Electricity flows through wire #34 to the emergency disconnect switch (S21) and out through wire #44 to main contactor coil (K10). This closes contactor tips. Closing main contactor tips allows electricity to flow through drive motor fuse (F01) to drive motor transistor regulator (A1, terminal B+). Electricity is also available at drive motor transistor regulator (A1, terminal A).

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PS S5.0 Electrical Functions

5000

Version no

T-code

001

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K10

A5 44

F01 3

B+

2 A1 K13 M1

S21 101

902

K11

K13

K11 8

M 1

805 29

R01

50 30

F50

Y01

505 +3.7V

K11

510 0V 802 803 808

K13

504 +7.4V

36V only S48 43

S23 S21

S17

R02

Legend

111

49 22

501

102 809 40 511

Battery negative Battery positive LED OFF (Not lit) LED input (lit) LED output (lit)

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3. Direction Selection

4 2 3 7 8 5 6 9 0

CAUTION Releasing parking brake and accidentally moving direction/speed joystick to the right causes unexpected truck travel.

After each initial start up, a travel direction must be selected. The default travel direction is always forks first. Moving direction/speed control potentiometer (R01) to the left approximately 3/16 in. will select the next travel direction. Moving direction/speed control potentiometer (R01) to the left will decrease voltage from 3.7 volts to approximately 3 volts. The lower voltage sends current from main electronic card (A5, terminal 802) to direction contactor (K11), opening the normally closed tips and closing the normally open tips, lighting the main electronic card (A5) 802 LED. An electrical path is available for current to flow from drive motor field (M1) to drive motor transistor regulator (A1, terminal M) The brake transducer (R02) is activated by depressing the pedal. NOTE! The brake transducer is a potentiometer with variable resistants.

The decrease in voltage from the transducer (R02) to main electronic card (A5, terminal 511), and input from brake switch (S48) to main electronic card (A5, terminal 111) will send current from main electronic card (A5, terminal 805) to parking brake coil, lighting the main electronic card (A5) 805 LED. NOTE! The direction contactors are shown closing with direction selection for training purposes. They actually fully close when direction/speed control potentiometer (R01) is moved to the right for acceleration. © BT Products

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PS S5.0 Electrical Functions

5000

Version no

T-code

001

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K10

A5 44

F01 3

B+

2 A1 K13 M1 K13

K11

6 10

S21 101

902

609-

610 +0-5V

K11 8

M 1

805

Y01

802

K11

803

K13

1 F50

808 501

36V only 21

S21

S17

22 29 R01

50 30

809 504 +7.4V

505 +3.7V 510 0V

Legend Battery negative Battery positive LED OFF (Not lit) LED input (lit) LED output (lit)

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4. Reverse Direction Selection CAUTION

Avoid crushing feet by keeping feet clear of the drive wheel while steering.

Moving direction/speed control potentiometer (R01) again to the left approximately 3/16 in. will select the next travel direction. Moving direction/speed control potentiometer (R01) to the left will decreases voltage from 3.7 volts to approximately 3 volts. The lower voltage to main electronic card (A5) sends current from terminal 803 to direction contactor (K13), closing the normally open contact tips and opening the normally closed tips, lighting the main electronic card (A5) 803 LED. An electrical path is available for current to flow from drive motor field (M1) to drive motor transistor regulator (A1, terminal M). NOTE! The direction contactors are shown closing with direction selection for training purposes. They actually fully close when direction/speed control potentiometer (R01) is moved to the right for acceleration.

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K10

A1 3

B+

B-

S21

2 K13 M1

K11

K13

101

A5 44

F01

902

609-

610 +0-5V

K11 8

M 1

805

Y01

802

K11

803

K13

1 F50

808 36V only

501

811810+ S21

S17

22 29 50 R01 S64

30 56

809 504 +7.4V

505 +3.7V 510 0V 201

Legend Battery negative Battery positive LED OFF (Not lit) LED input (lit) LED output (lit)

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5. Forward Drive This diagram shows forward travel and the relationship between speed reference voltage and direction/speed control potentiometer’s (R01) voltage. The forward travel speed reference voltage is 0 - 5 volts and direction/speed control potentiometer’s (R01) voltage is 3.7 6.5 volts. When moving direction/speed control potentiometer (R01) to the right, voltage increases to a maximum of 2.5 volts. For every 0.5 volt increase of the direction/speed control potentiometer (R01), the speed reference will increase 1 volt. The speed reference voltage is the main electronic card (A5, terminal 610) to drive motor transistor regulator (A1, terminal 10) through wire #36. Wire #35 is connected to drive motor transistor regulator (A1, terminal 6) and main electronic card (A5, terminal 609) is the negative for the speed reference voltage. The speed sensor (S64) is sending pulses to the main electronic card (A5, terminal 201) to determine drive motor speed.

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K10

A5 44

F01 3

B+

B-

S21

7 2

A1 K13 M1 K13

K11

902

K11

101

609-

610 +0-5V

103

M 1

805

Y01

802

K11

803

K13

32 31 S125

F50

105

36V only 32

31 S21

S17

22 29

50 R01

S64

Legend

808 501 811810+ 809 504 +7.35V

505+3.7V 510 0V 201

Battery negative Battery positive LED OFF (Not lit)

65 30

R02

511

LED input (lit) LED output (lit)

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6. Plug Braking CAUTION Releasing parking brake while on incline will couse truck to move. A momentary movement left of the directional/speed control potentiometer (R01) causes the main electronic card (A5) to de-energize the forward contactor (K11) and energize the reverse contactor (K13), lighting the main electronic card (A5) 805 LED. The drive motor transistor regulator (A1) reads the signal from the drive motor armature EMF generator, located on top of drive motor. Electricity from the drive motor transistor regulator (A1, terminal 8) flows to the main electronic card (A5, terminal 103) through wire #38 indicating plug braking, lighting the main electronic card (A5) 103 LED. Plug braking may be regulated with the direction/speed control potentiometer (R01). Moving to the right will increase plugging. There is a second plug brake available on this truck. This second plug brake uses a drive motor direction sensor (S125), drive motor speed sensor (S64), and a brake transducer (R02). To use the second plug brake, raise the brake pedal approximately 1 in. This causes a decrease in voltage at brake transducer (R02) to main electronic card (A5, terminal 511) through wire #65. The drive motor direction sensor (S125) tells the main electronic card (A5, terminal 105) which direction the drive motor is rotating. This information is then processed and the opposite directional contactor closed. Located on top of the drive motor, the drive motor transistor regulator (A1, terminal A) reads the signal from the drive motor armature EMF generator. Electricity from the drive motor transistor regulator (A1, terminal 8) flows to main electronic card (A5, terminal 103) through wire #38 indicating plug braking, lighting the main electronic card (A5) 103 LED. © BT Products

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The drive motor speed sensor (S64) tells the main electronic card (A5, terminal 201) how fast the drive motor is rotating. During this phase, the main electronic card (A5) takes over all speed control, ignoring any information from the directional/ speed control potentiometer (R01). To regain control of direction/speed control potentiometer (R01), the brake pedal must be fully depressed again.

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203 A

S66 32 59

S67

204 B

57 S65

202 180°

902 (0V) F51 25

1 60 M6

901 903 +

Legend

Battery negative Battery positive LED OFF (Not lit)

904 -

62 503 IN U1

G 63

LED input (lit)

502 IN

LED output (lit)

7. Steering Componets This diagram covers the channel “A” steering wheel sensor (S66), channel “B” steering wheel sensor (S67), 180 degree steering wheel sensor (S65), fuse (F51), steer motor (M6), steering tachometer (U1), and main electronic card (A5). Electrical power for steer motor (M6) and steering tachometer (U1) is supplied through wire #1 to fuse (F51) and through wire #25 to main electronic card (A5, terminal 901). The channel “A” steering wheel sensor (S66), channel “B” steering wheel sensor (S67), and 180 degree steering wheel sensor (S65) receive directional information from drive gear rotation. © BT Products

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A5 56

S64 +12V (-)

201

S66

203 A

32 59

S67 22

S65

40 F51

60 M06

204 B

202 180° 902 (-) 901 903 (+)

Legend

61 Battery negative Battery positive LED OFF (Not lit)

62 U01

503 IN

G 63

LED input (lit)

904 (-)

502 IN

LED output (lit)

8. 12-Volt Power Supply This diagram covers the common 12-volt power supply produced by main electronic card (A5) to drive motor speed sensor (S64), channel “A” steering wheel sensor (S66), and channel “B” steering wheel sensor (S67). The 180 degree sensor requires battery voltage to operate.

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S31

A5 22 79

Legend

Battery negative Battery positive LED OFF (Not lit)

R01 32

LED input (lit)

31 S64

30 56

809 107

504 +12V 505 510 0V 201

LED output (lit)

9. Driving speed reduction switch This diagram covers the driving speed reduction switch(S31). Driving speed reduction switch (S31) operates when forks are raised above freelift height. This closes the circuit and allows electricity to the main electronic card (A5, terminal 107) through wire #79, lighting the main electronic card (A5) 107 LED. Main electronic card (A5) processes the information that is received from the drive motor speed sensor (S64) to determine the speed on the drive motor rotation. Using this information, the main electronic card (A5) reduces the overall truck speed to a pre-programmed value. © BT Products

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A8 3+

4 0V

-2 A5 A7 +7

-3

6 0V

+1 -5

S45

125

405 +

126 402 127 128

403 + 404 -

106 207

U10 +

205 A

206 B

Legend Battery negative Battery positive LED OFF (Not lit) LED input (lit) LED output (lit)

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10. Height Indicator and Preset Selector 10.1. Height Indicator This diagram covers the interface between the height counter (U10) (a pulse sensor), main electronic card (A5), and back to the height indicator (A8) (a digital display of fork height). Raising the forks to and above freelift height closes mast upper position switch (S45) allowing electricity to flow to main electronic card (A5, terminal 207) through wire #106, lighting the main electronic card (A5) 207 LED. A pulsed signal is sent by the height counter (U10) to main electronic card (A5, terminal 205 and 206). This information is then processed and sent out main electronic card (A5, terminal 405 and 402) through wire #125 and #126 to the height indicator (A8).

10.2. Height Preset Selector This diagram also covers the height preset selector (A7). The height preset selector (A7) works with the same information supplied to the height indicator (A8) from the main electronic card (A5), with the exception of height programmable reference points (fork heights). Once the fork height stop positions are entered in the height preset selector (A7), fork heights can be selected at any time. After lifting forks to the selected fork height, the height preset selector (A7) allows electricity to flow to main electronic card (A5, terminal 403 and 404) through wire #127 and #128, disabling the lift for a brief period of time. Once the program has been executed, the lift/lower resumes normal operation. The height preset selector (A7) has 99 possible fork height positions.

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K10

K10 A5

A1 44 3

SA2

B+

B-

S21 101

902

M 2 SA1 K13

K11 M1

K13

K11 8 M 802 41

208

K11

K13

803

42 209

Legend Battery negative Battery positive LED OFF (Not lit) LED input (lit) LED output (lit)

11. Drive Motor Brush Indicator Switch This diagram covers the drive motor brush indicator switches (SA1 and SA2). These switches indicate when drive motor brushes need replacing by displaying the error code on the dash display. These switches will not disable travel or lift on this truck, but brushes should be inspected or replaced. When brushes are worn and require servicing, the drive motor brush indicator switches (SA1 and SA2) close the circuit and allow electricity to the main electronic card (A5, terminal 208 and/or 209) through wire #41 and #42, lighting the main electronic card (A5) 208 and/or 209 LED.

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F03

M03A SA2

M03F

B+

B-

SA1 A5

Legend

210

Battery negative Battery positive 78

LED OFF (Not lit)

211

LED input (lit) LED output (lit)

12. Pump Motor Brush Indicator Switch This diagram covers the pump motor brush indicator switches (SA1 and SA2). These switches indicate when pump motor brushes need replacing by displaying the error code on the dash display. These switches will not disable travel or lift on this truck, but brushes should be inspected or replaced. When brushes are worn and require servicing, the pump motor brush indicator switches (SA1 and SA2) close the circuit and allow electricity to the main electronic card (A5, terminal 210 and/or 211) through wire #77 and #78, lighting the main electronic card (A5) 210 and/or 211 LED. © BT Products

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K10

A1 3

B+

M01

2 A1

S21 34

101 902

K11

K13 M01 K13

K11 8

Legend Battery negative Battery positive LED OFF (Not lit) LED input (lit) LED output (lit)

13. Safety Check This diagram covers the safety check on the main electronic card (A5) . Once a year a safety check of the system must be done . The safety check is done by turning the key switch “ON”, placing a jumper from drive motor transistor regulator (A1, terminal B-) to drive motor transistor regulator (A1, terminal 2). The jumper will cause the line contactor (K10) to open and confirm that the safety circuit is in operating condition.

