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Service Manual TMX Electric Tow Tractor Effective Serial Number TMX0026288001

Warning Read and observe all warnings on this unit before operating it.

NOT operate this equipment unless all Warning DO factory installed guards and shields are properly secured in place. Part no: 303047-000

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Date: March 20, 1998

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BT Standard Codes Version no

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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 ................................................................................................ 3 Warning Symbols .................................................................................................. 11 Warning Levels .................................................................................................. 11 Prohibitory Symbols ............................................................................................. 12 Ordinance Symbols ........................................................................................... 12 Introduction, Service Manual ............................................................................... 13 Contents, Section M .............................................................................................. 15 Machine Information .......................................................................................... 15 General Product Information ............................................................................... 17 Presentation of the TMX. ................................................................................... 17 Intended Application of the Trucks ............................................................ 17 Forbidden Application of the Trucks .......................................................... 18 Truck Data ................................................................................................. 18 TMX Dimensions ....................................................................................... 19 Data Plate .................................................................................................. 20 Main Components .............................................................................................. 21 Inch (SAE) and Metric Fasteners ......................................................................... 23 Introduction ........................................................................................................ 23 Nomenclature, Threads ..................................................................................... 24 Strength Identification ........................................................................................ 25 Conversion of Metric and English Units ............................................................. 31 Technical Service Data ......................................................................................... 33 Ordering Spare Parts ............................................................................................ 35 Contents, Section P .............................................................................................. 37 Planned Maintenance ........................................................................................ 37 Introduction, Maintenance ................................................................................... 39 Safe Jacking Procedure ..................................................................................... 39 Service Schedule .................................................................................................. 41 Planned Maintenance Schedule ........................................................................ 41 Planned Maintenance Procedures ..................................................................... 44 Services to be Performed Daily ................................................................. 44 Services to be Performed Monthly ............................................................. 46 Services to be Performed Annually ........................................................... 49 Lubrication Chart .................................................................................................. 51 © BT Products

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Table of Contents Oil and Grease Specifications ............................................................................. 53 Approved Oils and Grease ................................................................................ 53 Contents, Section S .............................................................................................. 55 Service Instructions ........................................................................................... 55 Chassis .................................................................................................................. 57 General Information ........................................................................................... 57 Drive Motor Mounting Points ............................................................................... 59 Drive Motor Brush .............................................................................................. 60 Removal and Installation ........................................................................... 60 Drive Motor Assembly ........................................................................................ 60 Remove ..................................................................................................... 60 Installation .................................................................................................. 61 Drive Motor ............................................................................................................ 63 General Information ........................................................................................... 63 Operating Conditions ......................................................................................... 63 Troubleshooting ................................................................................................. 63 Drive Motor Service .............................................................................................. 69 Motor Repair ...................................................................................................... 70 Disassembly .............................................................................................. 70 Inspection and Troubleshooting ......................................................................... 73 Drive End Head ......................................................................................... 73 Commutator End Head .............................................................................. 73 Bearings ..................................................................................................... 73 Brush and Commutator .............................................................................. 74 Armature .................................................................................................... 74 Frame and Field Assembly ........................................................................ 75 Assembly ................................................................................................... 77 Changing Brushes ............................................................................................. 78 Transmission ......................................................................................................... 79 System Description ............................................................................................ 79 Troubleshooting ................................................................................................. 79 Removal ............................................................................................................. 80 Installation .......................................................................................................... 81 Transmission Axle Seal ........................................................................................ 83 General Information ........................................................................................... 83 Removal ..................................................................................................... 83 Installation .................................................................................................. 83

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Table of Contents Transmission Disassembly / Assembly .............................................................. 85 Disassembly ...................................................................................................... 86 Assembly ........................................................................................................... 86 Parking Brake System .......................................................................................... 89 Brake Theory of Operation ................................................................................ 90 Brake Adjustment .............................................................................................. 91 Brake Shoe Removal / Installation ..................................................................... 92 Brake Interlock Switch ....................................................................................... 93 Drive Wheel ............................................................................................................ 95 Removal ..................................................................................................... 95 Installation .................................................................................................. 96 Load Wheels .......................................................................................................... 97 Steering Control Arm ............................................................................................ 99 Control Handle Stem ........................................................................................ 100 Removal .................................................................................................... 100 Installation ................................................................................................. 101 Hand Brake Levers ........................................................................................... 102 Removal .................................................................................................... 102 Disassembly ............................................................................................. 102 Assembly .................................................................................................. 102 Installation ................................................................................................. 103 Steering Handle head .......................................................................................... 105 Control Handle Head ........................................................................................ 107 Removal .................................................................................................... 107 Installation ................................................................................................. 107 Direction Control Switches ................................................................................ 108 Horn Switch ...................................................................................................... 109 Potentiometer ................................................................................................... 111 300/400 Amp Contactor ....................................................................................... 113 Maintenance ..................................................................................................... 114 Removal/Replacement of Contact Tips .................................................... 114 “EE” Contactor ..................................................................................................... 117 Maintenance ..................................................................................................... 118 Removal/Replacement of Contact Tips .................................................... 118 Battery Controller / Hourmeter / Speed Dropout ............................................... 121 General Information .......................................................................................... 121 Electrical ........................................................................................................... 121

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Table of Contents Voltage ...................................................................................................... 121 Battery Controller (BC) ..................................................................................... 122 General Information .................................................................................. 122 Reset ........................................................................................................ 124 Key Switch ................................................................................................ 124 Hourmeter ................................................................................................. 124 Troubleshooting ................................................................................................ 125 Battery Discharge Indicator (BDI) ............................................................. 125 Hourmeter ................................................................................................. 127 Battery Discharge Indicator / Hourmeter ........................................................... 129 General Information .......................................................................................... 129 Electrical ........................................................................................................... 129 Voltage ...................................................................................................... 129 Battery Discharge Indicator (BDI) ..................................................................... 130 General Information .................................................................................. 130 Key Switch ................................................................................................ 130 Hourmeter ................................................................................................. 130 Troubleshooting ................................................................................................ 131 Battery Discharge Indicator (BDI) ............................................................. 131 Hourmeter ................................................................................................. 132 24 Volt 400 Amp Electrical System ..................................................................... 135 Electrical Panel Components ............................................................................ 135 List of Symbols ................................................................................................. 136 Circuit Diagram 1(3) .................................................................................. 138 Circuit Diagram 2(3) .................................................................................. 139 Circuit Diagram 3(3) .................................................................................. 140 Description of Function ..................................................................................... 141 General Information .................................................................................. 141 References Information ............................................................................ 141 Key Switch S17 in the ON Position ........................................................... 141 The Operating Arm in Drive Position, S10, Brake Switch Closed ............. 141 Driving, Load Wheels Direction ................................................................ 142 Driving, Steer Wheel Direction .................................................................. 142 Reversing/Motor Brake Load Wheels Direction to Steer Wheel Direction 142 Reversing/Motor Brake Steer Wheel Direction to Load Wheels Direction 142 Horn .......................................................................................................... 142 24 Volt, 400 Amp Transistor Controller .............................................................. 143 Maintenance ..................................................................................................... 143 Safety ........................................................................................................ 143 Cleaning .................................................................................................... 143 Diagnostics and Troubleshooting ............................................................. 144 Basics Of Circuit Operation .............................................................................. 146 Control Features ....................................................................................... 148 © BT Products

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Table of Contents Motor Circuit ..................................................................................................... 150 Control Circuit ................................................................................................... 150 Diagnostics and Troubleshooting ..................................................................... 153 1307 Programmer Diagnostics ................................................................. 153 Troubleshooting Chart .............................................................................. 154 Technical Specification ............................................................................. 158 Troubleshooting Chart Using the Handset ................................................ 159 24 Volt, 400 Amp Transistor Controller Troubleshooting ................................ 161 Troubleshooting Chart Index ............................................................................ 161 Troubleshooting Charts .................................................................................... 162 Handset Operation ............................................................................................... 171 Operating Modes .............................................................................................. 173 Revert to Previous Settings .............................................................................. 177 Handset Self Test ............................................................................................. 177

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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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TMX

Introduction, Service Manual The information in this Service Manual covers model TMX. 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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TMX

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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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PS M1.0 General Product Information Version no

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TMX

General Product Information 1. Presentation of the TMX. The TMX is a battery powered center riding tow tractor. This truck is intended solely to be used for towing loads indoors. In their standard design the truck is equipped with a steering arm with all the controls for operating within easy access. The trucks have a maximum rolling load capacities of 1200 lb. (review data plate on the truck to note the maximum towing capacity). This truck is equipped with a 24 volt electrical system and the speed is regulated by means of a transistor controller to provide infinite control of acceleration and speed while driving. The towing devices at rear of truck can be positioned for proper alignment of tow trailer by unbolting device and repositioning. 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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TMX

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

Do not use in areas that contain gases which can cause fires or explosions

Do not use to tow other trucks

Do not use to transport passengers

Do not use to drive on gravel or grass

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

Truck data

TMX

Operating speed without load, mph

8.0 mph

Operating speed with load, mph

6.0 mph

Service weight without battery, lb

1350 lb

Service weight including battery, lb Minimum battery weight is 400 lb

Above + battery weight

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

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TMX

1.4. TMX Dimensions The following diagram shows external dimensions for the TMX truck in its standard design. 43.7” R

34.1”

51.3” Area of ride platform (541 in.2) 30° Battery compartment 13.3”

17.3”

54.3”

51.5”

6.9” 2.9”

31.8” 2.1”

12.1” max 6.6” mim 11.7” max 5.9” mim 3.6”

15° 9.7”

11.7” max 6.2” mim

Battery 26° roller height 8.9” 34.0” 53.2”

Important Use only batteries that meet the following specifications: Compartment Size: Deep Wide Battery Weight

Minimum Maximum 12.8” [325 mm] 13.3” [338 mm] 32.9” [836 mm] 33.4” [848 mm] (Consult Data plate on truck)

For smaller industrial battery sizes, provide blocking to restrain the battery from moving not more than 0.5” [12.7 mm] in any horizontal direction. © BT Products

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TMX

1.5. Data Plate The following diagram shows the data plate used on the truck.

Legend 1 Truck model number 2 Truck type 3 Truck serial number 4 Truck weight (Less battery weight) 5 Truck voltage 6 Minimum battery weight 7 Battery type 8 Maximum battery weight 9 Battery maximum AMP hours 10 Drive tire part number 11 Drawbar maximum pull 12 Drawbar normal pull 13 Coupler height at maximum drawbar pull 14 Coupler height at normal drawbar pull

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TMX

2. Main Components 11

1/2

1 8

I O

12 1

7,8 1. Steering control handle: The truck is to be controlled by the operator with 180 degree steering angle. 2. Battery: 24 volt with different capacities and weights. 3. Drive unit with brake: Drive motor, gears drive wheel and brake combined in the drive unit. 4. Data plate: Contains data designation, manufacturing number, year of manufacture, service weight, battery weight, classified lifting capacity, battery voltage and manufacturer. © BT Products

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5. Cover: Removable to provide good access for servicing. 6. Gauge: This provides information on the truck’s running hours and battery status. 7. Electronics: All the electronics compartment.

are

collected

protected

8. Circuit breaker: 12A, BT Control circuit breaker part number 301889-000 150A, BT Drive circuit breaker part number 307601-000 9. Key switch (toggle switch): Shuts off electrical power to control system. 10. Emergency stop The emergency stop switch will stop all control functions. 11. Handle brake lever Hand controlled lever that is squeezed to apply brake. 12. Parking brake lever Parking brake lever must be placed in the engaged position when truck is not in use (parked) or hand brake lever is not squeezed. 13. Horn switch the horn sounds to warn others of your position. 14. Travel speed / direction selection To select direction rotate in the direction you wish to move. The further in that direction you rotate the faster you move.