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Shunt Wire

A5 606 607

608

606 -(+) 607 -(-)

608 +

Legend Battery negative Battery positive LED OFF (Not lit) LED input (lit) LED output (lit)

14. Shunt Wire The shunt measures the + and - voltage on the negative side for battery indication. This is a special length of wire and must be replaced with the correct parts for proper operation.

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Symbol

Designation

Function

Transistor regulator

Drive motor

Transistor regulator

Pump motor

Electronic card

Main card

Electronic card

Display

Electronic card

Height preset

Electronic card

Height indication

A22

Key Pad

Coded access

Battery

Capacitor

Suppressor H

Fuse

Drive motor

250 Am

Fuse

Pump motor

24V-425A 36V-355A

Fuse

(2) 250 Amp fuses

RRX45/RDX30/ RSX50 only

F50

Fuse

Control circuit

10 Amp

F51

Fuse

Steering motor

30 A

Horn

K10

Contactor

Main contactor

K11

Contactor

Driving in direction of forks

Forward

K13

Contactor

Driving in direction of operator

Reverse

K34

Contactor

Bypass lift

RRX45/RDX30/ RSX50 only

150

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Symbol

Designation

Function

Motor

Drive motor

Motor

Pump motor

Motor

Steering motor

M11

Fan

Drive motor

M12

Fan

Electronics

Potentiometer

Speed control, travel direction

Potentiometer

Brake transducer

Resistor

R11

Potentiometer

Speed control, fork lift/lower

R12

Potentiometer

Speed control, reach in/out

R13

Potentiometer

Speed control, tilt

R14

Potentiometer

Speed control, sideshifter

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Symbol

Designation

Function

S17

Switch

Key

S18

Switch

Horn

S21

Switch

Emergency stop

S23

Switch

Right foot

S28

Switch

Travel direction

S31

Switch

Speed reduction, driving

S32

Switch

Lift limit

S33

Switch

Lift limit override

S45

Inductive sensor

Mast, upper position

S48

Switch

(Left foot) Brake switch

S64

Inductive sensor

Drive motor speed

S65

Inductive sensor

Steering wheel sensor, 180°

S66

Inductive sensor

Steering wheel sensor, channel A

S67

Inductive sensor

Steering wheel sensor, channel B

S125

Inductive switch

Drive motor direction

SA1

Switch

Carbon brush indicator, drive/pump motor (-)

SA2

Switch

Carbon brush indicator, drive/pump motor (+)

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Symbol

Designation

Function

Zener diode

Voltage regulator

Tachometer

Steering

U10

Pulse sensor

Height counter

Connectors

Brake coil

Parking brake

Y10/2

Valve

Lift of forks

Y10/3

Valve

Proportional valve, lower of forks

Y12

Valve

Direction A

Y13

Valve

Direction B

Y14

Valve

Reach out

Y15

Valve

Reach in

Y16

Valve

Sideshifter

Y17

Valve

Tilt

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Component Location (Figure 1 of 2) K11

K10

4 2 3 7 8 5 6 9 0

S17

R14

U01

R12 R13

2 3

R11

K13

S28 K34

1 2 3 4

F01 F03

K10 K11

K13

Y14

Y15 Y17

Y16

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Component Location (Figure 2 of 2) Y12

M03

S64

Y13 A5

S18 Y01 M11 F50 F51

M01

M06

S48

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Sh. = Sheet or page of Diagram First number = Previous page wire was found. Second number = Next page wire is found.

Legend

15. Circuit Diagram 1(11)

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Legend

16. Circuit Diagram 2(11)

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Legend

17. Circuit Diagram 3(11)

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Legend

18. Circuit Diagram 4(11)

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Legend

19. Circuit Diagram 5(11)

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Sh. = Sheet or page of Diagram First number = Previous page wire was found. Second number = Next page wire is found.

Legend

20. Circuit Diagram 6(11)

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Legend

21. Circuit Diagram 7(11)

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Legend

22. Circuit Diagram 8(11)

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Legend

23. Circuit Diagram 9(11)

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Legend

24. Circuit Diagram 10(11)

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Legend

25. Circuit Diagram 11(11)

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Transistor Regulator

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1. Motor Connections The transistor regulator has four connections for power cables, as set out in the table below. Terminal Number

Function

Brake diode to the motor's series field and armature

B-

Battery minus

B+

Battery plus

Minus connection to the motor's series field

1.1. Connections for controls Terminal Connection Number 1

Supply voltage

Safety test

7 1

168

Return

Function

Not used

Common connection B -

Negative speed/current reference

Safety signal for main contactor

Plug braking

Stabilizing voltage 13,5 V

7 8 9

Reference value 0-5 V

Current limit 0-5 V

LED No.

Color

10 11

Green

Supply voltage

Yellow

Upper/lower temperatur

Red

Fault in power circuits

Red

Fault in reference value circuit

3 4 6

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2. Safety Control 2.1. Checking Transistor Regulator’s Safety Circuits. This check applies to all BT trucks equipped with a transistor regulator type. 1. Jack up the truck. 2. Block truck securely.

WARNING The truck can overturn. Risk of great personal injury and damage to property. Ensure the truck is stable and that the drive wheel does not have contact with the ground. 3. Remove control pod and console cover.

71 7 8 9 10 11

4. Reinstall control pod.

1 2 3 4 5 6

5. Turn the key switch so that the electronic card is on. 6. Connect jumper wire between the battery negative (B-) (1) and the contact for the control current (pin number 2) on the transistor regulator. The main contactor, K10, should now open to indicate that the transistor regulator’s safety system is functioning. If K10 does not open, replace the entire transistor regulator.

7. Reset the safety circuits by turning the ignition key to the OFF position. 8. Return the truck to its original condition after the check.

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Electronic Card

101 to 111

201 to 211

301 to 304

402 to 405

501 to 511

601 to 611

701 to 710

801 to 811

901 to 904

Terminal Locations

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

172

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Terminal Number

LED no.

101

Drive chopper - OK

102

Right foot switch

103

Plug braking

104

Drive, change direction

105

Drive direction

106

Lift limit override

107

Speed reduction

111

Brake switch

LED No.

Color

Function

Green

Height indication/height preset--TX, transmits data

Green

Height preset--RX, receives data

Terminal Number

LED no.

Connection

201

Drive measuring

202

Steering wheel reference 180°

203

Steering angle A

204

Steering angle B

205

Height counter A

206

Height counter B

207

Height reference

208

Brush wear indicator -

209

Brush wear indicator +

210

Brush wear indicator -

211

Brush wear indicator +

Connection

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Terminal Number

Connection

Function

302

Display power -

303

TX positive display

304

TX negative display

Connection

Function

402

TX negative height unit

403

RX positive height unit

404

RX negative height unit

405

TX positive height unit

Terminal Number

LED No.

501

Connection

Function

24/36 Volt select

502

Steering/tach +

503

Steering/tach -

504

Positive 7.35 V

505

Speed reference value

506

Lift/lower potentiometer

507

Reach/retract potentiometer

508

Tilt potentiometer

509

Sideshifter potentiometer

511

395/396/397/398/399

Display power +

510

Return

T-code

301

Terminal Number

C-code

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Zero Voltage I

Analog brake transducer

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Terminal Number

174

Return

Connection

Function

601

Negative for 602-604

602

Lift reg. temperature

603

Lift reg. voltage

604

Lift reg. current

606

Battery indicator current +

607

Battery indicator current -

608

Battery indicator +

609

Speed/current reference -

610

Speed reference value +

611

Current limit +

LED No.

Connection

Function

701

Negative for 702-703

702

Lift reg. speed reference value +

703

Lift reg. current limit +

704

Fork lift

705

Direction A

706

Direction B

707

Reach out

708

Reach in

709

Sideshfter

710

Tilt

711

Spare 2A

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Terminal Number

LED No.

801

Spare 2B

802

Drive, operator direction (reverse)

803

Drive, fork direction (forward)

804

Fork lower

805

Brake coil

808

+24/36 Volt

809

+24/36 Volt supply outputs

Connection

Function

806 807

810

Sensor feed +

811

Sensor feed -

Terminal Number

Return

Connection

Function

901

+24/36 V steer motor

902

Zero Voltage

903

+ steer motor

904

- steer motor

LED

Color

Function

POWER

Green

Indication, all voltage is fed to the electronic card

STEER PWR

Green

Voltage feed to control electronics

STEER OK

Green

Steering OK

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Switch

Function

SW 1

Switch to program parameters and error codes

SW 2

Switch to program parameters and error codes

SW 3

Switch to program parameters and error codes

Potentiometer RV2

176

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Function Adjustment of lowering speed

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Version no

000

C-code

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1. Display It is possible to look at the truck’s specific register and program the clock. The truck cannot be driven with any functions when it is in the programming mode. To look at the truck’s specific register: 1. Remove right-hand access panel in operator’s compartment. 2. Turn the key switch so that the electronic card is ON. 3. Press button SW3 three times on the electronic card to view specific registers.

SW1

SW3 SW2

•

Press SW1 to see date error code was registered.

•

Press SW1 again see time error code was registered.

•

Press SW1 to see next registered error code.

•

Turn key switch OFF or wait approximately 20 seconds to return to run mode.

4. Press SW3 once again to view parameters setting. •

Press SW2 to scroll through parameters

•

SW1 has no function at this time.

The character window (C) will present the different functions:

I H G F

Return

•

Warning and error codes

•

Parameters

•

Running time

The address register will be shown in the left-hand section and the value in the right-hand section for the “Warning/Error Codes” and “Parameters”.

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2. Time It is possible to program the clock. The hour character window (B) will flash after pressing SW3. Press SW3 again and the minutes will flash. 1. Change time by stepping up using SW2 and down using SW1. 2. Save the values and display the function by pressing SW3. 3. Exiting this function can be dose in three ways; •

Press SW3 three more times.

•

Waiting approximately 20 seconds.

•

Turn key switch OFF.

SW1

SW3

Function

SW2

Value

Hours

09=9h

Minutes

35=35 min.

When error codes are displayed in the character window (C), the character box (G) will light. When the parameters are displayed in character window (C), the character box (F) will light. However, it is not possible to reprogram the parameters in this mode. To change to the programming mode, see “Programming Parameters”. Complete programming by turning the key switch off and on once. Programming mode will quit if you do not press a key within 10 seconds.

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3. Warning Codes Character

Error Warning

When an error has occurred, a signal sounds and a code is displayed for 10 seconds in the right-hand section of the character window (C). The character box (G) illuminates. If the error remains after 1 minute the warning and signal will be activated again for a 2 seconds period. This happens as long as the error is not rectified. The truck can still be driven with all functions, as set out in the Warning Code table below and on next page. WARNING Ignoring error indications. The safety of the truck is jeopardized. Always check the operation of the truck before use.

Warning Codes Without Registering Error No.

Return

Error Code Name

Comment

Pump Chopper Lim

Steer Chopper Lim

Wheel Ind Error

Height Ind Error

Height counter error

Pump Brush Error

Worn Pump motor brush

Drive Brush Error

Worn drive motor brush

Nov Ram Error

Control Module internal error

Default Par

Pump Voltage Error

Lift Pot Z Error

Lift pot not centered at key on time

Tilt Pot Z Error

Tilt pot not centered at key on time

Reach Pot Z Error

Reach pot not centered at key on time

Sideshfter Pot Z Error

Sideshfter pot not centered at key on time

Bat Measure Error

Low battery voltage detected

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Warning Codes with Registering Error No.

Error Code Name

Comment

O Lift Error

Shorted or opened lift valve output

O Tilt Error

Shorted or opened tilt valve output

O Dir A Error

Shorted or opened direction A valve output

O Dir B Error

Shorted or opened direction B valve output

O Sideshfter Error

Shorted or opened sideshfter valve output

O Spare In Error

Unused output/input

O Spare Out Error

Unused output

O Reach In Error

Shorted or opened reach in valve output

O Reach Out Error

Shorted or opened reach out valve output

O Lower Prop Error

Shorted or opened lowering proportional valve output

O Forward Contactor Error

Shorted or opened forward contactor output

O Backward Contactor Error

Shorted or opened backward contactor output

Lift Pot Error

Shorted or opened lift potentiometer input

Tilt Pot Error

Shorted or opened tilt potentiometer input

Reach Pot Error

Shorted or opened reach potentiometer input

Sideshfter Pot Error Shorted or opened sadist potentiometer input

Pot Ref Error

Potentiometer supply voltage

When the warning code is displayed, it is automatically registered. Registration takes place in the first of 80 possible positions and moves the previous error one step downward. With warning errors 52-64, the valve, contactor or wires are either broken or short circuited. With warning errors 90-95, the potentiometer or wires are broken. Only the actual function is disabled; other functions are not affected. 180

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Version no

C-code

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4. Error Codes Character

Error Error

When an error has occurred, a buzzer sounds at the same time an error code is displayed in the right-hand section of the character window (C). The character box (G) illuminates. The signal sounds until the key switch is switched off. If the error remains when the key switch is switched on again, the codes will be shown and the signal will sound again. The truck can still be used with the hydraulic functions listed in the Error Codes table on next page. SW1

SW3 SW2

When an error code is shown, the code is automatically registered in the error register. (The meaning of the error code is shown in the Error Codes table on next page.) Registration takes place in the first of 80 possible positions and moves the previous error one step downward. When the register is shown in the character window, the latest codes are shown with the error code. To see the date when the error occurred, press SW1 once and to see the time press SW1 again. To see more of the registered errors, press SW2.

WARNING Ignoring error indications. The safety of the truck is jeopardized. Always check the operation of the truck before use.

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Error Codes with Registering

182

Error No.

Error Code Name

Comment

100

Pump Temp Error

Pump chopper over or under temperature

101

Pump Curr Error

102

Drive Chopper Error

Drive chopper internal error

110

P Brake Pot Ref Error

Pedal/parking brake potentiometer supply voltage

111

P Brake Pot Error

Pedal/parking brake potentiometer adjustment or failure

112

P Brake Sw Error

Pedal/parking brake switch adjustment or failure

113

P Brake Out Error

Shorted or open parking brake output

115

Spd Sens Error

Drive motor speed sensor failure

116

Dir Sens Error

Drive motor direction sensor failure

117

Rev Signal Error

Drive chopper reversing signal failure

120

Steer Data Error

Control module internal error

121

Steer Chopper Error

Steer chopper error

122

Steer Temp Error

Steer chopper over temperature

123

Steer Volt Error

124

Steer Curr Error

125

Steer Tacho Error

Steer tacho motor error

126

Steer Conn Error

Opened steer motor output - motor or connection failure

127

Steer Comm Error

Control module internal error

130

Slave Comm Error

Control module internal error

131

Sec Rel Error 1

Security relay error 1

132

Steer Pwr Error

Steer chopper supply voltage under voltage

133

Sec Rel Error

Security relay error 2

140

Check Sum Error

Control module internal error

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C-code

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5. Effect on the Truck All hydraulic functions except fork lowering are stopped.

6. Parameters The significance of the different parameters is shown in the table in section “Program parameters” on next page. To see the different parameters, press SW2 or SW3.

7. Running time When running time reading is shown, the character box (E) is illuminated. The time is shown as follows: Character

SW1

SW3

Time Key time

SW2

Total running time Drive motor time Pump motor time

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8. Programming Parameters 1. Press SW3 on the electronic card at the same time as you turn the key switch ON. 2. Step using SW2 (up) and SW1 (down) to the parameter you wish to change. 3. Press SW3 (the character window flashes). 4. Change the value using SW1/SW2. 5. Press SW3 to accept the value (the character window stops flashing). If you wish to change more parameters, step using SW1/SW2 to the parameter you wish to change and repeat from “Press SW3” (the character window flashes). NOTE! Truck handling. Modifying specific truck parameters will change the driving characteristics of the truck. Do not change any parameters without the necessary knowledge.

SW1

SW3 SW2

Programming Parameters No.

Parameter Name

Inc

Values

Comment

Steer Prog Par 1-6

1-Least sensitivity 5-Most sensitivity 6-Test curve

Speed curve selection. Speed curve selection has a greater affect at high speed.

Steer Wheel Par

(1)

0-Least sensitivity 2-Most sensitivity

Steer tacho motor sensitivity.

Top Speed Par 10-100%

100

% of maximum speed

Drive speed reduction.

Red Speed Par

10-100%

(40)

% of maximum speed

Limited speed reduction.

Accel Par

10-100%

(50)

% of maximum acceleration

Acceleration reduction.

184

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Value Rang

0-2

Default

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Programming Parameters No.

Parameter Name

Value Rang

Default

Inc

Reach Scale Par

10-100%

(80RR35) (45RR45)

Spare Scale Par

10-100%

Spare function speed reduction Not used.

Spare Curr Par

0-100%

(0)

Spare function current limit reduction. Spare function is disabled when this valve is set to zero. Not used.

Spec Height Par

0-531 in.

(0)

Maximum allowed lifting height

Special height

Fork Ref Par

60-177 in.

(90)

Mast free height

Mast reference height

Steer Dir Par

0-1

(1)

0-Backward (Eur.) 1-Forward (US)

Steer direction

Timer Sel Par

1-4

(2)

1-Key time (total time) 2-Drive and pump time (active time) 3-Drive time 4-Pump time

Displayed timer

Battery Par

1-30

(20)

1-Shallow discharge 29-Deep discharge (not a permanent parameter)

Battery type

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Values

% of maximum reach speed

1997-07-15

Comment

Reach movement speed reduction.

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Programming Parameters No.

Parameter Name

Value Rang

Pump Type Par

0-2

{2}

Clock Year

0-99

Clock Year

Clock Day

0-31

Clock Day

Clock Month

0-12

Clock Month

186

Return

Default

Inc

Service Manual

Values

0-36V Std. 1-24V Std. 2-36V HD.

Comment

Hydraulic pump type

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9. Adjustment Procedures for Setting Brake Switch and Brake Transducer 1. Remove cover panel for A5 card. 2. Remove floor plate. 3. Go into programming mode. Refer to Programming Parameters. •

Set parameter 12 at 4

•

Set parameter 15 at 50

6. After changing these parameters, turn key switch OFF and turn back ON. 7. The display should read 10 with the brake pedal all the way up. 8. Press brake pedal all the way down and the display should read 247. 9. To adjust with the pedal all the way up, bend pedal stop bracket down until you read 10 on the display. 10. To adjust with the pedal all the way down loosen the bolts on the brake transducer and adjust until 247 appears on the display. 11. The brake switch should be adjusted so it actuates between 45 and 52 on the display when depressing the pedal. 12. After making adjustments, go back into programming mode. •

Set parameter 12 at 2.

•

Set parameter 15 and 97.

13. Reinstall floor plate and cover.

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S5.3

5810 Pump Motor

Version no

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Pump Motor

ROTATION C.C.W.C.E. Counterclockwise when viewed from commutator end.

Return

POS. NO

DESCRIPTION

POS. NO

DESCRIPTION

Cover band

Terminal stud

Head, commutator end

Field coil

Thrust washer

Head, drive end

Bearing, ball sealed

Brush plate assembly

Armature & fan assembly

Spring, brush

Fan

Brush

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1. Component Repair 1.1. Motor Disassembly 1. Remove the cover band (1) from the commutator end of the motor. 2. Use a brush hook to reach into the motor and lift the brush springs (6). Pull the brushes (7) out of the brush holders. Either position the brushes outside the motor or remove the brush retaining screws, and remove the brushes (7) from the motor. 3. Scribe or center punch locating marks in the end head and the frame. Although locating marks are not always necessary, they can save time when the motor does not have locating pins. 4. Remove the commutator end head retaining screws. Most motors have a slip fit bearing at the commutator end, and the end head can be removed with very little trouble. On motors that have a shaft extension on both ends of the armature, the attachment on the commutator end of the shaft must be removed before the end head can be separated from the motor. 5. Remove the drive end head retaining screws if necessary. Some of the smaller pump motors retain the drive end head with the motor through bolts. Separate the armature (12) and drive end head (10) as an assembly from the frame and field coil assembly. 6. Separate the armature (12) from the drive end head (10). This operation is usually done by pressing the armature out of the drive end bearing. On some of the larger motors, the end head and bearing will have to be removed with a puller. When a puller is used, protect the end of the armature shaft with a nut or a thick flat washer.

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5810 Pump Motor

Version no

000

CAUTION

T-code

395/396/397/398/399

If the shaft, coupling, or spline is damaged when removing the end head, the armature or the drive spline usually has to be replaced. Use caution, and DO NOT damage the armature.

7. Separate the bearing (4) from the end head (2). On larger motors, the bearing is retained with a snap ring. Remove the snap ring. Then press the bearing out of the end head. 8. The ventilation fans (13) are cast aluminum. Once these fans have been pressed onto the armature, they must be heated to be removed without damage. Install a puller and apply slight pressure against the fan. Use a small propane torch to heat the area of the fan around the shaft. When the fan becomes loose on the shaft, as evidenced by the puller becoming loose, remove as quickly as possible. 9. When the fan (13) is reassembled on the shaft, make sure it is a tight fit. Use “Loctite Retaining Compound 40” or equivalent on the inside of the fan hub when reassembling fan. 10. After the motor has been separated into all its major subassemblies, the components should be cleaned and inspected for wear or damage. Use “Loctite” on this area of shaft

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5810

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000

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2. Inspection and Troubleshooting After the motor components have been thoroughly cleaned and dried, they should be inspected for the following:

2.1. Drive End Head 1. Check bearing recess for any signs of wear. 2. Check mounting holes for any stripped or crossed threads or broken studs.

2.2. Commutator End Head 1. Check bearing recess for any signs of wear. 2. Check brush holder insulation for cracks or any signs of burning. 3. Check brush holders and springs for wear.

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Version no

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Streaky film with commutator wear. Bar edge burning. Uneven film. Carbon dust bridging between bars.

Brushes should be inspected for uneven wear and signs of overheating, i.e.:

Discolored brush shunts. Discolored brush springs. Refer to the Brush Chart at the end of this section.

2.5. Armature 1. Check security of fan. 2. Check for loose commutator bars. Loose commutator bars will usually be indicated by excessive wear or burning on one bar. The commutator can be checked for loose bars by lightly tapping all of the bars with the handle of a plastic or wooden handled screwdriver. A contrasting dull thud or vibration will indicate a loose bar. Replace the armature if the commutator bars are loose. 3. Check for grounded circuits using a test light. Most commercial growlers incorporate a test light. Check the armature for grounded circuits by placing one test lead of the test lamp on the commutator and the other test lead on the

Grounded Circuit Test

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armature shaft. If the test light lights, the armature is grounded. 4. Standard Winding Armatures are tested on a growler using a steel strip or hacksaw blade to locate any shorted windings. Check for shorted windings by slowly rotating the armature in the growler while holding the strip or blade so that it passes over each armature core slot. If a winding is shorted, the strip or blade will vibrate and the blade will get hot.

Test for Shorted Windings on Armature

NOTE! If the armature has been turned and undercut prior to testing, check for and remove any copper buildup or filings between commutator bars and at the commutator riser. This condition will cause an armature to check shorted and usually results from a dull undercutting tool. 5. Check commutator bars for any signs of burning. If deep burned sections are evident, either in the brush track or on the riser ends of the commutator bars, an open or short circuit in the armature windings is indicated.

Test for Shorted Windings on Armature

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5810 Pump Motor

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Grounded Circuit Touch one test lead to a clean bare metal spot on the frame and check all terminals with the other lead. If a grounded condition exists, the test light will light.

Open Circuit Check between all connecting terminals with test leads. If the bulb fails to light, an open circuit is indicated.

Shorted Circuit Shorted windings in series coils are very difficult to detect. Generally, if the coil insulation is sound and these are no signs of overheating, the coil can be presumed good.

2.6.2. Frame and Field Service Notes If the inside of the motor is exceptionally dirty and there is evidence of a grounding condition caused by the dirt, the inside of the motor can be given an additional coat of insulating varnish. Red glyptol can be used if a better material is not available, however, we recommend using a class “H” Polyurethane air drying insulating varnish. This is readily available under various brand names from electrical repair or parts houses in aerosol type dispensers. Before spraying field coils, make sure they are absolutely clean and dry. Protect brush rigging, pole shoe faces, and end head seats to keep varnish off.

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NOTE: We do not recommend using a soldering gun or torch. A soldering gun cannot provide the heat concentration required, and a soldering torch can damage the insulation. 2. After field coil installation, connect the solder joint, making sure the solder is flowing properly to avoid a cold soldered joint.

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5810 Pump Motor

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Press against the inner race when installing onto a shaft. 2. End heads having slip-fit bearings are normally retained by a snap ring. Always install new snap ring(s). 2.7.3. After Assembly 1. The motor should be connected as specified in Troubleshooting, and tested to the specifications. 2. When testing motors, the voltmeter connections must be made at the motor terminals.