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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 Hea 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 Require

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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M2.0 Technical Service Data

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TMX

Technical Service Data DRIVE MOTOR Type

Shunt wound

Power

1.8 hp

Duty factor

60 min.

Min carbon brush length

0.62 in.

Min commutator diameter

2.80 in.

Min brush spring tension

40 oz.

Part number

305880-000

TRANSMISSION/GEAR Type

Vertical Motor spiral-bevel output

Gear ratio

14.8:1

Oil volume

About 1 quart

Normal temperature

SAE 80W90

Below +5°F-15°C

ATF

WHEELS Drive wheel

10.5 in. x 5 in. x 6.5 in.

Drive wheel weight without load with battery, lb Drive wheel weight with rated load and battery, lb Torque axle nut

250 ft-lb

Load wheel

7 in. x 4 in.

Load wheel weight with rated load, lb

FUSES

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Drive circuit breaker

150 Amp

Control circuit

12 Amp

Service Manual

1997-10-02

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BATTERIES Dimension W x L x H

31-3/4 in. x 13 - 5/8 in. x 32 in.

Capacity (Minimum/Maximum Amp-hrs.)

400/750

Weight (Minimum)

1000 lb

DRIVING SPEEDS Without load

8.0 mph

With rated load

5.0 mph

CURRENT CONSUMPTION Driving without load

80 Amp

Driving with rated load

Amp

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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1997-10-02

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PS Version no

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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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1997-07-15

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PS M3.0 Ordering Spare Parts Version no

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000

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1997-07-15

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PS Version no

Section

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P Contents, Section P T-code

000

Contents, Section P 1. Planned Maintenance

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P1.0

INTRODUCTION, MAINTENANCE

P2.0

SERVICE SCHEDULE

P3.0

LUBRICATION CHART

P4.0

OIL AND GREASE SPECIFICATIONS

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P1.0 Introduction, Maintenance

Version no

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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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1997-07-15

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PS P1.0 Introduction, Maintenance Version no

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000

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P2.0 Service Schedule

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Service Schedule 5200

3100

5300

4100 3100 0840

0840

3500 5300 5400 5710

5110 0000

1700 3100

2550 3500

1. Planned Maintenance Schedule ITEM 0000 0000.1 0000.2 0000.3 © BT Products

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WORK REQUIRED Interval in Hours Interval in Days/Weeks/Months Chassis Check that the truck data plate is legible Check for damage and cracks Retighten the truck body bolts Service Manual

5 1d

25 1w

100 1m

300 3m

600 6m

1200 12 m

3600 36 m

X X X 1997-10-02

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ITEM 0000.4 0640 0640.1 0640.2 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 3100.3 3100.4 3500 3500.1 3500.2 3500.3 4100 4100.1 4100.2 5110 5110.1

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WORK REQUIRED Interval in Hours Interval in Days/Weeks/Months Check the cover screws Operator Controls Check that the travel direction/ speed selectors operational Check that the horn button is 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 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 Steering Wheel Check fasteners Check ease of steering Battery Electrolyte level, 1/2 - 5/8 inch above cell plates

5 1d

25 1w

100 1m

300 3m

600 6m X

1200 12 m

3600 36 m

X X

X X X X X

X X X X X X X X X

Service Manual

X X X X

1997-10-02

ITEM 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

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WORK REQUIRED Interval in Hours Interval in Days/Weeks/Months 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 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

Service Manual

5 1d

25 1w X

100 1m

300 3m

600 6m

1200 12 m

3600 36 m

X X X

X X X X X

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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 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 this reach truck. 2.1.1. Battery Discharge Indicator with slow down The battery guard indicates the current charge status of the truck’s battery. 1

Full charge battery

1/2

Half charged battery

Discharged battery

The battery guard has an integrated cut-out function that cuts out the truck’s drive 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 percent discharge, a warning signal is given via flashing lights. A further 10 percent of the battery’s capacity can then be used before the battery guard cuts out the drive function. 2.1.2. Frame/Sheet Metal 1. Inspect the truck for loose, damaged or missing parts. All shields must be in place and functional. 2. Report any problems to the proper authorities. DO NOT operate the truck until it has been inspected and repaired by a qualified technician.

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2.1.3. 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. 2.1.4. Functions/Operations 1. 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. 2. Report any problems to the proper authorities. DO NOT operate the truck until it has been inspected and repaired by a qualified technician.

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2.2. Services to be Performed Monthly 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 Check the transmission fluid level. The level check point is a plug on the side cover of the transmission about 4 in. [100 mm] above the bottom of the transmission case. Remove the plug and inspect the level of the fluid inside the transmission case. The fluid level should come to about 3/8 in. [10 mm] below plug and should never be above the level of the plug. 2.2.3. Brakes The brakes should stop a fully loaded truck at full speed in approximately one truck length. Adjust the brake linkage as required. 2.2.4. Battery Contact your battery dealer for specific instructions on care and maintenance of the battery. An average battery will have a specific gravity of 1.170 at the 80 percent discharged level. However, there are many different batteries on the market. Only the battery manufacturer can accurately determine the fully charged and 80 percent charged levels. Contact the battery manufacturer for this information. 2.2.5. Electrical Connections 1. 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. 2. 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. This compound is 46

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available through the parts department of your authorized dealer. 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 Inspect drive motor for brush wear and condition of the commutator. 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 1. Blow out the drive motor fan and vents. 2. Check for any signs of oil on the drive motor fan and air vents. 3. 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. 2.2.9. Frame Lube (“Lubrication Chart” on page 5 1) 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.

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2.2.10. 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.

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2.3. Services to be Performed Annually 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 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. The drain port is the lower left hand bolt holding the side cover in place. 1. Remove the bolt to drain the transmission fluid. 2. Flush the transmission case with safety solvent. 3. Pour clean solution into the level check plug in the side cover. 4. With drive tire off the floor, allow solution to run out of drain port while transmission is running. Stop flushing when the solution run clean. Allow the solvent to drain well before replacing the drain plug bolt. 5. Replace the drain plug bolt. 6. 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. Brakes 1. Remove brake drum, and inspect brake shoe linings and brake drum for wear. If the brake drum is damaged or worn, a new drum should be fitted. 2. The brake shoes should be replaced if the linings

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TMX

have worn down so much that the brakes will not meet stopping and holding specifications. 3. See the procedures for adjusting brakes before replacing the brake shoes.

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1997-10-02

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P3.0 Lubrication Chart

Version no

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000

TMX

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Lubrication Chart Pos. no

Service point

Interval/Running hours 300h

1 2 3 4 5

Wheel bearings Handle pivot Steering bearings Drive gea Drive gear drain

600h

1200h

Lubricant (See Chart in Section P4.0 Code)

L L L O

L= Lubrication

C = Check

A A A C

O = Oil change

2 3

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1998-03-11

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PS P3.0 Lubrication Chart Version no

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000

TMX

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1998-03-11

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PS P4.0 Oil and Grease Specifications Version no

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000

TMX

Oil and Grease Specifications 3. Approved Oils and Grease Lubricant

Grease

Transmission oil

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Specification Above 5°F-15°C

Below 5°F-15°C

Tex. Ref. C and C #880 SAE 80W/90

Tex. Ref. C and C #880 SAE 75W

Service Manual

1998-03-11

Application area Below -10°F-23°C Tex. Ref. C and C #880 SAE 75W

Bearings and bushings Gears

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PS P4.0 Oil and Grease Specifications Version no

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000

TMX

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1998-03-11

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PS Version no

Section

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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

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1997-04-15

9000

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PS S Contents, Section S Version no

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000

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1997-04-15

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S0.0

0340 Chassis

Version no

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000

TMX

Chassis 1. General Information 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 bolt on panels and covers is for access of components when servicing the truck. 16 14 15 1 10

2 11 12

13 4

6 5

POS. NO

DESCRIPTION

POS. NO

DESCRIPTION

Screw

Cover

Screw

Bracket, hitch

Door

Bumper, door

Pad, platform

Latch

Pad, knee

Plate, platform

Plate, latch

Cushion, backrest

Screw

Angle, platform

Cover

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DESCRIPTION

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1998-03-11

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PS Chassis

S0.0

0340

Version no

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000

TMX

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1998-03-11

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PS S0.1 0450 Drive Motor Mounting Points Version no

T-code

000

CMX,TMX

Drive Motor Mounting Points 1

2 4

8 7 3 6

POS. NO

Return

DESCRIPTION

POS. NO

DESCRIPTION

Key

Transmission

Brake assembly

Drive motor

Screw

Drum, brake

Bracket, cable

Nut

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1997-09-22

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PS S0.1 0450 Drive Motor Mounting Points Version no

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000

CMX,TMX

1. Drive Motor Brush 1.1. Removal and Installation 1. Park the truck on a level surface and make sure the load wheels are blocked to prevent accidental movement. 2. Disconnect battery from the unit to prevent accidental operation. 3. Drive motor brushes are accessible by opening cover door and turning steering control handle. 4. Remove the shields around motor end cover to expose brushes. 5. Remove screws holding brush lead. 6. Lift spring off brush, remove brush from holder.