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198

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Section

S6.0 6000 Hydraulic System

Version no

000

C-code

T-code

395/396

Hydraulic System Valid from machine number: 27091001 to 27135000

1. Operation Refer to Hydraulic Schematics in this Section

1.1. Supply A voltage to controller (A5) from one of the hydraulic function potentiometers (R11 to R14) gives a signal to the transistor regulator (A2) to drive the pump motor (M3). Oil is feed feed from the pump (P) out into the system. If the pressure in the system increases to the relief valve’s preset value, this opens and oil flows back to the tank.

1.2. Lifting By pulling back potentiometer (R11), there is an decrease in voltage from (R11) to (A5) which initiates a voltage to the coil, connection 2 on valve (Y10). Oil is feed from the valve to the free lift and staging cylinders. The free lift cylinder having less weight on it will lift first. After the free lift cylinder has reached full extension, the staging cylinders will begin to lift.

1.3. Lowering By pushing potentiometer (R11) forward, there is a increase in voltage from (R11) to (A5) which initiates a voltage to the coil, connection 3 on valve (Y10). Oil flows from the cylinders through valve (Y10) to the tank. The lowering speed is determined by valve (Y10/3) which is a proportional valve whose position is in direct proportion to the voltage from (R11).

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T-code

000

395/396

C-code

6000

connection 2. Oil is feed through (Y13) direction B through (Y14) to the rear ports on the reach cylinders and drives the pistons outwards. The oil flows from the front ports of the cylinders through (Y15) to direction A (Y12) to the tank.

1.5. Retract By pulling back potentiometer (R12), there is a increase in voltage from (R12) to (A5) which initiates a voltage to the direction A (Y12) valve coil, connection 2. A voltage will also be supplied to (Y14 and Y15) coils, connection 2. Oil is feed through (Y12) direction A through (Y15) to the front port on the reach cylinders and drives the pistons inwards. The oil flows from the rear ports through (Y14) to direction B (Y13) valve to the tank.

1.6. Tilt Up By pulling back potentiometer (R13) there is an decrease in voltage from (R13) to (A5) which initiates a voltage to direction B (Y13) valve coil, connection 2. A voltage is also supplied to (Y17) valve coil, connection 2. Oil is feed through direction B (Y13) valve to the rear port of the tilt cylinder driving the piston outward. The oil flows from the front port of the tilt cylinder through (Y17) valve to direction A (Y12) valve to the tank.

1.7. Tilt Down By pushing potentiometer (R13) forward, there is a increase in voltage from (R13) to (A5) which initiates a voltage to the direction A (Y12) valve coil, connection 2. A voltage is also supplied to (Y17) valve coil, connection 2. Oil is feed through direction A(Y12) valve to (Y17) valve to the front port of the tilt cylinder, driving the piston inward. The oil flows from the rear port of the tilt cylinder to the direction B (Y13) valve to the tank.

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S6.0 6000 Hydraulic System

Version no

000

C-code

T-code

395/396

1.8. Sideshifting Right By pulling back potentiometer (R14), there is an decrease in voltage from (R14) to (A5) which initiates a voltage to the direction B (Y13) valve coil, connection 2. A voltage is also supplied to (Y16) valve coil, connection 2. Oil is feed through direction B (Y13) valve to (Y16) valve to the rear port of the sideshifter cylinder driving the piston outward. The oil flows from the front port of the cylinder to direction A (Y12) valve to the tank.

1.9. Sideshifting Left By pushing potentiometer (R14) forward, there is a increase in voltage from (R14) to (A5) which initiates a voltage to the direction A (Y12) valve coil, connection 2. A voltage is also supplied to (Y16) valve coil, connection 2. Oil is feed through direction A (Y12) valve to the front port of the sideshifter cylinder, driving the piston inward. The oil flows from the rear port of the cylinder through the (Y16) valve to direction B (Y13) valve to the tank.

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C-code

6000

Symbol

Designation

Function

1-2

Cylinder

Staging

Cylinder

Free lift

Cylinder

Reach/retract

Cylinder

Tilt

Cylinder

Sideshifter

11-12

Valve

Staging velocity fuse

Valve

Free lift velocity fuse

Valve

Relief

Filter

Main filter

Motor

Pump motor

Pump

Hydraulic pump

Y10

Valve

Lift/lower

Y12

Valve

Direction A

Y13

Valve

Direction B

Y14

Valve

Reach out

Y15

Valve

Reach in

Y16

Valve

Sideshifter

Y17

Valve

Tilt

202

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Remarks

1997-12-16

F-code

Section

S6.0 6000 Hydraulic System

Version no

000

C-code

T-code

395/396

2. RRX35/45 Hydraulic Schematic

3 13

1 12

6 Y16

3 B

Y17 4 H Y10

A 1

Y10

Y14

Y13

Y15

M P Y12 R F

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1997-12-16

203

F-code

Section

PS S6.0 Hydraulic System Version no

T-code

000

395/396

204

Return

C-code

6000

Service Manual

1997-12-16

F-code

Section

S6.1 6000 Hydraulic System

Version no

001

C-code

T-code

395/396/397/398/399

Hydraulic System Valid from machine number: 27135001 and UP

WARNING DO NOT use your hands to check for hydraulic leakage. Use a piece of cardboard or paper to search for leaks. Escaping fluid under pressure can penetrate the skin causing serious injury. Relieve pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Keep hands and body away from pinholes and nozzles which eject fluids under high pressure.

1. Operation Refer to Hydraulic Schematics in this Section

1.1. Supply A voltage to (A5) controller from one of the hydraulic function potentiometers (R11 to R14) gives a signal to the transistor regulator (A2) to drive the pump motor (M3). Oil is feed from the pump (P) out into the system. If the pressure in the system increases to the relief valve’s preset value, this opens and oil flows back to the tank.

1.2. Lifting By pulling back potentiometer (R11), there is an decrease in voltage from (R11) to (A5) which initiates a voltage to the coil, connection 2 on valve (Y10). Oil is feed from the valve to the free lift and staging cylinders. The free lift cylinder, having less weight on it, will lift first. After the free lift cylinder has reached full extension, the staging cylinders will begin to lift.

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205

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PS S6.1 Hydraulic System

C-code

6000

Version no

T-code

001

395/396/397/398/399

1.3. Lowering By pushing potentiometer (R11) forward, there is a increase in voltage form (R11) to (A5) which initiates a voltage to the coil, connection 3 on valve (Y10). Oil flows from the cylinders through valve (Y10) to the tank. The lowering speed is determined by valve (Y10/3) which is a proportional valve whose position is in direct proportion to the voltage from (R11).

1.4. Reach By pushing potentiometer (R12) forward, there is an decrease in voltage from (R12) to (A5) which initiates a voltage to the direction B (Y13) valve coil, connection 2. A voltage will also be supplied to (Y14 and Y15) valve coil, connection 2. Oil is feed through (Y13) direction B through (Y14) to the rear ports on the reach cylinders and drives the pistons outwards. The oil flows from the front ports of the cylinders through (Y15) to direction A (Y12) to the tank.

1.6. Tilt Up By pulling back potentiometer (R13), there is an decrease in voltage from (R13) to (A5) which initiates a voltage to direction B (Y13) valve coil, connection 2. A voltage is also supplied to (Y17) valve coil, connection 2. Oil is feed through direction B (Y13) valve to the rear port of the tilt cylinder, driving the piston outward. The oil flows from the front port of the tilt cylinder through (Y17) valve to direction A (Y12) valve to the tank. 206

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S6.1 6000 Hydraulic System

Version no

001

C-code

T-code

395/396/397/398/399

1.7. Tilt Down By pushing potentiometer (R13) forward, there is a increase in voltage from (R13) to (A5) which initiates a voltage to the direction A (Y12) valve coil, connection 2. A voltage is also supplied to (Y17) valve coil, connection 2. Oil is feed through direction A(Y12) valve to (Y17) valve to the front port of the tilt cylinder driving the piston inward. The oil flows from the rear port of the tilt cylinder to the direction B (Y13) valve to the tank.

1.8. Sideshifting Right By pulling back potentiometer (R14) there is an decrease in voltage from (R14) to (A5) which initiates a voltage to the direction B (Y13) valve coil, connection 2. A voltage is also supplied to (Y16) valve coil, connection 2. Oil is feed through direction B (Y13) valve to (Y16) valve to the rear port of the sideshifter cylinder driving the piston outward. The oil flows from the front port of the cylinder to direction A (Y12) valve to the tank.

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C-code

6000

Version no

T-code

001

395/396/397/398/399

Symbol

Designation

Function

1-2

Cylinder

Staging

Cylinder

Free lift

Cylinder

Reach/retract

Cylinder

Tilt

Cylinder

Sideshifter

Valve

Staging velocity fuse

Valve

Free lift velocity fuse

Valve

Relief

Filter

Main filter

Motor

Pump motor

Pump

Hydraulic pump

Y10

Valve

Lift/lower

Y12

Valve

Direction A

Y13

Valve

Direction B

Y14

Valve

Reach out

Y15

Valve

Reach in

Y16

Valve

Sideshifter

Y17

Valve

Tilt

208

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Remarks

1997-12-16

F-code

Section

S6.1 6000 Hydraulic System

Version no

001

C-code

T-code

395/396/397/398/399

2. RRX35/45 Hydraulic Schematic

3 13

1 11

6 Y16

3 B

Y17 4 H Y10

A 1

Y10

Y14

Y13

Y15

M P Y12 R F

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1997-12-16

209

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Section

C-code

PS S6.1 Hydraulic System

6000

Version no

T-code

001

395/396/397/398/399

3. RDX30 Hydraulic Schematic

3 13

6 A

Y16

3 5

Y17 4 H Y10

A 1

Y10

Y14

Y13

1 4

Y15

P Y12 R F

210

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Section

S6.1 6000 Hydraulic System

Version no

001

C-code

T-code

395/396/397/398/399

4. RSX40/50 Hydraulic Schematic

H Y10

Y10 Y13

14 M

P Y12

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1997-12-16

211

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PS S6.1 Hydraulic System

C-code

6000

Version no

T-code

001

395/396/397/398/399

212

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1997-12-16

F-code

Section

S7.0 7110 Mast, 3 Stage

Version no

000

C-code

T-code

395/396/397/398/399

Mast, 3 Stage

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1997-07-15

213

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Section

C-code

PS S7.0 Mast, 3 Stage

7110

Version no

T-code

000

395/396/397/398/399

1. Shimming Mast on Truck WARNING When blocking mast columns to prevent lowering always block both side of the column. If not the truck could tip over on its side.

1.1. Shimming the Carriage/Reach 1. Disconnect battery and remove battery from truck. 2. Attach a hoist to top of carriage/reach and hoist to loosen lift chains. Read and follow the correct operating procedures for your jack or hoist. This will allow removal of lift chain anchor pins, and electrical cable. 3. Thoroughly clean off all outside dirt around mast roller bearings. 4. Determine the amount of shims required by prying the rear of carriage/reach to one side and slipping shims between the bearings and web on the column. Add shims by hand until no more can be added. 5. Divide shims as equally as possible between the two bearings and install under bearings. 6. Hydraulically lift up inner column enough to remove carriage/reach. 7. Lower carriage/reach inner column to expose bearings. Remove bearings to install shims behind bearings. 8. Raise carriage/reach inner column as far as it will go under normal operation. Check bearing shimming as the carriage/reach is raised. Remove shims as required, if tight spots are encountered where assembler cannot move carriage/reach smoothly. Check for excessive bearing clearance with carriage/reach in fully lowered position by prying carriage/reach to one side and checking with a 0.030-in. shim. Maximum clearance must not exceed 0.030-in. Check for excessive bearing clearance with carriage/reach in the fully raised 214

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Section

S7.0 7110 Mast, 3 Stage

Version no

000

C-code

T-code

395/396/397/398/399

position by prying carriage/reach to one side and checking with a 0.030-in. shim. Maximum clearance must not exceed 0.030-in. 9. Lower carriage/reach to install lift chain anchor pins, and electrical cable. When installing lift chains, chains are to be free of twists and adjusted for equal tension with adjusting nuts (wheel nuts) and locknuts (jam nuts) torqued to 200 ft-lb (271 N•m). Chains are to be centered on sheave within 1/32 in. 10. Remove hoist from carriage/reach and test operation of unit. Check operation first with no load, then with capacity rated load.

1.2. Shimming the Rails. In order to shim the mast rails the carriage/reach will have to be removed. 1. Disconnect battery and remove from unit. 2. The truck will have to be hoisted and blocked a foot off the floor before work can begin. Read and follow the correct operating procedures for your jack or hoist. WARNING Always make sure unit is on level surface before work can begin. 3. Attach a hoist to top of carriage/reach and raise carriage/reach. Loosen lift chains. 4. Remove chain anchor pins, attachment hydraulic hoses and electrical cable. Hydraulically raise inner column enough to remove carriage/reach. Lower carriage/reach down and out inner column. Place it away from truck. 5. Attach hoist to top of inner column and hoist to loosen lift chain. This will allow removal of lift chain anchor pins. 6. Before disconnecting hoses and fittings from inner column, thoroughly clean off all outside dirt around © BT Products

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215

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PS S7.0 Mast, 3 Stage

7110

Version no

T-code

000

395/396/397/398/399

fittings. After disconnecting hoses, immediately cap ports on tubes and hoses to prevent contaminates from entering the hydraulic system. NOTE! Make note of which port the hoses are from for easier installation. 7. Raise inner column. 8. Determine the amount of shims required by prying inner column to one side and slipping shims between bearings and web on column. Add shims by hand until no more may be added. 9. Divide shims as equally as possible between the two bearings on both top and bottom of column and install under bearings. 10. Lower inner column down and move the intermediate column out to expose two bottom bearings and install shims under bearings. 11. Divide shims as equally as possible between the two bearings on top of intermediate column and install under bearings. 12. Raise inner column up intermediate column as far as it will go under normal operation. Check bearing shimming as inner column is raised. Remove shims as required, if tight spots are encountered where assembler cannot move mast smoothly. Check for excessive bearing clearance with columns in lowered position by prying column to one side and check with 0.030-in. shim. Maximum clearance must not exceed 0.030-in. 13. Attach a hoist to top of both inner and intermediate column. Read and follow the correct operating procedures for your jack or hoist. 14. Remove cap screws which secure lift staging cylinders from top of intermediate column. Once columns are lifted with hoist, the lift cylinder is free to move or fall. Secure lift cylinder in place. 15. Determine the amount of shims required by prying intermediate column to one side and slipping shims 216

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Section

S7.0 7110 Mast, 3 Stage

Version no

000

C-code

T-code

395/396/397/398/399

between bearing and web on column. Add shims by hand until no more may be added. 16. Divide shims as equally as possible between the two bearings on both top and bottom of column and install under bearings. 17. Lower intermediate column down and move the outer column out to expose the two bottom bearings and install shims under bearings. 18. Raise intermediate column up outer column as far as it will go under normal operation. Check bearing shimming as intermediate column is raised. Remove shims as required if tight spots are encountered where assembler cannot move mast smoothly. Check for excessive bearing clearance with columns in the fully lowered position by prying column to one side and check with a 0.030-in. shim. Maximum clearance must not exceed 0.030in. Check for excessive bearing clearance with inner column in fully raised position by prying column to one side and checking with a 0.030-in. shim. Maximum clearance must not exceed 0.030-in. 19. Push intermediate and outer columns together and install cap screw in intermediate column to secure lift staging cylinder and attach a hoist to top of lift carriage into place in inner column. 20. Hoist carriage/reach up inner column to attach lift chain anchor pins. When installing lift chains, chains are to be free of twists and adjusted for equal tension with adjusting nuts (wheel nut) and locknuts (jam nuts) torqued to 200 ft-lb (271 N •m). Chains are to be centered on sheaves within 1/32 in. 21. Connect electrical cable and attachment hydraulic hoses. 22. Remove hoist from mast and lower unit to floor. 23. Install and connect battery to unit. 24. Loosen jam nut and tighten chains equally until the top of the rails are level in the fully lowered © BT Products

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217

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C-code

PS S7.0 Mast, 3 Stage

7110

Version no

T-code

000

395/396/397/398/399

position. Retighten jam nut and torque. Carriage chains should be adjusted in the fully lowered position. Adjust chains until the heel of the forks are 1/2 in. (12.7 mm) off of the floor. Retighten locknuts on chain anchors. 25. Test operation of mast and check for tight or loose spots and reshim if found. Check operation first with no load, then with capacity rated load.

218

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Section

S7.0 7110 Mast, 3 Stage

Version no

000

C-code

T-code

395/396/397/398/399

2. Three Stage Mast 2.1. Removal WARNING Always make sure unit is on level surface before work can begin.

Bolts

1. Disconnect battery and remove from unit. 2. Disconnect hydraulic supply line which is located, then lower left corner of battery box and cap. 3. Disconnect two hydraulic supply lines located by emergency disconnect and then cap. 4. Disconnect electric wiring harness located, by emergency disconnect. 5. If truck is equipped with lift and or fan package, disconnect harness located at base of OHG support bar. 6. Connect hoist to top tie bars of mast and tighten enough to remove all slack in chains. 7. Remove two mast bolts located in the middle of battery box. 8. Remove two side mounting plates at pivot points on mast. 9. Lift mast enough to clear chassis and lay mast on floor.

Plate

Bolts

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219

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C-code

PS S7.0 Mast, 3 Stage

7110

Version no

T-code

000

395/396/397/398/399

2.2. Installation 1. Install mast using hoist. 2. Install side mounting plates. 3. Install two bolts in middle of battery box. 4. Connect hydraulic hoses to lift cylinders. 5. Connect all electrical connectors. 6. Adjust lift chains. Loosen jam nut and tighten chains equally until the top of the rails are level in the fully lowered position. Retighten jam nut and torque. Carriage chains should be adjusted in the fully lowered position. Adjust chains until the heel of the forks are 1/2 in. (12.7 mm) off of the floor. 7. Grease all chain sheaves. 8. Bleed air from cylinders. 9. Install and connect battery and test operations of mast and unit.

220

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S7.0 7110 Mast, 3 Stage

Version no

000

C-code

T-code

395/396/397/398/399

2.3. Disassembly 1. Lower mast assembly to a horizontal position before work can begin. 2. Remove lift chain anchors, lift chain, attachment hydraulic hoses and electrical cable from mast. 3. Remove freelift chain anchor and two cotter pins and two cylinder anchor pin from inner column and remove free lift cylinder assembly by pulling straight up. NOTE! Lift cylinder can be repaired at this time, if needed. 4. Remove chain sheaves and cable sheaves from all columns. 5. Remove column stops from outer column. 6. Pull inner column straight forward until it stops (hits bearings) and then 90 degrees straight up from intermediate column. 7. Remove cap screws from top of intermediate column and remove staging cylinder assemblies by pushing intermediate column forward. NOTE! Lift cylinder can be repaired at this time, if needed. 8. Pull intermediate column straight forward until it stops (hits bearings) and then pull 90 degrees straight up from outer column. 9. Remove mast bearings and shim washers from all columns. 10. Thoroughly clean all parts.

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PS S7.0 Mast, 3 Stage

7110

Version no

T-code

000

395/396/397/398/399

2.4. Assembly 1. Thoroughly clean all parts and air dry.

WARNING Be extremely careful when working with solvent. Even a small explosion or fire could cause injury or death. WARNING Compressed air used for cleaning MUST be reduced to less than 30 p.s.i., and then only with effective chipguarding and personal protective equipment. 2. Install mast roller bearing on both the intermediate and outer columns. 3. Assemble intermediate column in the outer column and slide columns together. 4. Determine the amount of shims required by prying the inner column to one side and slipping shims between the bearing and web on the mast. Add shims by hand until no more can be added. 5. Divide shims as equally as possible between the two bearings and install under bearings. 6. Extend intermediate column through outer column as far as it will go under normal operation. Check bearing shimming as column is extended. Remove shims as required, if tight spots are encountered where assembler cannot roll mast by hand. Check for excessive clearance with columns in the fully closed position by prying column to one side and checking with a 0.030-in. shim. Maximum clearance must not exceed 0.030-in. Check for excessive bearing clearance with columns in the fully extended position by prying column to one side and checking with a 0.030-in. shim. Maximum clearance must not exceed 0.030in. 7. Assemble inner column in the intermediate column and slide columns together. 222

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S7.0 7110 Mast, 3 Stage

Version no

000

C-code

T-code

395/396/397/398/399

8. Determine the amount of shims required by prying the inner column to one side and slipping shims between the bearing and web on the mast. Add shims by hand until no more can be added. 9. Divide shims as equally as possible between the two bearings and install under bearings. 10. Extend inner column through intermediate column as far as it will go under normal operation. Check bearing shimming as column is extended. Remove shims as required, if tight spots are encountered where assembler cannot roll mast by hand. Check for excessive clearance with columns in the fully closed position by prying column to one side and checking with a 0.060-in. shim. Maximum clearance must not exceed 0.060-in. Check for excessive bearing clearance with columns in the fully extended position by prying column to one side and checking with a 0.030-in. shim. Maximum clearance must not exceed 0.030in. 11. Install column stops in outer column and torque to 260 ft-lb (350 N•m). 12. Install staging lift cylinder assembly in intermediate column lower end. 13. Press roller bearings in lift chain sheaves, grease roller bearings, and slide inner races in roller bearings. 14. Install shim washers on either side of lift chain sheaves and install in intermediate column. Slide pins through sheaves and secure pins with two (2) cap screws and lockwashers. Do this to both chain sheave pins. 15. Install bearing in electrical sheave, grease bearing and install spacers on either side of bearing. 16. Install electrical sheave in proper location on intermediate column and secure with one cap screw and lockwasher. 17. Push intermediate and outer columns together and install cap screw in intermediate column to secure © BT Products

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PS S7.0 Mast, 3 Stage

7110

Version no

T-code

000

395/396/397/398/399

staging lift cylinder. 18. Install lift chain anchors through outer column and thread wheel nut on anchors and secure with jam nut. 19. Install lift chain on chain anchors and secure with chain pins. After chain pins have been installed, run lift chain over chain sheaves. Make sure chain and sheaves are properly aligned. 20. Install freelift cylinder assembly on inner column and secure with four cap screws and nuts. 21. Connect hydraulic lines to lift cylinder. 22. Lubricate the grease fittings with Tex. Ref. C & C No. 880 using a standard lube gun.

224

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F-code

Section

C-code

S7.1

7210 Sideshifter

Version no

T-code

000

Sideshifter

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1997-07-18

225

F-code

Section

C-code

PS S7.1 Sideshifter

7210

Version no

T-code

000

POS. NO

226

Return

DESCRIPTION

POS. NO

DESCRIPTION

POS. NO

DESCRIPTION

Slide, top

Hook, lower

Cylinder assembly

Anchor, cylinder

Screw, set

Spacer, nylon

Spacer

Screw

Spacer

Fitting

Lockwasher

Seal, gland

Ring, retainer

Frame, sideshifter

Retainer, wiper

Slide, lower

Nut

Wiper, rod

Nut

Spacer

Ring, retainer

Service Manual

1997-07-18

F-code

Section

C-code

S7.1

7210 Sideshifter

Version no

T-code

000

1. Mounting Instructions 1.1. Installation 1. Remove lower hooks (8) from sideshifter assembly. 2. Lift sideshifter onto the truck’s carriage while holding up the cylinder to keep the upper slides in place. 1

9 3. Make sure the centering lug (X) on the cylinder anchor (2) fits completely in the center notch of the truck carriage. 4. Remount the lower hooks (8) with a minimum clearance of 1/16 in. and a maximum clearance of 1/8 in. Retighten the bolts to 55 ft-lb. NOTE! Clearance between the lower hooks and the truck carriage is very important. The centering lug on the sideshifter can jump out of the center notch of the truck carriage if this distance is not set accordingly. 5. Secure the lower hook (8) in place by tightening the set screws (9) to 42 ft-lb. 6. Connect the hydraulic fittings (4) to the sideshifter cylinder (15). Side shift the unit several times to insure there are no leaks. Check the sideshifter for smooth operation with no interference. © BT Products

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227

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Section

C-code

PS S7.1 Sideshifter

7210

Version no

T-code

000

2. Operation and Maintenance Always operate the truck controls in a smooth manner. Sudden movements of the sideshifter at high lifts can compromise the stability of the truck, as well as cause damage to the overall system. Maintenance on the sideshifter is minimal. Lubrication is not required due to special oil impregnated nylon slides. However, lubrication will extend the life of the slides if the unit is not operated in extremely dirty environments. In a dirty environment, the lubrication may attract contamination, causing increased wear. The top slides are completely covered and protected from contamination. The lower slides have a wiper that protects the slide from contamination as long as the truck carriage is not nicked or grooved.

Every 1000 hours: 1. Inspect hydraulic hoses for wear. 2. Inspect the cylinder (15) and fittings (4) for leaks. 3. Clean the lower slides (6) and truck carriage lower bar. Inspect for wear. 4. Inspect and adjust the lower hooks (8) for the proper clearance adjustment. 5. Check the torque on the lower hook mounting bolts (10) and set screws (9). NOTE! In a dirty environment or rough operations, it is necessary to inspect the sideshifter more frequently.

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C-code

S7.1

7210 Sideshifter

Version no

T-code

000

2.1. Lower Slides 1. The original thickness of a lower slide is approximately 3/ 16 in. and has a useful life of 1/2 its thickness. 2. Replace the lower slide if contamination is present or excessive play becomes evident.