2. Drive Motor Assembly 2.1. Remov 1. Park the truck on a level surface and make sure the load wheels are blocked to prevent accidental movement. WARNING There is no brake on truck when drive motor is removed from transmission assembly. Block all wheels to prevent truck from rolling. 2. Disconnect battery from the unit to prevent accidental operation. 3. Open the access door on the front of the truck 3. Disconnect brake cable at yoke by removing cotter pin and yoke pin. 4. Disconnect power cables from drive motor and noting their proper position. Remove four drive motor mounting cap screw (3).

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1997-09-22

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PS S0.1 0450 Drive Motor Mounting Points Version no

000

T-code

CMX,TMX

WARNING With all four cap screws (3) removed from drive motor, the drive motor will be loose and can fall injuring you or damaging other equipment. 5. Remove drive motor from transmission and place drive motor assembly on a bench to continue disassembly. 6. At drive end armature shaft remove locknut and pinion gear from drive motor. 7. At commutator end armature shaft remove locknut and brake drum from drive motor. Lifting one brake shoe at a time the brake assembly mounting bolts can be removed without disassembling brake assembly. 8. Thoroughly clean gasket eliminator from mating faces of drive motor and transmission housing.

2.2. Installation 1. Thoroughly clean all parts with safety solvent or other non-corrosive cleaning fluid. Air dry all parts. The transmission should be assembled in a dirt-free area. 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 psi. and then only with effective chip-guarding and personal protective equipment. 2. Install brake assembly by lifting on brake shoe at a time and installing mounting bolts. (See Brake section for proper installation and adjustment of brakes). 3. Install brake drum on drive motor armature shaft over the key. © BT Products

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PS S0.1 0450 Drive Motor Mounting Points Version no

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000

CMX,TMX

4. Install pinion gear on drive motor over the key and tighten locknut. Place a wrench on both locknuts and tighten nuts to 30 ft-lb. 5. Apply gasket eliminator on the mating faces of drive motor and transmission. 6. Slide drive motor in gear case and work it around until motor lines up with intermediate gear. 7. Install four motor mounting screws (3) and torque screws to 35 ft-lb. 8. Connect the power cables to their proper terminals. 9. Connect brake cable yoke to brake lever. Install yoke pin and secure with cotter pin. 10. Adjust brake cable for proper adjustment (see parking brake section 3300 in this manual). 11. Install door cover. 12. Remove blocks, connect battery and test operation of truck.

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1997-09-22

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S1.0

1700 Drive Motor

Version no

T-code

001

Drive Motor 1. General Information A 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 key to planned maintenance of the brush and commutator is recognizing the undesirable brush and commutator conditions. If this is done, corrective action can be taken before a major component is damaged beyond serviceability. The brushes and commutator should be inspected for even wear and good commutation.

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)

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.

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Service Manual

1997-07-15

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PS S1.0 Drive Motor

1700

Version no

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001

TABLE #1 Drive Motor Troubleshooting

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

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 6-14-15-16-17-18-19-20-21-2829 25-27-28-29-38-39-40-41-42

Wrong brush grade Fluctuating contact drop

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

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

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

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S1.0

1700 Drive Motor

Version no

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001

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

Indications Appearing at Commutator Surface Indications

Immediate Causes

Primary Faults

Brush chipping or breakage

Commutator surface condition

See specific surface fault in evidence 15-16-17 52 See “Chattering or noisy brushes” 14

Looseness in machine Vibration Chattering 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 copper 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”

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1997-07-15

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PS S1.0 Drive Motor

1700

Version no

T-code

001

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

Indications Appearing as Heating 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 copper 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 commutator

Heating at brushes

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

1997-07-15

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S1.0

1700 Drive Motor

Version no

T-code

001

TABLE # 2

Primary Sources of Unsatisfactory Brush Performance Preparation and Care of Machine 1. 2. 3. 4. 5. 6.

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 7. 8. 9. 10. 11. 12. 13.

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 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.

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 25. 26. 27. 28. 29. © BT Products

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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

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PS S1.0 Drive Motor

1700

Version no

T-code

001

Machine Design 30. 31. 32. 33. 34. 35. 36. 37.

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 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50.

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 51. 52. 53. 54. 55. 56. 57. 58. 59. 60. 61. 62.

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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

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1997-07-15

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S1.1 1700 Drive Motor Service

Version no

T-code

001

392,CMX,RMX,HMX,TMX

Drive Motor Service

POS. NO

Return

DESCRIPTION

POS. NO

DESCRIPTION

Coil, field

Endhead, commutator

Lead assembly

Band, head

Brus

Armature

Spring

Ring, retainer

Plate, brush

Bearing

Endhead, drive

Washer, wave

Seal, shaft

Service Manual

1997-09-22

F-code

Section

PS S1.1 Drive Motor Service Version no

C-code

1700

T-code

001

1. Motor Repair 1.1. Disassembly 1. Remove the cover band from the commutator end of the motor.

2. Use a brush hook to reach into the motor and lift the brush springs. Pull the brushes 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 and drive end head as an assembly from the frame and field coil assembly.

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Service Manual

1997-09-22

F-code

PS Version no

001

Section

C-code

S1.1 1700 Drive Motor Service T-code

392,CMX,RMX,HMX,TMX

6. Separate the armature from the drive end head. 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. 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.

Bearing Inner Race Snap ring

Press Ram

Pipe (same size as Inner Race)

7. Remove snap ring from the end head then press the bearing out of the end head. Commutator end hea

Bearing Snap ring

Armature shaft Pressing end head back on armature shaft

End head

8. The ventilation fans are cast aluminum. Once these fans have been pressed onto the armature they must be heated to be removed without damage. A puller is installed and a slight pressure exerted 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, it should be removed as quickly as possible.

Use “Loctite” on this area of shaft © BT Products

Return

9. When the fan is assembled 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 assembling fan.

Service Manual

1997-09-22

F-code

Section

PS S1.1 Drive Motor Service Version no

C-code

1700

T-code

001

10. After the motor has been separated into all its major subassemblies, the components should be cleaned and inspected for wear or damage.

Return

Service Manual

1997-09-22

F-code

PS Version no

001

Section

C-code

S1.1 1700 Drive Motor Service T-code

392,CMX,RMX,HMX,TMX

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 the armature shaft. Ball bearings that have been pulled off of 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. Although the bearing may appear or feel good, the bearing races have been brinelled and will fail within a relatively short period of service.

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Service Manual

1997-09-22

F-code

Section

PS S1.1 Drive Motor Service Version no

C-code

1700

T-code

001

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, scored or 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 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, in which case the armature must be replaced. 3. Check for grounded circuits using a test light. Most commercial growlers incorporate a test light as shown in the illustration below. 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. 4. Standard winding armatures are tested on a growler (see the illustration) using a steel strip or hacksaw 88

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Service Manual

1997-09-22

F-code

PS Version no

001

Section

C-code

S1.1 1700 Drive Motor Service T-code

392,CMX,RMX,HMX,TMX

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. 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.

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 condition of all other insulation such as brush rigging under coil connections and around terminal studs. 2.6.1. Testing Frame and Field Assembly 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

1997-09-22

F-code

Section

PS S1.1 Drive Motor Service Version no

C-code

1700

T-code

001

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.

Return

Service Manual

1997-09-22

F-code

PS Version no

001

Section

C-code

S1.1 1700 Drive Motor Service T-code

392,CMX,RMX,HMX,TMX

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.

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. Soldering guns cannot provide the heat concentration required and soldering torches can damage the insulation.

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. Press on the outer race when installing into end heads. © BT Products

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Service Manual

1997-09-22

F-code

Section

PS S1.1 Drive Motor Service Version no

C-code

1700

T-code

001

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

The motor should be connected, as specified in Troubleshooting, and tested to the specifications.

When testing motors the voltmeter connections must be made at the motor terminals.

3. Changing Brushes When changing brushes the commutator must be serviced as follows:

Return

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.

Service Manual

1997-09-22

F-code

Section

S2.0 2550 Transmission

Version no

C-code

T-code

001

CMX,TMX

Transmission 1. System Description This transmission is of the double reduction gear type. The gears are a combination of helical and straight cut gears for strength and low noise. The final drive gear is mounted on opposing tapered roller bearings, and the intermediate gear is mounted on ball bearings. Gears and bearings are enclosed in an oil filled case. The drive motor is mounted externally with the drive motor pinion gear mounted on the armature shaft. The brakes are on the drive motor.

Technical data Gear Ratio

14.8:1

Oil Type

GL5 80W90

Oil Capacity

Approximately 1 quart

Drive Tire Size

10.5 in. x 5 in. x 6.5 in.

2. Troubleshooting Because of the uncomplicated nature of this transmission troubleshooting is limited to identifying whether problems are mechanical or electrical in nature. Fluid leaks are obviously mechanical in nature and can be found by visual inspection. Unusual noise and/or slow running could be mechanical or electrical in nature. Generally speaking, if the problem is caused internally in the transmission then metal contamination will be evident in the oil. If there is a mechanical problem outside of the transmission then it will become evident by inspecting the drive motor and brakes.

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Service Manual

1997-07-15

F-code

Section

C-code

PS S2.0 Transmission

2550

Version no

T-code

001

CMX,TMX

3. Removal Handle Stem assembly

1. Park the truck on a level surface and make sure the load wheels are blocked to prevent accidental movement. 2. Disconnect and remove the battery from the unit to prevent accidental operation. Small Felt Seal

3. Open the access door on the front of the truck and remove from the truck by lifting off hinge pins.

Bearing Con

4. Remove kick panel around transmission.

Bearing Cup

5. Label power cables and disconnect from the drive motor. Remove power cables from the transmission case and housing. Cables can be left attached to the electrical control panel on the truck. 6. Remove the cotter pin and yoke pin attaching the brake cable to the brake lever at the motor. 7. Remove the wires to the brake interlock switch and detach the brake cable bracket. 8. Remove six socket head screws that secure the handle stem to the transmission pivot tube. Lift the handle stem from transmission.

Large Felt Seal

Bearing Cup

Bearing Cone

Transmission assembly

WARNING Transmission assembly is secured to the truck frame with bolts that mount the control handle tube. When released the transmission can fall away from the truck causing injury. 9. Use an overhead lifting device to lift the truck off the transmission assembly. The bearing may be tight on the transmission tube. WARNING The transmission must be supported to keep it from falling over when the tube clears the truck frame. When released the transmission can fall away frame truck causing injury. 11. Remove the transmission from under truck.

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Service Manual

1997-07-15

F-code

Section

S2.0 2550 Transmission

Version no

001

C-code

T-code

CMX,TMX

4. Installation Handle Stem assembly

NOTE! Pack the upper and lower bearing with grease before installing.

Small Felt Seal

1. Install the bearing cup in the bottom of the truck frame. The bearing cup is a slip fit and may be retained using a dab of heavy grease between the cup and frame.

Bearing Con

2. Place a new felt seal in the groove formed by the bearing cup and frame. 3. Install the lower bearing cone on the transmission case. Seat the bearing tight on the case.

Bearing Cup

4. Raise the truck frame with an overhead lifting device and position the transmission under the frame. Carefully lower the frame onto the transmission. Be careful not to dislodge the bearing cup or felt seal. 5. Install bearing cup in top bore of truck frame. 6. Install the upper bearing and felt seal on top of the transmission tube. 7. Route power cables and wiring harness through housing, and connect cables to drive motor.

Large Felt Seal

8. Install handle stem and secure with six socket head screws. 9. Adjust brakes and brake switch.

Bearing Cup

Bearing Cone

10. Lube the transmission pivot bearing while slowly rotating the transmission only filling the space between the bearing. 11. Install kick panel and access door. 12. Test operation.

Transmission assembly

Return

Service Manual

1997-07-15

F-code

Section

C-code

PS S2.0 Transmission

2550

Version no

T-code

001

CMX,TMX

Return

Service Manual

1997-07-15

F-code

Section

C-code

S2.1 2550 Transmission Axle Seal

Version no

T-code

002

Transmission Axle Seal 1. General Information The drive axle seal can be replaced without removing the gear case cover by following these steps. Before starting disassembly of any parts thoroughly clean out side of assembly with safety solvent or other non-corrosive cleaning fluid. Air dry all parts. WARNING Be extremely careful when working with solvent. Even a small explosion or fire could cause injury or death.

1.1. Removal 1. Drain transmission oil. 2. Disconnect the battery. Trucks with side battery exit, check to make sure the battery retainer plate is properly installed to prevent battery from moving. 3. Jack the front of the truck so the drive wheel is approximately 1 in. [25.4 mm] off the floor. Block the truck in this position. 4. Remove flanged nut on drive axle and remove drive wheel. 5. Remove axle seal with seal puller or pry out with pry bar. Take care not to damage sealing surface or mounting bore.

1.2. Installation 1. Check thread on hub and nut for damage. 2. Install new oil seal. 3. Install drive tire on drive axle. Secure with new axle nut torqued to 250 ft-lb [339 N•m]. Failure to use a new nut could result in damage to the wheel and/or transmission.

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Service Manual

1998-07-06

103

F-code

Section

C-code

PS S2.1 2550 Transmission Axle Seal Version no

T-code

002

NOTE! Replace axle nut with new nut each time drive axle is removed. Failure to replace with new nut could result in damage to drive wheel and/ or transmission. 4. Lower truck off blocks. 5. Refill transmission case with new fresh oil.

104

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Service Manual

1998-07-06

F-code

Section

C-code

PS S2.1 2550 Transmission Disassembly / Assembly Version no

T-code

002

Transmission Disassembly / Assembly 1 2

15 14

6 5 11 10

Torque nut to 250 ft-lb while turning wheel.

12 9 6

POS. NO

Return

DESCRIPTION

POS. NO

DESCRIPTION

Case

Washer, drain bolt

Dowel pin

Bearing

Key

Gear, idler

Pinion gear

Axle bearing

Pinion nut

Axle spacer

Cover bolts

Axle seal

Cover

Axle nut

Fill plug

Gear, drive

Service Manual

1998-07-06

105

F-code

Section

C-code

PS S2.1 2550 Transmission Disassembly / Assembly Version no

T-code

002

1. Disassembly After draining gear case lubricant thoroughly clean outside with safety solvent or other non-corrosive cleaning fluid. Air dry all parts and proceed with disassembly of transmission as follows. 1. Remove transmission from truck. 2. Remove gear case cover (7). 3. Block transmission with gear case side down. Allow room for gears to drop between blocks. 4. Heat retaining collar with propane torch and press drive axle (16) through spacer (13) and bearing (12). Drive axle (16) and intermediate gear (11) will come out together. 5. Remove old bearings (12) and races from gears (10,12) and case (1). 6. Clean transmission case.

2. Assembly Heat bearing cone on bearing heater to facilitate installation. 1. Install new bearings (10) on intermediate gear (11). 2. Install new inner bearings cones (12) on drive axle (16). 3. Install new bearings cups (12) in transmission case (1). NOTE! Bearing cups are slip fit in transmission case. 4. Position transmission on work bench with gear case side up. Place drive axle (16) and intermediate gear (11) in case (1) as a unit with gears (11,16) meshed. Because of gear size and bearing interference these pieces cannot be installed separately. 5. Use Loctite 515 ® gasket eliminator on mating surface and install gear case cover (7). Be sure that two dowel pins (2) are in case (1) to position 106

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Service Manual

1998-07-06

F-code

Section

C-code

PS S2.1 2550 Transmission Disassembly / Assembly Version no

T-code

002

cover (7). Torque cover screws (6) to 30 ft-lb [41 N•m]. 6. Reposition transmission case so that it rests on gear case cover (7). 7. Temporarily install drive motor in transmission case (1) using only two bolts to hold motor in place. 8. Install outer drive axle bearing cone and retaining collar: a. Place bearing cone (12) over shaft. Use a standard M24 nut (15) and bearing installation tool to push bearing (12) on drive axle (16). At this time, bearing (12) will not seat on shoulder of drive axle (16). Remove nut (15) and pusher. b. Install drive axle seal (14) in transmission case (1). c. Install spacer (13) on drive axle (16). Use bearing installation tool and nut (15) to press spacer (13) on axle shaft (16). This should also press bearing (12) down to seat on shoulder. NOTE! Replace axle nut with new nut each time drive axle is removed. Failure to replace with new nut could result in damage to drive wheel and/ or transmission. Turning axle shaft (16) while you torque nut (15) to 250 ft-lb [339 N•m]. Control the drive axle (16) turning by holding brake lever on drive motor. NOTE! Failure to use a new nut (15) can result in damage to the wheel and/or transmission.

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Service Manual

1998-07-06

107

F-code

Section

C-code

PS S2.1 2550 Transmission Disassembly / Assembly Version no

T-code

002

108

Return

Service Manual

1998-07-06

F-code

Section

C-code

S3.0 3300 Parking Brake System

Version no

T-code

001

CMX,TMX

Parking Brake System 1

2 4

8 7 3 6

POS. NO

Return

DESCRIPTION

POS. NO

DESCRIPTION

Key

Transmission

Brake assembly

Drive motor

Screw

Drum, brake

Bracket, cable

Nut

Service Manual

1997-07-15

F-code

Section

C-code

PS S3.0 3300 Parking Brake System Version no

T-code

001

CMX,TMX

1. Brake Theory of Operation Hand Operated Levers

The brake used on this electrical truck is a cable operated design. Brake drum is mounted on drive motor armature shaft. Brake shoes are mounted on a backing plate directly bolted to drive motor. This design gives excellent braking and long life since the drum and shoes are protected from dirt and other abrasive materials. Braking is accomplished by operating either one of two hand operated levers on control handle. Levers are connected through a cable to brake arm on brake backing plate. Brake arm operates a cam that forces the brake shoes against brake drum. This action clamps brake shoes against drum and provides braking any time handle levers are operated. When levers are released a spring inside the brake drum returns brake shoes and linkage to the “Brake released” position. Control handle stem has a parking brake lever mounted on the side towards operator’s compartment. The parking brake is applied by lifting lever and latching it in the slot provided. Release the brake by lifting lever out of latching slot and sliding lever down.

Disengaged Position (Brake OFF)

Engaged Position (Brake ON)

Parking Brake Lever

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Service Manual

1997-07-15

F-code

PS Version no

001

Section

C-code

S3.0 3300 Parking Brake System T-code

CMX,TMX

2. Brake Adjustment 1. Disconnect battery, block drive wheel off floor and open front access door. Disengaged Position (Brake OFF)

Engaged Position (Brake ON)

2. Place parking brake linkage in the “brake released” position. 3. Loosen cable sheath mounting nuts at bracket by the drive motor and adjust cable to increase or decrease braking action. To increase braking action move cable sheath away from bracket. (Move mounting nuts toward end of cable.) To decrease braking action move cable sheath towards bracket. (Move mounting nuts to allow more of the threaded end of cable to be exposed.) 4. After the proper cable adjustment is made, tighten mounting nuts to prevent cable sheath from moving. 5. Adjust brake interlock switch so that it operates as brakes are released and applied. Switch should close when brakes are released. 6. The brake drum may be removed and operating lever moved one spline to compensate for brake shoe wear. WARNING Before adjustments are make disconnect battery from truck to prevent accidental operation.

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Service Manual

1997-07-15

F-code

Section

C-code

PS S3.0 3300 Parking Brake System Version no

T-code

001

CMX,TMX

3. Brake Shoe Removal / Installation 1. Disconnect battery and block truck with drive tire about 1 in. [25.4 mm] off floor. 2. Disconnect main spring (5) of brake. 3. Move brake lever and parking brake handle to “BRAKE RELEASED” position and disconnect clevis from brake cam arm. 4. Loosen nut and remove brake drum. 5. Move one shoe at a time to center and remove mounting bolts.

60°

During assembly the brake lever should be checked to see that it is set at 60 degrees and that brake drum nut is torqued to 30 ft-lb [41 N•m]. Adjust brake linkage and brake interlock switch (see adjustment section of this manual).

POS. NO 1 2

3 4

DESCRIPTION

Cam

Plate

Lever

Clip

Spring

Shoe

5 WARNING Before adjustments are make disconnect battery from truck to prevent accidental operation.

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Service Manual

1997-07-15

F-code

Section

C-code

S3.0 3300 Parking Brake System

Version no

001

T-code

CMX,TMX

4. Brake Interlock Switch The brake interlock switch is located on brake cable bracket at drive motor. Parking brake interlock switch is activated by the brake linkage. The function of this switch when activated is to shut off electrical power to the control circuit when brake is applied. With parking brake interlock switch open no electrical power can flow to drive motor if travel function is used when brake is applied. The operation of parking brake interlock switch must be checked frequently to ensure that switch opens when brake is applied. To adjust the interlock switch: 1. Park truck on level surface and block truck from moving. 2. Disconnect battery. 3. Move parking brake lever on handle stem to the latched position. 4. Turn steering handle fully to the right or left to access brake interlock switch. 5. Loosen two machine screws securing switch to bracket. 6. Adjust switch so that it is just open. 7. Test switch operation. Switch must close when brake is released. 8. Connect battery, and test brake interlock switch operation. WARNING Before adjustments are make disconnect battery from truck to prevent accidental operation.