2.2. Upper Slides 1. The original thickness of upper slide (1) is approximately 1/8 in. and should be replaced if the slide is worn beyond 1/16 in. at any point on the round surface. 2. Replace the upper slides (1) if there is an unacceptable clearance (greater then 1/8 in. after adjustment) between the lower hooks (8) and the truck carriage. 3. When replacing the upper slides (1), always replace all of the slides at the same time to ensure even wear and proper sideshifter movement.

2.3. Cylinder 1. The hydraulic cylinder (15) is basically a non-serviceable style, with the exception of the gland O ring. It is © BT Products

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PS S7.1 Sideshifter

7210

Version no

T-code

000

recommended that a leaking or defective cylinder be replaced. 2. If the cylinder rod becomes scored, a minimal amount of scoring may be removed by polishing with a fine emery cloth. Deep scoring requires that the cylinder (15) be replaced.

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S7.2 7240 Reach, Single

Version no

001

C-code

T-code

394/395

Reach, Single 1. Maintenance The only maintenance required on the reach mechanism is the normal Preventive Maintenance per the schedule.

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PS S7.2 Reach, Single

7240

Version no

T-code

001

394/395

POS. NO

232

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DESCRIPTION

POS. NO

DESCRIPTION

POS. NO

DESCRIPTION

Nut, thin

Cover, valve

Shim

Washer

Manifold

Screw

Frame, rear

Frame, forward

Anchor, chin

Screw

Pin, roll

Shim

Arm, left

Shaft

Bushing

Nut

Fitting, grease

Bar, fork

Clamp

Arn, inner

Screw

Manifold assembly

Shaft, pivot

Washer

Screw

Arm, right

Bracket

Bushing

Washer, flat

Screw

Plug, wear

Nut, jam

Pin, yoke

Bearing

Set, bearing

Pin, cotter

Washer

Screw

Manifold

Clamp

Cap

Busking

Cover

Bearing

Screw

Bumper

Service Manual

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Section

S7.2 7240 Reach, Single

Version no

001

C-code

T-code

394/395

2. Reach Repair NOTE! The reach can be removing from mast.

repair

without

1. Remove forks. 2. Remove load backrest. 3. Raise and block reach at height for easy repair. 4. Extend reach approximately half way and block so it will not retract. 5. Disconnect battery.

2.1. Disassembly 2.1.1. Front Frame Removal 1. Disconnect hydraulic hoses from tilt cylinder and sideshifter cylinder and then cap with plugs to prevent contamination. 2. Remove nut (1) and washer (2) at the front frame (20). 3. Pins (26) can be driven to the outside by hitting with soft hammer. 4. Remove front frame (20) from inner arm (8) rollers (13). 2.1.2. Outer Arm Removal 1. Remove nut (29) and washer (28). 2. Remove outside bearing (30). 3. Remove right outer arm (27). 4. Repeat steps 1 thru 3 to remove left outer arm (5). 5. Remove screws (31), caps (32), and rollers (33) from outer arms. 2.1.3. Inner Arm Removal 1. Drive pins out of reach cylinder rod end pins. 2. Disconnect hydraulic lines from the manifold block and plug to prevent contamination. © BT Products

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C-code

PS S7.2 Reach, Single

7240

Version no

T-code

001

394/395

3. Remove pins from inner frame. 4. Remove nut (1) and washer (2) at the rear frame (3). 5. Drive pins (39) out by hitting a with soft hammer. 6. Remove inner arms (8). 2.1.4. Rear Frame Removal 1. Lift rear frame (3) until tension is removed from lift chains. 2. Remove lift chain anchors from rear frame. 3. Disconnect hydraulic hoses and plug to prevent contamination. 4. Disconnect electrical cable. 5 Lower rear frame. NOTE! Connect a hoist to rear frame because it could drop when channel is raised. 6. Raise inner mast channel. 7. Remove rear frame. 8. Remove rollers (33). Keep track of shims (35) to each roller and roller to pin location. 9. Clean and inspect all bearing, pins, rollers, washers and wear strips for wear. 2.1.5. Reach Cylinder Removal WARNING Block reach to keep it from collapsing. 1. Disconnect hydraulic hoses and plug to prevent contamination. 2. Raise reach to full freelift to remove lock pins from rear frame. 3. Lower reach to working height and remove cylinder tube mounting pins. 4. Repair reach cylinders as needed. 234

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F-code

Section

S7.2 7240 Reach, Single

Version no

001

C-code

T-code

394/395

2.2. Assembly Install new bearing, rollers, and pins as needed. 2.2.1. Reach Cylinder Installation 1. Raise reach to full free lift height to install rear frame pins. 2. Install locking pins. 3. Connect hydraulic hoses. 2.2.2. Rear Frame Installation 1. Install shims (35) and rollers (33). NOTE! Install same number of shims as removed for initial adjustment. 2. Lower inner mast channel onto rear frame rollers (33). NOTE! Adjust frame rollers so there is 0.000 in.0.030 in. side movement of rear frame at tight part of the inner mast channel. 3. Connect hydraulic hoses. 4. Connect electrical cable. 5. Install lift chain anchors. 2.2.3. Inner Arm Installation 1. Install upper end of inner arms (8) into rear frame (3). 2. Install new bearing in the side arms. 3. Install pins (39) into rear frame and inner arms (8). 4. Install washers (2) and nuts (1), and tighten. Torque to 85 ft-lb (115 N •m). Arms should pivot freely with some drag. 5. Install washers (14), rollers (13), and cap (12). 6. Connect hydraulic hoses to the reach cylinder. 7. Install pins in rod end of reach cylinder. 8. Install roll pins into cylinder rod pins. © BT Products

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235

F-code

Section

C-code

PS S7.2 Reach, Single

7240

Version no

T-code

001

394/395

2.2.4. Outer Arm Installation 1. Install rollers (33), caps (32) and screws (31) on arms (5 and 27). 2. Install bearing (30) in outer arms (5 and 27). 3. Install outer arms (5 and 27) on center stud of inner arm (8). 4. Install washer (28) and nut (29), and tighten. Torque nut to 295 ft-lb (405 N•m) 5. Check for side clearance. Arms should pivot freely with some drag. 6. Install front frame (20). 7. Connect tilt cylinder hoses. 8. Grease all fittings on the reach. 9. Test for proper operation of reach. Install forks and load backrest.

236

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1997-07-15

F-code

Section

C-code

S7.3 7310 Freelift Cylinder, 3 Stage

Version no

T-code

000

Freelift Cylinder, 3 Stage POS. NO

DESCRIPTION

POS. NO

DESCRIPTION

Tube

O ring

Snap ring

Back-up ring

Plug

Gland nut

Spring

Wear ring

Packing

Bearing retainer

Wiper

Rod

The lift cylinders are the positive displacement type, meaning there are NO seals on the lower end of the cylinder rod. The lift cylinder can be resealed without removing from the truck. NOTE! CLEANLINESS! Perform procedures in a clean environment. Make sure all parts are cleaned before disassembly and kept clean during assembly.

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237

F-code

Section

C-code

PS S7.3 7310 Freelift Cylinder, 3 Stage Version no

T-code

000

1. Freelift Cylinder Repair 1.1. Removal 1. Park the truck on a level surface and apply the brake. 2. Fully extend the cylinder to inspect the rod (19) for gouges or pits. If gouges or pits are detected, then the cylinder must be removed for repair. 3. Lift the carriage/reach approximately 6 inches. Block the carriage/reach to prevent lowering. WARNING When blocking mast columns to prevent lowering, always block both sides of the column. Otherwise, the truck could tip over on its side. 4. Lower cylinder so the chains, hoses, and electric cables are loose. Disconnect the battery 5. Remove chains, hoses, and electric cables from the crosshead. 6. Remove the crosshead from the cylinder rod. 7. Clean the exterior of the lift cylinder. WARNING Be extremely careful when working with solvent. Even a small explosion or fire could cause injury or death. WARNING Compressed air used for cleaning MUST be reduced to less than 30 p.s.i., and then only with effective chip-guarding and personal protective equipment.

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F-code

Section

C-code

S7.3 7310 Freelift Cylinder, 3 Stage

Version no

T-code

000

1.2. Disassembly 1. Remove gland nut (12) from the cylinder tube (3). 2. Remove and discard packing, back-up ring, O ring, rod wiper and bearing retainer from the gland nut (12). Use care NOT to damage the inside of the gland nut (12).

1.3. Assembly 1. Install new bearing, seals and rod wiper in the gland. The “lip” of the wiper must face outward. It is not necessary to replace wear ring (7), unless the rod was removed for repair.

1.4. Installation 1. Install crosshead, chains, hoses and electric cables. 2. Connect battery. 3. Test for proper operation.

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239

F-code

Section

C-code

PS S7.3 7310 Freelift Cylinder, 3 Stage Version no

T-code

000

240

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Service Manual

1997-07-15

F-code

Section

C-code

S7.4 7310 Staging Cylinder, 3 Stage

Version no

T-code

000

395/396/397/398/399

Staging Cylinder, 3 Stage

POS. NO

Return

DESCRIPTION

POS. NO

DESCRIPTION

Screw

Ring, wear

Washer, seal

Piston

Cylinder tube, 1 Port

Ring, retainer

Cylinder tube, 2 Port

Rod, cylinder

Plugger assembly

O ring

Spring

Bearing

Plug

Seal, rod

O ring

Wiper

Service Manual

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241

F-code

Section

C-code

PS S7.4 7310 Staging Cylinder, 3 Stage Version no

T-code

000

395/396/397/398/399

1.1. Removal 1. Park the truck on a level surface and apply the brake. 2. Fully extend the cylinders to inspect the rod (12) for gouges or pits. If gouges or pits are detected, then the cylinder must be removed for repair. 3. Lift mast so inner column is raised approximately 12 inches. Securely block mast, using 4 in. x 4 in. blocks under each side of the inner columns.

WARNING When blocking mast columns to prevent lowering, always block both sides of the column. If both sides are not blocked, the truck could tip over on its side.

4. Remove bolts from top end of staging cylinder rods. Lower cylinder rods hydraulically. 5. Clean the exterior of the lift cylinder.

WARNING Be extremely careful when working with solvent. Even a small explosion or fire could cause injury or death.

1.2. Disassembly 1. Remove gland nut (12) from the cylinder tube. 2. Remove and discard all seals, rod wiper (15) and bearing (14) from the gland nut (12). Us care NOT to damage the inside of the gland nut.

1.3. Assembly 1. Install new bearing (14), seals and rod wiper (16) in the gland. The “lip” of the wiper must face outward. It is not necessary to replace wear ring (9), unless the cylinder was removed for rod repair.

242

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F-code

Section

C-code

S7.4 7310 Staging Cylinder, 3 Stage

Version no

000

T-code

395/396/397/398/399

1.4. Installation 1. Install crosshead, chains, hoses, and electric cables. 2. Test for proper operation.

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243

F-code

Section

C-code

PS S7.4 7310 Staging Cylinder, 3 Stage Version no

T-code

000

395/396/397/398/399

244

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Service Manual

1997-07-15

F-code

Section

C-code

S7.5

7320 Tilt Cylinder

Version no

T-code

001

395

Tilt Cylinder

Seal Kit Contains Items Marked with “K”

Return

POS. NO

DESCRIPTION

POS. NO

DESCRIPTION

POS. NO

DESCRIPTION

Tilt cylinder assembly

Seal

11K

O Ring

Bushing

Bearing, cylinder

12K

Ring, back-up

Retainer, cylinder

Ring, back-up

13K

Retainer

Screw, cap

O Ring

Tube, cylinder

Wiper

Rod, cylinder

Service Manual

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245

F-code

Section

C-code

PS S7.5 Tilt Cylinder

7320

Version no

T-code

001

395

1. Removal 1. Park the truck on a level surface and apply the brake. 2. Raise reach approximately 12 inches and block so reach will not lower. 3. Relieve pressure on the tilt cylinder (1). 4. Pivot carriage/reach upward and block to prevent the carriage/reach from lowering. 5. Remove the strap (3) and cap screws (4) that secure cylinder to carriage/reach. 6. Remove hydraulic hoses from tilt cylinder (1). 7. Remove tilt cylinder (1) from the truck.

2. Disassembly NOTE! CLEANLINESS! Perform procedures in a clean environment. Make sure all parts are cleaned before disassembly and kept clean during assembly.