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Service Manual

1997-07-15

F-code

Section

C-code

PS S3.0 3300 Parking Brake System Version no

T-code

001

CMX,TMX

Return

Service Manual

1997-07-15

F-code

Section

C-code

S3.1

3500 Drive Wheel

Version no

T-code

001

Drive Wheel 3.1. Removal The drive wheel can be removed, without removing the transmission by following these steps. 1. Park truck on level surface and block truck from moving. 2. Disconnect the battery. 3. Hoist machine and securely block truck with drive tire about 1 in. [25.4 mm] off floor. 4. Remove axle hub and wheel retaining nut. Pull tire and wheel from axle.

5. Press drive tire (2) from wheel hub (3). NOTE! If hub is rusted to axel, two bolts threaded in holes on hub can be used to push hub from axle.

1 3

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Service Manual

1997-07-15

115

F-code

Section

C-code

PS S3.1 Drive Wheel

3500

Version no

T-code

001

3.2. Installation 1. Press drive tire (2) onto wheel hub (2). This is usually done while pressing off old tire. Press hub to center of tire.

1 3

2. Install drive tire and hub on axle. The drive tire retaining nut should be torqued to 250 ft-lb [339 N•m]. Failure to use a new nut could result in damage to the wheel and/or transmission.

Torque to 250 ft-lb [339 N•m]

NOTE! Replace axle nut with new nut each time drive axle is removed. Failure to replace with new nut could result in damage to drive wheel and/ or transmission.

116

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Service Manual

1997-07-15

F-code

Section

C-code

S3.2

3500 Load Wheels

Version no

T-code

001

TMX,TWX

Load Wheels

POS. NO

DESCRIPTION

POS. NO

DESCRIPTION

Spacer

Fitting, grease

Guard, string

Washer

Bearing

Screw, cap

Wheel, load 1. Park truck on level surface, and apply the brake. 2. Hoist machine so load wheels are approximately two inches off the floor, and securely block. 3. Remove socket screw (7), washer (6) and string guard (2). 4. Remove wheel (4), inner string guard (2) and spacer (1). 5. Remove bearings (3) from wheel (4) and grease fitting (5).

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Service Manual

1997-10-02

F-code

Section

C-code

PS S3.2 Load Wheels

3500

Version no

T-code

001

TMX,TWX

6. Thoroughly clean all parts and inspect bearings (3) for damage. Replace both bearing (3) on wheel (4) if only one bearing (3) is damaged. 7. Repack bearings (3) and install in new load wheel (4). Also install grease fitting (5). 8. Slide spacer (1) and string guard (2) on axle against truck frame. 9. Slide new load wheel (4) with bearings (3) installed over axle and against string guard (2). 10. Place outer string guard (2) against load wheel bearing (3). Next place flat washer (6) on socket head screw (1) and thread screw (1) in axle. Torque screw (1) to 75-80 ft-lb. 11. Pump grease through grease fitting (5) in wheel (4) to finish filling voids in wheel (4) cavity. 12. Lower truck to floor and check operation.

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Service Manual

1997-10-02

F-code

Section

C-code

S4.0 4100 Steering Control Arm

Version no

T-code

000

TMX

Steering Control Arm 12 1

10 2

6 7

14 16

4 40

20 22

19 18

21 17 23 24 25

27 2

31 37 38

CONNECT TO BRAKE

POS. NO

DESCRIPTION

POS. NO

DESCRIPTION

POS. NO

DESCRIPTION

1 2 3 4 5 6 7 8 9 10 11 12 13 14

Stem, handle Screw Pin, yoke Cotter, internal Link, pivot Bushing, flanged Washer, shim Pin, groove Pin, spring Bracket, hand brake Screw Control head Cover Handle

15 16 17 18 19 20 21 22 23 24 25 26 27 28

Grip Bushing Pivot Screw Spring Clevis Nut, jam Bar, brake link Screw Joint, ball Nut Handle, park brake Nut, clip Cover, brake

29 30 31 32 33 34 35 36 37 38 39 40 41 42

Spring Nut, jam Anchor, spring Cable, brake Pin with cotter pin Base Latch, ba Spring Bolt, shoulder Bushing, flanged Bolt, shoulder Shaft, pivot Handle Bolt, shoulder

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Service Manual

1997-09-24

F-code

Section

PS S4.0 Steering Control Arm Version no

T-code

000

TMX

C-code

4100

1. Control Handle Stem 1.1. Removal 1. Park the truck on a level surface and make sure parking brake is applied. 2. Disconnect battery from unit to prevent accidental operation. 3. Remove the six retaining screws from outer edge of the switch cover. NOTE! Do not remove the center screw and nut. 4. Lift switch cover off assembly and lay to one side. 5. Remove the two socket head screws from inside head that secure head and handle stem together. 6. Lift entire head assembly from handle stem and disconnect wiring harness plug. Disassembly head assembly on bench. 7. Pull control handle tilt knob on side of handle stem to tilt control handle back allowing more room for disassembly handle stem. 8. Remove screws (2) securing brake cover (28) and disconnect wires from gauge. 9. Inside control handle stem disconnect clevis (20) and spring (29). 10. Remove screw (39) from inside handle stem. 11. Open access door fully and remove handle pivot shaft (40) by driving from one side. Remove handle stem while guiding out wiring harness and brake cable.

100

Return

CAUTION

The handle stem will be free to fall when pivot shaft (40) is removed.

Service Manual

1997-09-24

F-code

Section

C-code

S4.0 4100 Steering Control Arm

Version no

T-code

000

TMX

1.2. Installation 1. Install bushings (38) in handle stem base (34). 2. Thread wiring harness and brake cable up through handle stem and place handle stem in handle base (34). 3. Aligning handle stem (1), base (34), and install pivot shaft (40) securing with screw (39). 4. Install clevis (20) using yoke pin (3) and secure with cotter pin (4). 5. Install spring (29). 6. Connect wires to gauge and install brake cover (28) using six screws (2). 7. Connect head assembly wiring harness to main wiring harness plug in handle stem. 8. Install two socket head screws inside head assembly to secure hand head assembly to handle stem. 9. Move switch cover plate assembly back in place and secure with six screws. 10. Connect battery and test operation of all control handle functions. WARNING Testing of parking brake function is made with drive wheel blocked off the floor. Risk of serious personal injury or possibly death may occur from run way truck.

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000

TMX

C-code

4100

2. Hand Brake Levers 2.1. Removal 1. Park truck on a level surface and block securely. 2. Remove grip from parking brake handle (15). 3. Remove two socket flat head screws (2) on hand brake cover (28) and remove. 4. Remove cotter pin (4) and yoke pin (3). 5. Remove brake assembly cover (13). 6. Remove two flat head screws (2) on each side of control handle stem securing hand brake assembly and remove assembly.

2.2. Disassembly 1. Place assembly on bench with pivot link (5) up and brake lever toward rear. 2. Remove spring (19). 3. Remove spring pins (9) from hand brake bracket plate and pivots (17). 4. Using a punch and remove groove pins (8) from pivots (17). 5. Remove brake levers (14), washer pivots (17), and pivot link (5).

shims (7),

2.3. Assembly 1. Place hand brake bracket on bench with top of plate up and to the rear. 2. Place brake handle lever (14) in hand brake bracket. 3. Install washer shim (7) on lever. 4. Install pivot (17) with spring pin up and pivot pointing toward rear. 5. Install groove pin (8) in pivot and lever, make sure 102

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Version no

T-code

000

TMX

lever is pointing up away from table. 6. Install second washer shim (7) on lever. 7. Install remaining lever (14) in hand brake bracket with one washer shim (7), pivot (17), and pivot link (5). 8. Install remaining washer shims (7) between pivot and pivot link. Place shim between pivot and pivot link, pull lever out until washer lines up with lever. 9. Push lever in and install groove pin in pivot and lever. 10. Replace spring pins (9) in hand brake bracket plate and install springs (19).

2.4. Installation 1. Install brake lever assembly and secure with two screws (2). 2. Side cover (13) in place and secure. 3. Install yoke pin (3) and cotter pin (4) to secure pivot link (5) in clevis (20). 4. Install cover (28) and secure in place with two screws (2). 5. Side hand grip (15) on parking brake handle (26). 6. Connect battery and test operation of parking brake lever and adjust if needed. WARNING Testing of parking brake function is made with drive wheel blocked off the floor. Risk of serious personal injury or possibly death may occur from run way truck.

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104

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4100

Service Manual

1997-09-24

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Section

C-code

S4.1 4100 Steering Handle head

Version no

T-code

000

TMX,TWX

Steering Handle head 1 2 3 4 5 6 38

7 10 5 12

15 16 17

8 9

13 14

38 27

29 24 18

28 44 22

19 21

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43 35

105

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000

TMX,TWX

POS. NO

C-code

4100

DESCRIPTION

POS. NO

DESCRIPTION

POS. NO

DESCRIPTION

Cover

Pin, roll

Nut

Spring

Grip, handle

Switch, Forward

Bracket

Knob assembly

Spacer

Screw

Screw, flat head

Switch, Rearward

Pin, roll

Screw, socket

Screw, machine

Cam

Guard, wide

Heater, freezer pkg.

Return

Bolt, shoulder

Screw, flat head

Spring

Pin, roll

Screw, flat head

Housing, switch

Potentiometer assembly

Cover

Bushing

Gear

Switch, Horn

Shaft, cam

Spring

Control, thumb

Clamp, cable

Bracket, switch

Pin, threaded

Lockwasher

Screw

Block

Bracket

Screw

Coupler

Nut

106

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PS Version no

000

Section

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S4.1 4100 Steering Handle head T-code

TMX,TWX

1. Control Handle Head 1.1. Removal 1. Park the truck on a level surface and make sure parking brake is applied. 2. Disconnect battery from unit to prevent accidental operation. 3. Remove six retaining screws (38) from outer edge of the switch cover (39). NOTE! Do not remove center screw (37) and nut (30). 4. Lift switch cover (39) off assembly and lay to one side. 5. Remove two socket head screws (20) from inside head that secure head and handle stem together. 6. Lift entire head assembly from control stem and disconnect wiring harness plug. The head assembly is free to be disassembled on a bench.

1.2. Installation 1. Connect head assembly wiring harness to main wiring harness plug in handle stem. 2. Install two socket head screws (20) inside head assembly and secure head assembly to handle stem. 3. Move switch cover (39) plate assembly back in place and secure with six screws (38). 4. Connect battery and test operation of all control handle functions.

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000

TMX,TWX

C-code

4100

2. Direction Control Switches The direction control switches are mounted in control handle head. It is not necessary to remove head to change switches. 1. Park the truck on a level surface and make sure parking brake is applied. 2. Disconnect battery from unit to prevent accidental operation. 3. Remove six retaining screws (38) from outer edge of the switch cover (39). NOTE! Do not remove center screw (37) and nut (30). 4. Lift switch cover assembly plate off assembly and lay to one side. 5. Remove two screws (44) holding forward/rearward switch bracket (29) to housing. 6. Remove switch wires from wire harness plug and remove switches and bracket (29). 7. The switches (32,34) may now be replaced by unbolting them from the bracket (29). 8. Reconnect switch wires and reinstall bracket (29) in housing. 9. Test switch operation and adjust bracket (29) before installing switch cover plate (39). 10. Move switch cover (39) plate assembly back in place and secure with six screws (38). 11. Connect battery and test operation of all control handle functions. WARNING Testing drive function is made with drive wheel blocked off the floor. Risk of serious personal injury or possibly death may occur from run way truck.

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TMX,TWX

3. Horn Switch The horn switch is mounted in switch cover plate on control handle head. Horn switch is molded in switch bar replace assembly only as a single part. It will not be necessary to remove the handle head to change the horn switch. 1. Park the truck on a level surface and make sure parking brake is applied. 2. Disconnect battery from unit to prevent accidental operation. 3. Remove six retaining screws (38) from outer edge of switch cover (39). NOTE! Do not remove center screw (37) and nut (30). 4. Lift switch cover assembly plate from hand head assembly and lay to one side. 5. Remove center screw (37) and nut (30) securing switch bracket (42) to cover (39). Remove switch bar (40) and springs (41). 6. Disconnect head wiring harness from stem wiring harness and remove switch wires from head wiring harness plug. The wires are removed by pushing terminals out the back of head wiring harness plug. NOTE! Remember to mark wire terminals position when removing to make installation easier. 7. Install switch bar (40) in cover (39) making sure that switch bar (40) is placed in its proper location. Next install return springs (41) in wells on each of the switch bar (40). Place switch bracket (42) on springs (41) making sure spring align with dimples in switch bracket (42) and wires from switch go though holes. This whole assembly is secured with one screw (37), clamp (27), and nut (30) placed in center. 8. Test switch operation that switch bar (40) will return and dose not bind before installing switch cover plate assembly on handle head. © BT Products

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9. Install new switch wire terminals in head wiring harness plug. 10. Install switch cover plate assembly back in place and secure with six screws (38). 11. Connect battery and test operation of all control handle functions.

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4. Potentiometer The accelerator potentiometer is accessible inside the control handle head by removing the switch plate. The accelerator potentiometer operates off a gear toothed shaft (rack) that is moved when the travel controls are twisted. 1. Park the truck on a level surface and make sure parking brake is applied. 2. Disconnect battery from unit to prevent accidental operation. 3. Remove the six retaining screws (38) from outer edge of the switch cover (39). NOTE! Do not remove center screw (37) and nut (30). 4. Lift switch cover assembly plate off assembly and lay to one side. 5. Disconnect head wiring harness from stem wiring harness and remove potentiometer wires from head wiring harness plug. The wires are removed by pushing terminals out the back of head wiring harness plug. NOTE! Remember or marking the wire terminals position when removing to make installation easier. 6. Remove two screws (43) securing potentiometer assembly (24) to the control head housing (9). Remove and discard potentiometer assembly (24) and gear (25). Replace with new. 7. Install new potentiometer assembly (24) and gear (25) on control head housing (9) and hold in place with screws (43). Do Not tighten completely. 8. Connect ohmmeter leads to potentiometer wires. 9. While holding potentiometer bracket (24) against control head housing (9) and make sure gear (24) on potentiometer are engaged with return (7) gears teeth. In neutral ohmmeter reading should be 5500 to 6000 ohms and will reduce to below 50 ohms as © BT Products

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the travel controls are operated to high speed. By sliding potentiometer assembly (24) up or down as necessary taking measurements and make adjustments. If slotted holes in potentiometer bracket (24) do not allow enough adjustment bracket may be lifted slightly and potentiometer drive gear (25) can be rotated by one tooth. 10. Tighten potentiometer assembly (24) mounting screws (43) and install potentiometer wire terminals in head wiring harness plug. 11. Test operation of potentiometer gear (25) and return (7) by moving travel controls before installing switch cover plate assembly on head. 12. Install switch cover plate assembly back in place and secure with six screws (38). 13. Connect battery and test operation of all control handle functions. WARNING Testing drive function is made with drive wheel blocked off the floor. Risk of serious personal injury or possibly death may occur from run way truck.

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S5.0 5190 300/400 Amp Contactor

Version no

T-code

000

300/400 Amp Contactor 1 7

3 6 4

8 POS. NO

Return

DESCRIPTION

POS. NO

DESCRIPTION

Screw

Coil & frame

Cover

Contactor tip, fixed

Return spring

Nut & lockwasher

Contactor tip, moving

Armature cap

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PS S5.0 5190 300/400 Amp Contactor Version no

T-code

000

1. Maintenance 1. Check armature and movable contacts for freedom of movement by depressing movable arm with a screwdriver or small rod. 2. Check for any restrictions to movement and for return of parts by action of spring. 3. Inspect contact tips. Look for any worn or eroded surfaces. Look for evidence of tip welding. Inspect for evidence of any contaminants on tips (paint, dirt, paper, or cloth material, etc.) which would impair operation. NOTE! Do not use sandpaper or file tips. Any damage must be corrected by tip replacement. NOTE! Tips must be replaced before they wear through and damage copper base.

1.1. Removal/Replacement of Contact Tips NOTE! Before attempting to disassemble a contactor to install a new contact tip set carefully observe location and orientation of each part. 1. Loosen and remove two cover screws (1) securing cover (2) to coil frame (5). Observe position of positive (+) marking on the cover. 2. Remove cover (2). Be sure to note location of spring seat and spring (3) under cover. 3. Remove nut and lockwasher (7) from each stationary contact tips (6). 4. Remove contact tips (6) from cover (2). 5. Install new contact tips (6) and secure with lockwashers and nuts (7). Tighten nuts firmly on each contact tips (6). 6. Remove moving contact tip assembly (4) from coil frame (5). Observe location of components upon removal. 156

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000

7. Install new moving contact tip assembly (4) plunger shaft back in coil frame (5) and place spring (3) on top of contact tip assembly (4). 8. Position cover assembly (2) over spring (3) making sure spring (3) is not bent and is in the cover recess. 9. Secure cover assembly (2) with screws (1). NOTE! When assembling cover to base (frame) make sure cover is installed with the positive sign (+) markings located properly. NOTE! Use a bar or rod to move contacts making sure movement is free of binding. Be certain contact tips are in correct orientation and tips contact correct mating parts.

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000

158

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S5.1 5190 “EE” Contactor

Version no

C-code

T-code

000

“EE” Contactor

3 11

4 5 6 7 8

10 9

POS. NO

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Service Manual

DESCRIPTION

POS. NO

DESCRIPTION

Shroud

Return spring

Screw

Contactor tip, moving

Insulator

Coil & frame

Screw

Contactor tip, fixed

Shield

Nuts & lockwasher

Cover

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PS S5.1 “EE” Contactor

5190

Version no

T-code

000

1.1. Removal/Replacement of Contact Tips NOTE! Before attempting to disassemble a contactor to install a new contact tip set carefully observe location and orientation of each part. 1. Remove two cover screws (2) securing the shroud (1) to coil frame (9). Remove shroud (1). 2. Loosen and remove two cover screws (4) securing cover (6) to coil frame (5). Observe position of positive (+) marking on the cover. 3. Remove cover (6). Be sure to note location of spring seat and spring (7) under cover. 4. Remove nut and lockwasher (11) from each stationary contact tips (10). 5. Remove contact tips (10) from cover (6). 6. Install new contact tips (10) and secure with lockwashers and nuts (11). Tighten nuts firmly on each contact tips (10).

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000

7. Remove moving contact tip assembly (8) from coil frame (9). Observe location of components upon removal. 8. Install new moving contact tip assembly (8) plunger shaft back in coil frame (9) and place spring (7) on top of contact tip assembly (8). 9. Position cover assembly (6) over spring (7) making sure spring (7) is not bent and is in the cover recess. 10. Secure cover assembly (6) with screws (4). 11. Put shroud (1) over top of contactor and secure to coil frame (9) with screws (2). NOTE! When assembling cover to base (frame) make sure cover is installed with the positive sign (+) markings located properly. NOTE! Use a bar or rod to move contacts making sure movement is free of binding. Be certain contact tips are in correct orientation and tips contact correct mating parts.

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PS S5.1 “EE” Contactor

5190

Version no

T-code

000

162

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C-code

PS S5.2 5230 Battery Controller / Hourmeter / Speed Dropout Version no

T-code

001

TMX

Battery Controller / Hourmeter / Speed Dropout 1. General Information This instrument consists of a single, quartz hourmeter (H), a 10 bar multicolored battery discharge controller (BC), and a lockout relay. The lift lockout relay is operated so that if there is a current passing through the relay contacts when the instrument registers empty battery the contacts stay closed until the current ceases. There will be no lockout of the lift during the lift operation. The hourmeter features a liquid crystal display (LCD) which has six segment digits with a decimal point before the last digit. This provides resolution of 0.1 hours or 6 minutes. Battery Display LED 2 Red, 3 Yellow, 5 Green

Hourmeter LCD

2. Electrical 2.1. Voltage The instrument is supplied as a pin selectable dual voltage unit with the voltage of 12/48 VDC.

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2.1.1. The Contact Voltage and Current Ratings for Switching Resistive Loads.

Open Contact Voltage

200

VDC

Max

Closed Contact Current

ADC

Max

Volt Ampere Product

Max

2.1.2. Memory Retention The instrument contains an internal battery (BC) which allows memory retention when external power is removed. Typical battery life is 10 years. The hourmeter has a solid state, nonvolatile memory which does not require battery backup.