1. Before disassembly, clean exterior of the tilt cylinder (1) in a cleaning solvent to remove all contamination.

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F-code

Section

C-code

S7.5

7320 Tilt Cylinder

Version no

T-code

001

395

5. Remove bearing assembly, seals, rings, rod (10) and piston seals. 6. Remove and discard all seals and rod wiper (5,6,8,9,11, and 12). 7. Inspect mounting bushings (2) located at both ends of the cylinder. It will not be necessary to remove them unless they are found to be unfit for further service.

3. Inspection 1. Carefully clean all parts in a cleaning solvent and position them on a clean work surface

WARNING Be extremely careful when working with solvent. Even a small explosion or fire could cause injury or death. 2. Check the piston rod (10) for damage. Look for gouges, scratches, corrosion, or evidence of unusual wear. Minor surface damage can be repaired by the use of fine abrasion cloth or stoning. Be extremely careful you do not remove the chrome plating. Deeper damage will require replacement of the piston rod assembly. Make sure the threads on the rod are free of damage. 3. Check cylinder bore for any damage. Parts with deep gouges or pitted surfaces will require replacement. 4. Check threaded section of the cylinder tube to be sure the threads have not been damaged.

4. Assembly 1. Install new packing and rod wipers in the bearing assembly. The “lip” of the wiper must face outward. 2. Install new bearing seals, back-up ring and retainer (13) on the bearing assembly. © BT Products

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Service Manual

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247

F-code

Section

C-code

PS S7.5 Tilt Cylinder

7320

Version no

T-code

001

395

3. Install new piston seals on the piston. 4. Install piston on rod. 5. Apply clean hydraulic fluid to the piston rod assembly. Coat the inside of the cylinder barrel and bearing assembly with clean fluid. 6. Carefully slide bearing assembly on the piston rod. Be sure the rod end does not cut or nick the wiper or packing upon installation. 7. Install piston and rod into cylinder barrel. Be careful that the piston seals are not nicked or cut on the edge of the cylinder barrel or when sliding them over the groove within the barrel. 8. Next, install bearing assembly into cylinder barrel. Again, use care so the seals are not nicked or cut upon installation. 9. Check installation by making sure the piston rod assembly moves fairly easy within the barrel assembly without binding. 10. Install bearing fastening ring and retainer.

5. Installation 1. Install cylinder on reach front frame. 2. Install mounting straps (3) and secure with four cap screws (4). 3. Properly connect correct hydraulic hoses to front and rear of tilt cylinder. 4. Remove blocking and chains. 5. Fill hydraulic reservoir with new clean oil. 6. Connect battery. 7. Operate the tilt to remove air from hydraulic hoses and check operation of the of whole hydraulic system.

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F-code

Section

C-code

S7.5

7320 Tilt Cylinder

Version no

T-code

001

395

8. After running the hydraulic system, check and fill the hydraulic reservoir with more new clean oil.

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249

F-code

Section

C-code

PS S7.5 Tilt Cylinder

7320

Version no

T-code

001

395

250

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Service Manual

1997-07-16

F-code

Section

C-code

S7.6

7320 Tilt Cylinder

Version no

T-code

000

396/397

Tilt Cylinder

21 20

24 25

26 09

16 15 14

05 06

01 04

02 03 02

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251

F-code

Section

C-code

PS S7.6 Tilt Cylinder

7320

Version no

T-code

000

396/397

Pos. No

Description

Pos. No

Description

Pos. No

Description

Pos. No

Description

Pin, roll

Bearing

15K

O ring

22K

Seal, rod

Washer

Tube, cylinder

16K

Ring, sealing

23K

Wiper, rod

Bearing

Retainer

17K

O ring

Rod, cylinder

Nut

18K

O ring

Nut

Washer, flat

19K

Ring, sealing

Clevis

Pin, roll

13K

Ring, guide

Bearing

Kit, seal

Cylinder assy.

Piston

21K

Ring, guide

1. Removal 1. Park the truck on a level surface and apply the brake. 2. Raise reach approximately 12 inches and block so reach will not lower. 3. Relieve pressure on the tilt cylinder. 4. Pivot carriage/reach upward and block to prevent the carriage/reach from lowering. 5. Remove hydraulic hoses from tilt cylinder and mark their position. 6. Remove roll pin (06) and top mounting pin (05) and remove tilt cylinder from truck. 7. Repeat on other side of truck as needed.

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F-code

Section

C-code

S7.6

7320 Tilt Cylinder

Version no

000

T-code

396/397

2. Disassembly NOTE! CLEANLINESS! Perform procedures in a clean environment. Make sure all parts are cleaned before disassembly and kept clean during assembly.

1. Before disassembly, clean exterior of the tilt cylinder in a cleaning solvent to remove all contamination.

WARNING Be extremely careful when working with solvent. Even a small explosion or fire could cause injury or death. 2. Be sure all hydraulic fluid has been removed from the cylinder. Stroking the piston rod will help force the fluid out. 3. Put the base end of the cylinder in a vise equipped with soft jaws. 4. If needed, the roller bearing (03) at base of cylinder rod can be removed at this time. Remove a roll pin (01) and slide a mounting pin (04) from the clevis (26). 5. Remove the gland retainer (10) and fastening ring (20) by rotating the gland with a spanner wrench from cylinder tube (09). 6. Remove gland assembly, seals, rings, rod and piston, and piston seals. 7. Remove and discard all seals and rod wiper. 8. Inspect mounting bushings (08) located at the base end of the cylinder tube (09). It will not be necessary to remove them unless they are found to be unfit for further service.

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253

F-code

Section

C-code

PS S7.6 Tilt Cylinder

7320

Version no

T-code

000

396/397

3. Inspection 1. Carefully clean all parts in a cleaning solvent and position them on a clean work surface

WARNING Be extremely careful when working with solvent. Even a small explosion or fire could cause injury or death. 2. Check the piston rod (24) for damage. Look for gouges, scratches, corrosion or evidence of unusual wear. Minor surface damage can be repaired by use of fine abrasion cloth or stoning. Be extremely careful you do not remove the chrome plating. Deeper damage will require replacement of piston rod assembly. Make sure the threads on the rod are free of damage. 3. Check cylinder bore for any damage. Parts with deep gouges or pitted surfaces will require replacement. 4. Check threaded section of the cylinder tube (09) to be sure the threads have not been damaged.

4. Assembly 1. Install new packing and rod wiper in the gland assembly. The “lip” of the wiper must face outward. 2. Install new gland seals, back-up ring and O ring on the gland assembly 3. Install new piston seals on the piston. 4. Install piston on rod (24). 5. Install nut (11) on cylinder rod (24). Torque cylinder piston nut to 40 ft-lb (54 N•m). 5. Apply clean hydraulic fluid to the piston rod assembly. Coat the inside of the cylinder tube (9) and gland assembly with clean fluid. 6. Carefully slide the gland assembly onto piston

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F-code

Section

C-code

S7.6

7320 Tilt Cylinder

Version no

000

T-code

396/397

cylinder rod (24). Be sure the rod end does not cut or nick the wiper or packing upon installation. 7. Install piston and rod into cylinder tube (09). Be careful that the piston seals are not nicked or cut on the edge of the cylinder tube or when sliding them over the groove within the tube. 8. Next, install gland assembly into cylinder tube (09). Again, use care so the seals are not nicked or cut upon installation. 9. Check installation by making sure the piston rod assembly moves fairly easy within the tube assembly without binding. 10. Install gland bearing (20) and retainer (10). 11. The roller bearing and clevis assembly can be installed at this time if removed earlier.

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255

F-code

Section

C-code

PS S7.6 Tilt Cylinder

7320

Version no

T-code

000

396/397

5. Installation 1. Install tilt cylinder on carriage/reach front frame. Secure with mounting pin (05) with roll pin (06). 3. Properly connect correct hydraulic hoses to top and bottom of tilt cylinder. 4. Remove blocking and chains. 5. Fill hydraulic reservoir with new clean oil. 6. Connect battery. 7. Operate the tilt to remove air from hydraulic hoses and check operation of the of whole hydraulic system.

256

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F-code

Section

S7.7 7330 Reach Cylinder

Version no

C-code

T-code

001

Reach Cylinder

Seal Kit Contains Items Marked with “K” POS. NO

DESCRIPTION

POS. NO

Right reach cylinder

10K

Seal

Piston

Left reach cylinder

11K

Wiper

20K

Ring, guide

Pin, roll

Rod, cylinder

Nut, lock

Pin, clevis

Nut

22K

Retainer

Pin, clevis

Clevis

Right tube cylinder

Back-up ring

Spacer (2 stage mast only)

Left tube cylinder

O ring

16K

O Ring

Bearing

17K

Ring, back-up

Kit, seal

Ring, guide

18K

O Ring

Return

DESCRIPTION

Service Manual

1997-09-30

POS. NO

DESCRIPTION

257

F-code

Section

C-code

PS S7.7 Reach Cylinder

7330

Version no

T-code

001

1. Removal 1. Park the truck on a level surface and apply the brake. 2. Extend the reach about 1/2-3/4 of the total reach. 3. Block and chain the reach mechanism to prevent movement of the reach mechanism. 4. Relieve pressure on the reach cylinders. 5. Remove hoses from the reach cylinder. 6. Remove the front and rear mounting pins and remove reach cylinder from the truck. 7. To remove rear mounting pins, reach must be raised to full freelift.

258

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F-code

Section

S7.7 7330 Reach Cylinder

Version no

C-code

T-code

001

2. Disassembly NOTE! CLEANLINESS! Perform procedures in a clean environment. Make sure all parts are cleaned before disassembly and kept clean during assembly. 1. Before disassembly, clean exterior of the reach cylinder in a cleaning solvent to remove all contamination. WARNING Be extremely careful when working with solvent. Even a small explosion or fire could cause injury or death. WARNING Compressed air used for cleaning MUST be reduced to less than 30 p.s.i., and then only with effective chip-guarding and personal protective equipment. 2. Be sure all hydraulic fluid has been removed from the cylinder. Stroking the piston rod will help force the fluid out. 3. Put the base end of the cylinder in a vise equipped with soft jaws. 4. Remove the bearing retainer (22) and bearing (8) by rotating the bearing with a spanner wrench from cylinder tube (23 or 24). 5. Remove bearing assembly, seals, rings, rod (12) and piston (19) with spacer and piston seals. 6. Remove and discard all seals and rod wiper (11). 7. Inspect mounting bushings (25) located at base end of the cylinders. It will not be necessary to remove them unless they are found to be unfit for further service.

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259

F-code

Section

C-code

PS S7.7 Reach Cylinder

7330

Version no

T-code

001

3. Inspection 1. Carefully clean all parts in a cleaning solvent and position them on a clean work surface. WARNING Be extremely careful when working with solvent. Even a small explosion or fire could cause injury or death. WARNING Compressed air used for cleaning MUST be reduced to less than 30 p.s.i., and then only with effective chip-guarding and personal protective equipment. 2. Check the piston rod for damage. Look for gouges, scratches, corrosion, or evidence of unusual wear. Minor surface damage can be repaired by the use of fine abrasion cloth or stoning. Be extremely careful you do not remove the chrome plating. Deeper damage will require replacement of the piston rod assembly. Make sure the threads on the rod are free of damage. 3. Check cylinder bore for any damage. Parts with deep gouges or pitted surfaces will require replacement. 4. Check threaded section of the cylinder tube to be sure the threads have not been damaged.

260

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F-code

Section

S7.7 7330 Reach Cylinder

Version no

C-code

T-code

001

4. Assembly 1. Install new O rings and rod wiper in the bearing assembly. The “lip” of the wiper must face outward. 2. Install new bearing seals, back-up ring (17), and bearing (8) on the bearing assembly. 3. Install new piston seals on the piston (19). 4. Install piston (19) on rod. 5. Install nut (21) on cylinder rod (12). Torque reach cylinder piston nut to 40 ft-lb (N•m). 6. Apply clean hydraulic fluid to the piston rod assembly. Coat the inside of the cylinder tube and bearing assembly with clean fluid. 7. Carefully slide the spacer (if used) and bearing assembly onto the cylinder rod. Be sure the rod end does not cut or nick the wiper or packing upon installation. 7. Install piston (19) and cylinder rod (12) into cylinder tube (23 or 24). Be careful that the piston seals are not nicked or cut on the edge of the cylinder tube or when sliding them over the groove within the tube. 8. Next, install bearing assembly into cylinder tube. Again, use care so the seals are not nicked or cut upon installation. 9. Check installation by making sure the piston rod assembly moves smoothly within the tube assembly without binding. 10. Install bearing (8) and retainer (22).

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261

F-code

Section

C-code

PS S7.7 Reach Cylinder

7330

Version no

T-code

001

5. Installation 1. Raise reach to full freelift height and install reach cylinder and front and rear mounting pins. Secure mounting pins with roll pins. 2. Connect correct hydraulic hoses to reach cylinders. 3. Remove blocking and chains. 4. Fill hydraulic reservoir with new clean oil. 5. Connect battery. 6. Operate the reach to remove air from hydraulic hoses and check operation of the of whole hydraulic system.