3. Battery Controller (BC) 3.1. General Information The BC measures the state of the battery. The charge is indicated on a column of ten LEDs. Right: 1 - fully charged battery Left:

0 - empty battery

When the battery is fully charged the LED to the right will be illuminated. As the battery discharges LEDs to the right will stop glowing and show the current discharge level. When the battery is 70 percent discharged the two LEDs from the left will flash alternately to warn the driver that he should recharge the battery. When the battery is 80 percent discharged the last LED is lit, and the relay is opened. 3.1.1. Discharge Adjustment The BC features an adjustable discharge setting. The setting designators K-U are at the rear of the gauge. The initial factory setting is N but will depend on the battery and machine type. The given settings are approximate and might need to be fine tuned to get a 100 percent correct lockout for a specific application.

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PS S5.2 5230 Battery Controller / Hourmeter / Speed Dropout Version no

T-code

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TMX

Battery Ah 180 210 240

L-M M-N N-O

L-M means that you adjust on the line between L and M. N-O means that you adjust on the line between N and O. An hydrometer can be used for precise adjustment. When the bottom two LEDs are flashing on and off the specific gravity of the battery electrolyte should not be lower than 1.14. If they start to flash at higher specific gravity the discharge U potentiometer should be turned counterclockwise (towards K). If the two LEDs start to flash at a specific gravity below 1.14 turn the potentiometer clockwise (towards P). The letter designations for the voltage per cell (VPC) multipliers at empty battery are specified as tabulated below.

SETTING

VPC

SETTING

VPC

1.57

1.82

1.63

1.84

1.68

1.86

1.73

1.91

1.78

1.93

O P Q R S K DISCHARGE T

N M L

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PIN NO:

FUNCTION

Hourmeter (-)

Key switch (+)

Relay arm (+)

Relay NC (-)

Battery (-)

Hourmeter (+)

24 Volt (+)

48 Volt (+)

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TMX

NOTE! The discharge adjustments can be made at any time during a working cycle before lift lockout. However, discharge potentiometer adjustments made late in a working cycle have little or no effect in delaying the lift lockout in that particular working cycle. Normally discharge potentiometer. Adjustments are made before or at the beginning of a working cycle to effectively change the discharged profile of that working cycle. Once lift lockout does occur, the gauge must be reset before discharge potentiometer. adjustments can have an effect.

3.2. Reset The instrument is supplied with a fixed reset voltage setting. This factory-set reset voltage brings the BC to full regardless of its previous level. The reset will be done when the battery has been charged and connected to the machine.

3.3. Key Switch The electronics of the BC and the LCD of the hourmeter are energized as long as the machine battery remains connected to the gauge. The display of the BC is turned on and off by the key switch. The drive transistor controller enables the timing function of the hourmeter, whenever there is current going to the drive motor.

3.4. Hourmeter Hourmeter operation is indicated by flashing of the hourglass icon on the face of the LCD. The flash rate is 15 times a minute with a duty cycle of 3 seconds on and 1 second off. When the hourmeter is not in operation the icon is visible but does not flash.

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TMX

4. Troubleshooting This section is separated into two parts: Battery Discharge Indicator and Hourmeter.

4.1. Battery Discharge Indicator (BDI) 4.1.1. No Reset There are two ways to reset the instrument. Using the open circuit reset the instrument must first have a break in the power and then measure a voltage greater than 2.09 volts per cell across its pin 7 or 8 and pin 5. Verify that a leakage voltage is not present across these terminals by disconnecting one of the lines supplying battery voltage to the instrument. Replace this connection and measure the voltage across the gauge at its pin 7 or 8 and pin 5. It must be above 2.09 volts per cell. If it is, and the gauge does not reset to indicate full charge, the instrument is defective. The second method of resetting the instrument is by using the high voltage reset. This reset function also has two requirements to reset the instrument. The voltage across pin 7 or 8 and pin 5 must be above 2.35 volts per cell and must remain above this level for six minutes continuously. Measure the voltage across these pins and verify that it is greater than 2.35 volts per cell. Also, verify that it remains above this level for a minimum of six minutes. If these two conditions are met, and the instrument does not reset, it is defective. 4.1.2. Reset After Break in Power If the voltage of the batteries to which the instrument is connected is below 2.09 volts per cell, and the gauge was not formerly indicating full, it should not reset to full after a break in power. If it does its memory cell is depleted. This will not affect the discharge function of the instrument if it is always connected to a fully charged battery and allowed to track its discharge without break in power.

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NOTE! New instruments are shipped from the factory with a full reading in their memory. The first time the instrument is connected to the truck’s battery it will always show a full charge. It is either resetting to full because the battery is fully charged or if the battery is not fully charged it is repeating the information in its memory which is a full reading. 4.1.3. No Discharge, Gauge Does Not Run Down The instrument monitors loaded battery values. When connected to a partially discharged battery the gauge will not run down until it observes that the loaded values of the battery are at or below gauge current state. A working time of at least 30 minutes is required for the gauge to run from full to empty. To verify that the instrument will run down, measure across pin 7 or 8 and pin 5. A voltage less than 2.0 volts per cell is required to bring the gauge indication downwards from a full reading. 4.1.4. No Lockout The LED display must be alternately flashing the two leftmost red LEDs for lockout to occur. The J output functions like an SCR. At lockout, pins 3 and 4 will open as long as lift is inactive. To test this output: 1. Remove the wire leading to pin 3 when at lockout. 2. Replace the wire, and then try to lift. If the lift ceases to operate the instrument is good, but there is a leakage current somewhere in the lift circuit. 3. Check across the lift switch. After replacing the wire, if the lift operates, the instrument is defective. 4.1.5. No Lift First, verify that the gauge is not at lockout with its two red LEDs alternately flashing. The relay outputs should be closed above lockout and should read 0 ohms with an ohmmeter across pins 3 and 4. If not at lockout test the lift switch and

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TMX

contactor. 4.1.6. Early Lockout It is very important that the instrument is installed so that its pins are reading the true battery voltage. Any voltage drops caused by long lines, switches, fuses, or poor connections will be seen by the instrument as a deeper discharged battery. 1. To check for voltage drops use a voltmeter with its positive lead on the battery’s positive terminal and the meter’s negative lead on pin 7 or 8 (whichever pin B+ is connected to). Load the battery and record this measurement. 2. Repeat this procedure with the voltmeter’s positive lead on pin 5 and its negative lead on the battery’s negative terminal, and record the voltage measured. 3. Add the two voltage readings. This total should be less than 1 percent of the nominal battery voltage. Voltage higher than this will cause the instrument to calculate battery state-of-charge from incorrect readings. 4.1.7. LEDs Do Not Light The battery discharge indicator LEDs are illuminated by the keyswitch, pin 2. Verify that B+ is present across pin 2 and pin 5. If voltage is present and the LEDs do not light, the instrument is defective.

4.2. Hourmeter 4.2.1. No Display The LCD of the hourmeter will illuminate when power is applied at pin 7 or 8 and pin 5. If voltage is measured across these pins and the LCD does not turn on, the instrument is defective. 4.2.2. Hourmeter Glass Icon Does Not Flash If the icon does not flash, the hourmeter is not accumulating time. The key switch pin 2 must be on at B+, pin 7 or 8 must be connected to B+, and one or both of the hourmeter lines must be active. If the key switch is on, one or both inputs are

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correct, and the hourmeter icon does not flash, the instrument is defective. 4.2.3. Hourmeter Glass Icon Always Flashes When the icon is flashing, the hourmeter is accumulating time. Turn the truck’s key switch off. This should remove voltage from pin 2 of the instrument. Should voltage be present at pin 2 and the hourmeter’s icon continues to flash, the instrument is defective.

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PS S5.3 5230 Battery Discharge Indicator / Hourmeter Version no

T-code

000

Battery Discharge Indicator / Hourmeter 1. General Information This instrument consists of a single, quartz hourmeter (H) and a 10 bar multicolored battery discharge indicator (BDI). The hourmeter features a liquid crystal display (LCD) which has six segment digits with a decimal point before the last digit. This provides resolution of 0.1 hours or 6 minutes. Battery Display LED 2 Red, 3 Yellow, 5 Green

1/2

Power pin 1 Power pin 5

Battery negative 1

Key switch

1 10

Hourmeter LCD

Brake switch (Hourmeter input)

Not Used

2. Electrical 2.1. Voltage This instrument is supplied in two configurations as a dual voltage unit for 24/36 volt DC or a single 12 volt DC unit. On the 12 volt electrical system single use units, the battery voltage is connected to pin number 1 labeled above “Power Pin 1”. On the 24/36 dual voltage unit used on 24 volt electrical system, the battery voltage is connected to pin number 5 labeled above “Power Pin 5”. On the 24/36 dual voltage unit used on 36 volt electrical system, the battery voltage is connected to pin number 1 labeled above “Power Pin 1”. © BT Products

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PS S5.3 5230 Battery Discharge Indicator / Hourmeter Version no

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000

3. Battery Discharge Indicator (BDI) 3.1. General Information The BC measures the state of the battery. The charge is indicated on a column of ten LEDs. Right: 1 - fully charged battery Left:

0 - empty battery

When battery is fully charged the LED to the right will be illuminated. As battery discharges LEDs to the right will stop glowing and show the current discharge level. When battery is 70 percent discharged the two LEDs from the left will flash alternately to warn operator that battery needs recharging.

3.2. Key Switch The electronics of the BDI and the LCD of the hourmeter are energized as long as the machine battery remains connected to the gauge. The display of the BDI is turned on and off by the key switch. 12 Volt and 300 AMP Controllers The key switch also enables timing function of the hourmeter. With key switch ON, hourmeter can be activated by connection number 3 at rear of BDI. With key switch OFF, hourmeter will not respond to connection number 3, and LCD of hourmeter will be off. 400 AMP Controllers Drive transistor controller enables timing function of hourmeter, whenever there is current going to drive motor. Also, timing function is enabled whenever S52 raise switch is closed.

3.3. Hourmeter Hourmeter operation is indicated by flashing of hourglass icon on face of LCD. The flash rate is 15 times a minute with a duty cycle of 3 seconds on and 1 second off. When hourmeter is not in operation the icon is visible but does not flash. 150

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4. Troubleshooting This section is separated into two parts: Battery Discharge Indicator and Hourmeter.