CAUTION DO NOT use your hands to check for hydraulic leakage. Use a piece of cardboard or paper to search for leaks. Escaping fluid under pressure can penetrate the skin causing serious injury. Relieve pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Keep hands and body away from pinholes and nozzles which eject fluids under high pressure. 7. After running the hydraulic system, check and fill the hydraulic reservoir with more new clean oil.

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F-code

Section

S9.0 9310 Height Indicator

Version no

C-code

T-code

000

395/396/397/398/399

Height Indicator

18 14 10

1 16

11 12

9 7 8 2

Wiring Harness 4

POS. NO

Return

DESCRIPTION

POS. NO

DESCRIPTION

POS. NO

DESCRIPTION

Support

Ring, locking

Device, sensing

Cover

Bearing

Screw

Anchor, bottom

Washer

Nut

Spring

Screw

Roller

Arm

Cable

Bearing

Screw

Ring, snap

Setscrew

Service Manual

1997-07-15

263

F-code

Section

C-code

PS S9.0 Height Indicator

9310

Version no

T-code

000

395/396/397/398/399

1. Pulse sensor 1.1. Repair 1. Unplug wiring connector from assembly. 2. Remove screws (16) and remove cover (2). 3. To replace pulse sensor (15), loosen setscrew (14) and remove pulse sensor. 4. Remove screws (13) and remove arm (12). Reverse procedure to reinstall.

1.2. Cable 1.2.1. Removal 1. To replace cable (19), remove bolt from bottom anchor (3) relieving spring tension. 2. Remove spring (4) and anchor (3) from cable (19). 3. Remove cable (19) from top anchor, and remove from pulley. 1.2.2. Installation 1. Install new cable (19) on top anchor. Wrap cable once around pulley wheel. 2. Attach spring (14) and bottom anchor (3) to cable (19). 3. Stretch cable (19) tight and reinstall bottom anchor bolt.

1.3. Pulley 1.3.1. Removal 1. To replace pulley wheel (5), remove cover (2), pulse sensor, and cable (19). 2. Remove screw (11) and remove pulley wheel. 3. Remove bearing (9), retaining rings, (7 and 8) and bearing (6). 4. Reverse procedure to reinstall.

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1997-07-15

F-code

Section

C-code

PS S9.1 9390 Height Indication & Preset Height Version no

000

T-code

395/396/397/398/399

Height Indication & Preset Height 01

Return

Service Manual

POS. NO

DESCRIPTION

Indicator, lift height

Range of lift preseletion

1997-07-15

265

F-code

Section

C-code

PS S9.1 9390 Height Indication & Preset Height Version no

T-code

000

395/396/397/398/399

1. General A height indicator is fitted to trucks with high lifting heights which show the current position of the forks within the staging zone. The character window (01) shows the fork height, based on information from the sensing device (pulse sensor) (15) mounted on mast.

2. Operation The measurement in the staging zone starts when the reference switch (S45) is activated and sends a signal to the electronic card (A5). The pulse sensor (15) send pulses to (A5) which starts by indicating the preprogrammed free lift height on the display (02). The pulse sensor has two channels, A and B, which give signals at 90 degree to each other. This gives information to (A5) on whether the forks are moved up or down.

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F-code

Section

C-code

PS S9.1 9390 Height Indication & Preset Height Version no

000

T-code

395/396/397/398/399

3. Preset Height By using the preset height, the operator can lift and lower the forks to a maximum of 99 different programmable levels, within the main lift zone. Based on height information obtained from the pulse sensor, the lift and lowering mechanism is controlled to stop at the required level. Depositing or collecting of the load takes place manually. The correct height for depositing or collecting the pallet is requested/programmed via the keyboard. The selected level can be read on the display, which also indicates any error codes.

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267

F-code

Section

C-code

PS S9.1 9390 Height Indication & Preset Height Version no

T-code

000

395/396/397/398/399

4. Display The diagram shows the rear of the display for preset height. Table describes the contactor’s terminal number where I stands for input and O stands for output.

Contactor Terminal Number Terminal Number

Connection

TX (+), transmits data

RX (+), receives data

+48V

TX (-), transmits data

Minus

RX (+), receives data

Function

268

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Section

C-code

PS S9.1 9390 Height Indication & Preset Height Version no

000

T-code

395/396/397/398/399

5. Description of the display symbols. Symbol

Function Numerical push-buttons for setting height levels.

For control of the required height level while driving. STOP During automatic mode, height levels that have been incorrectly entered can be deleted. This cuts programming and causes a stop due to an error. Save “LEAVE level” when programming.

Save “COLLECT level” when programming. LOAD Push-button to indicate that the operator has a load on the forks when starting. Push-button to access programming routines. Display for indicating height levels and error codes.

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269

F-code

Section

C-code

PS S9.1 9390 Height Indication & Preset Height Version no

T-code

000

395/396/397/398/399

6. Programming Press the button PROG briefly to enter the programming mode. The LED in the button comes on and the display shows PL00 when programming routines have been started. You can program new lifting heights, modify programmed values, or remove programmed values.

6.1. Programming a Level Programming of lift heights can only take place within the staging zone, above initial lift. NOTE: Forks not horizontal. The load can slide off the forks or catch on the rack. When the load is left or collected, the forks should always be positioned horizontally.

6.1.1. Collection Level 1. Press the PROG button briefly. State the required level (e.g., 1+5=level 15). The numbers are shown on the display. 2. Lift the forks to the required level and press the button COLLECT. The LED flashes. 6.1.2. Leaving Level 1. Pick-up the load and wait three seconds. Lift the forks just enough so that the pallet can be removed from the rack. Ensure that there is sufficient space for safe handling. 2. Now press the LEAVE button, both LEDs for collecting and leaving will start to flash. 3. Press the PROG button until both the LEDs go out and the display indicates PL00, storing information. 4. Repeat from the first point to program more levels. 5. Press STOP to return to the display mode.

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6.2. Erasing Programmed Levels 1. Lower the forks to the free lift zone when programmed lifting heights are to be erased. 2. Enter the programming mode and state the required level (e.g., 1+5=level 15). The number is shown on the display. 3. Press the COLLECT button (the LED flashes) and then press the LEAVE button (both LEDs start to flash). 4. Press the PROG button until both LEDs stop flashing and the display shows PL00 to erase the memory. 5. Press the STOP button to return to the display mode. 6.2.1. Automatic Operations There are two different automatic operating modes, one where the forks are raised/lowered to required level without a load and the other with a load. 6.2.2. Collecting a Load 1. State the required height level using buttons 0-9, (e.g., 1+2=level 12). The display will show LE12. 2. Raise/lower the forks until they are automatically stopped by the electronics. If the wrong direction is chosen, no raise/lower movement will take place. The program expects the correct direction to be selected. 3. When the forks stop and the COLLECT LED comes ON, the forks can be maneuvered in under the load. NOTE: Forks not horizontal. The load can slide off the forks or catch on the rack. When the load is left or collected, the forks should always be positioned horizontally. 4. Lift the forks until they are automatically stopped by the electronics and the LED leave comes ON. © BT Products

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5. Move the load from the rack. When the work cycle has been completed, the LEDs will go OUT. 6.2.3. Leaving a Load 1. Press the LOAD button (the LED now comes ON). 2. State the required height level using buttons 0-9, (e.g., 5=level 05). The display will show LE05. 3. Raise/lower the forks until they are automatically stopped by the electronics. If the wrong direction is chosen, no raise/lower movement will take place. The electronics expects the correct direction to be selected. 4. When the forks stop and the LEAVE LED comes ON, the forks can be maneuvered out from under the load. NOTE: Forks not horizontal. The load can slide off the forks or catch on the rack. When the load is left or collected, the forks should always be positioned horizontally.

5. Lower the forks until they are automatically stopped by the electronics and the COLLECT LED comes ON. 6. Remove the forks from the rack. When the work cycle has been completed, the LEDs will go OUT.

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6.3. Parameters There are a number of parameters that can be modified in the preset height program. 1. Press the button PROG for three seconds to start programming routines. The LED comes on and the display show P_ _ _. 2. Use the numerical keys to enter code 852. The display will now show P_. 3. State the required parameter 1 - 9 and then press the LOAD button. The display shows the factory settings. These can be changed to any of the min/ max. values shown in the, Parameters table. NOTE: If a value outside the min/max. range is programmed in, this will be replaced by the max/min. factory setting.

4. Press the STOP button to complete programming.

P1 Select the measurement unit (meters or inches) you wish to use. Press the PROG button to save the unit you selected. The display shows P_.

P2 If the distance between lifting heights is equal on all levels, you can make a common program: 1. State parameter 2 and press the LOAD button. The display shows P 00 and you now enter the number of levels. Press the LOAD button and the display shows P000. 2. Enter the "collect height" for the first level, in steps of 10 mm. Press the LOAD button and the display shows P000. 3. The next value to enter is the distance between the collect and leave level, in steps of 10 mm. Press the LOAD button and the display shows P000.

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4. The last value to enter is the distance between each leave level, in steps of 10 mm. Press the PROG to save the programmed values. The display shows P_.

P3 Programming the crawling speed for braking distances: 1. State parameter 3 and press the LOAD button. The display shows the previously programmed value for the crawling speed lower. Enter the new value using the numerical keys. The permitted max/min. values are shown in the Parameters table. 2. Press the LOAD button to change the crawling speed lift. The display shows the value for the crawling speed. Enter the new value using the numerical keys. 3. Press the PROG button to save the new values. The display shows P_.

P5 Programming the tolerance for the "stop levels": 1. State parameter 5 and press the LOAD button. The display shows the previously programmed value for the tolerance. Enter the new value using the numerical keys. The permitted max/min. values are shown in the Parameters table. 2. Press the PROG button to save the new values. The display shows P_.

P7 Programming of the largest and smallest permitted programming distance between the levels collect and leave: 1. State parameter 7. The display shows the previously programmed value for the min. distance. Enter the new value using the numerical keys, (e.g., 030=30 mm). The permitted max/min. values are shown in the Parameters table.

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2. Press the Load button. The display shows the previously programmed value for the max distance. Enter the new value using the numerical keys, (e.g., 150=150 mm). 3. Press the PROG button to save the new values. The display shows P_.

P8 Reset all parameters to the factory settings. NOTE: Reset all factory parameters after upgrading to a new program version. 1. State parameter 8 and press the LOAD button. The display shows no value. 2. Press the PROG button until the display stops showing PP. 3. Turn the key switch on and off to start the new Program.

P9 Programming the braking distance for “leave/collect levels”. 1. State parameter 9 and press the LOAD button. The display shows the braking distance for lower. Enter the new value using the numerical keys, (e.g., 050=500 mm). 2. Press the LOAD button. The display shows the braking distance for lift. 3. Enter the new value using the numerical keys, (e.g., 030=300 mm). 4. Press the PROG button to save. The display shows P_.

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Parameter Table Parameter number

Max/min. value

001 002

Factory setting

Unit

Function

m-10 mm inch-10ths of an inch

Measurement unit

Programming of several levels at equal collect/leave distances. 1-69 0-999 0-255 0-999

10s of mm 10 mm 10 mm % of maximum speed

Crawling speed before stop: Lower Lift

0-127 0-127

015 020

0-255

010

Permitted error tolerance in stop position.

0-255 0-255

030 150

Minimum distance between leave/collect.

Resetting of all values to factory settings.

P9 0-255 0-255

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Number of levels. Distance first “collect height”. Distance collect-leave. Distance between “leave levels”.

050 030

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Position

Function

Leave level

Collect level

Staging zone

Free lifting zone

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C P3 P9 P7

A P5 B

P3 P5 P9

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Error Codes Error Code

Remark

Err 1

The requested height level is not programmed or is incorrect.

Err 2

The forks have stopped outside of the tolerance area (P5).

Err 9

Incorrect values stated when programming.

Err flashes

Communication error between the preset height and the truck computer.

• Four lines light up when started. This indicates that no communication has been established between the preset height and the main electronics. These go out when contact between the two units has been established.

• Four points are lit in the display when the forks are in the free lift zone.

• If the points flash, this indicates that the reference switch was active when the truck was started, e.g., the forks were over the free lift zone. If the points still flash, the preset mast height could be set to “ 0”; or when the forks are lowered, there can be a fault in the wiring; or the reference height switch can be faulty.

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BT Prime-Mover, Inc., 3305 N. Highway 38, Muscatine, Iowa 52761-8800 U.S.A Tel (319) 262-7700 • Fax (319) 262-7600

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