4.1. Battery Discharge Indicator (BDI) 4.1.1. No Reset There are two ways to reset the instrument. Using the open circuit reset the instrument must first have a complete break in the power and then measure a voltage greater than 2.09 volts per cell across its pin 1 or 5 and pin 2. Verify that a leakage voltage is not present across these terminals by disconnecting one of the lines supplying battery voltage to the instrument. NOTE! Holding down horn button for a few seconds will sometimes drop the charge in capacitors to zero volts and allow instrument to reset when it reads 2.09 volts per cell or above. Replace this connection and measure the voltage across the gauge at its pin 1 or 5 and pin 2. It must be above 2.09 volts per cell before gauge will reset. If it is, and the gauge will not reset to indicate full charge, the instrument is defective. The second method of resetting the instrument is by using the high voltage reset. This reset function also has two requirements to reset the instrument. The voltage across pin 1 or 5 and pin 2 must be above 2.35 volts per cell and must remain above this level for six minutes continuously. Measure the voltage across these pins and verify that it is greater than 2.35 volts per cell. Also, verify that it remains above this level for a minimum of six minutes. If these two conditions are met, and the instrument will not reset, it is defective. 4.1.2. Reset After Break in Power If the voltage of the batteries to which the instrument is connected is below 2.09 volts per cell, and the gauge was not formerly indicating full, it should not reset to full after a break in power. If it does its memory cell is depleted. This will not affect the discharge function of the instrument if it is always connected to a fully charged battery and allowed to track its discharge without break in power. © BT Products

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4.1.3. No Discharge, Gauge Does Not Run Down The instrument monitors loaded battery values. When connected to a partially discharged battery the gauge will not run down until it observes that the loaded values of the battery are at or below gauge current state. A working time of at least 30 minutes is required for the gauge to run from full to empty. To verify that the instrument will run down, measure across pin 1 or 5 and pin 2. A voltage less than 2.0 volts per cell is required to bring the gauge indication downwards from a full reading. 4.1.4. LEDs Do Not Light The battery discharge indicator LEDs are illuminated by the keyswitch, pin 6. Verify that battery voltage is present across pin 6 and pin 2. If voltage is present and the LEDs do not light, the instrument is defective.

4.2. Hourmeter 4.2.1. No Display The LCD of the hourmeter will illuminate when power is applied at pin 1 or 5 and pin 2. If battery voltage is measured across these pins and the LCD does not turn on, the instrument is defective. 4.2.2. Hourmeter Glass Icon Does Not Flash If the icon does not flash, the hourmeter is not accumulating time. The key switch pin 6 must be on at battery positive, pin 1 or 5 must be connected to battery positive, and one or both of the hourmeter lines must be active. If the key switch is on, 152

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one or both inputs are correct, and the hourmeter icon does not flash, the instrument is defective. 4.2.3. Hourmeter Glass Icon Always Flashes When the icon is flashing, the hourmeter is accumulating time. Turn the truck’s key switch off. This should remove voltage from pin 6 of the instrument. Should voltage be present at pin 3 and the hourmeter’s icon continues to flash, the instrument is defective.

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24 Volt 400 Amp Electrical System 1. Electrical Panel Components 2 (K10)

3 (A1)

1 (F1)

4 (H1)

5 (F50)

POS. NO

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DESCRIPTION

Breaker, Power circuit

Contactor, line

Controller

Horn

Breaker, Control circuit

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2. List of Symbols Symbol

Description

Transistor controller

A22

Driver Module

Battery

Circuit Breaker

Drive motor circuit

150 amp

F50

Circuit Breaker

Control circuit

12 amp

E10

Heater

Horn

Flashing Light

Travel Alarm

K10

Contactor

Main

Motor

Drive

Indicator

Hourmeter

Indicator

Battery indicator/Hourmeter

Indicator

BDI/HR/Speed cutback

Potentiometer

Speed

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Function

Remark

24 volt

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Symbol

Description

Function

S10

Switch

Brake

S14

Switch

High speed

S15

Switch

Load wheel direction

Reverse

S16

Switch

Steer wheel direction

Forward

S17

Switch

Key

S18

Switch

Horn

S21

Switch

Emergency stop

S60

Thermostat

Heater

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2.1. Circuit Diagram 1(3)

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Ledger

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138

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

Ledger

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

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Version no

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2.3. Circuit Diagram 3(3)

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3. Description of Function 3.1. General Information The Transistor controller (A1) regulates the infinitely variable speed control. When starting the truck, the controller checks the closing sequence of the micro switches in the circuit.

3.2. References Information For more information about adjustment of the speed potentiometer, the transistor controller, and the connection card see C-code 5460. The description is divided into different phases which correspond to the operational sequence steps.

3.3. Key Switch S17 in the ON Position When S17 closes, battery voltage is supplied to A1 J1-1, the controller will perform a single set of start-up tests including RAM, EEPROM, and voltage tests. As long as the controller detects that S10 is open (Brake applied), no further fault detection will be conducted. Only the above error conditions will have been tested during a normal power-up sequence of the vehicle. Faults that are detected during power-up and are tested during power-up can only be cleared by cycling S17. Faults that are detected only during normal operation after brake has been released can be cleared by cycling S10.

3.4. The Operating Arm in Drive Position, S10, Brake Switch Closed When the operating arm is pulled down to the driving position, S10 is activated and closes; and at the same time the brake is mechanically released. Voltage is supplied to A1 J1-15.

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3.5. Driving, Load Wheels Direction When the thumb control is activated for driving in the load wheels direction, S15 will close. The transistor controller checks that S10 is closed before S15 closes. If not, driving is blocked. Battery voltage to terminal A1 J1-11. The voltage at M- on A1 will vary from 24 volt to 1 volt. This voltage is proportional to the position of the speed potentiometer R1.

3.6. Driving, Steer Wheel Direction When the thumb control is activated for driving in the steer wheel direction, S16 will close. The transistor controller checks that S10 is closed before S16 closes. If not, driving is blocked. Battery voltage to terminal A1 J1-10 The voltage at M- on A1 will vary from 24 volt to 1 volt. This voltage is proportional to the position of the speed potentiometer R1.

3.7. Reversing/Motor Brake Load Wheels Direction to Steer Wheel Direction S15 returns to open position while S16 closes.

3.8. Reversing/Motor Brake Steer Wheel Direction to Load Wheels Direction S16 returns to open position before S15 closes.

3.9. Horn Micro switch S18 is activated. The horn (H1) receives positive voltage through wire number 8. Negative return through wire number 13.

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24 Volt, 400 Amp Transistor Controller 1. Maintenance There are no serviceable parts inside the transistor controller. No attempt should be made to open the controller.

OPENING THE CONTROLLER WILL VOID THE WARRANTY! It is, however, recommended that the controller exterior be cleaned periodically. When cleaning the controller gives a good opportunity to check the controller’s diagnostic history file with the hand-held terminal, if available.

1.1. Safety The controller is inherently a high-power device. When working around any battery powered vehicle, proper safety precautions should be taken. These include but are not limited to: proper training, wearing eye protection, avoiding loose clothing, removing watches and jewelry, and using insulated wrenches.

Warnin

Risk of short circuits. Remove all watches and jewelry, and always use insulated tools.

1.2. Cleaning Although the controller requires virtually no maintenance if properly installed, the following is recommended on a regular 250 hours basis. 1. Remove power by disconnecting the battery. 2. Discharge the capacitors in the controller by connecting a load (such as a contactor coil or the horn) across the controller’s B+ and B- terminals before doing any work on the controller. © BT Products

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3. Remove all dirt or corrosion from the bus bar area. The controller should be wiped clean with a moist rag. Allow it to dry before reconnecting the battery. 4. Make sure the connections to the bus bars are tight. Use two well insulated wrenches for this task in order to avoid stressing the bus bars.

1.3. Diagnostics and Troubleshooting The 1244 controllers provide diagnostics information to assist technicians in troubleshooting drive system problems. The diagnostics information can be obtained by reading the appropriate display on the PMC handset. The information can also be obtained by looking at the status LED built in the controller that is visible thought the window in label. 1.3.1. Handset Diagnostics The handset presents complete diagnostic information. Faults are displayed in the Diagnostic Menu, and the status of the controller inputs/outputs is displayed in the Test Menu. Accessing the Diagnostic History Menu provides a list of the faults that have occurred since the diagnostic history file was last cleared. Checking (and clearing) the diagnostic history file is recommended each time the unit is brought in for maintenance. See C-code 5710 for complete operating instruction for the PMC handset. Refer to the troubleshooting chart for suggestions covering a wide range of possible faults. 1.3.2. Troubleshooting Troubleshooting can be broken down into three sections: 1. Handset 2. Status LED on the controller 3. Electrical circuits These can be broken down into control circuit and power circuit. By knowing the exact symptoms of the truck operation, many hours of troubleshooting time can be saved. If the proper switch operates for the chosen direction and speed, then the problem can be found in the controller or the power circuit of that function. 144

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Only the travel functions are controlled by the transistor controllers. Lift, lower, and horn functions operate separately. To use this troubleshooting guide locate the failure symptom in the index on the following pages. Then go to the expanded outline, and follow the testing procedures described. Voltage tests are made with the negative lead of the volt meter connected to battery negative. If the negative lead is connected to a negative terminal on the electrical panel, you must first verify the negative connection to the battery by touching the positive meter lead to the positive battery post. The battery voltage must be at least 25.2 volts for a 24 volt system. If the battery voltage is below 22 volts (no load), then the controller may not operate properly. You will then have to charge the battery before starting the troubleshooting procedures. When testing voltage, the “POSITIVE SIDE” of any component refers to the terminal on that component that is closest electrically to the battery positive terminal. The “NEGATIVE SIDE” of any component refers to the terminal on that component that is farthest electrically from the battery positive terminal. It is possible and in many cases desirable to measure battery voltage on the negative side of a component. Forward direction refers to travel in the direction of the control handle with the load wheels trailing. Reverse direction refers to travel with the load wheels leading. The control handle operating position is between 20 degrees below fully raised and 10 degrees above fully lowered. When the control handle is fully raised or fully lowered, the brakes are applied; and the brake interlock switch cuts off all power to the travel control circuits. The line contactor will also open. After the final test is completed, the truck should be repaired and operating properly. If it is not, then you must verify your test results and possibly re-evaluate the failure symptoms. If you still have not repaired the truck, then you should call your local BT dealer for assistance. When you call, the following information is required: truck model and serial number; service hourmeter; actual battery voltage at open circuit and at hydraulic operation under full load; the precise operating symptoms; and the exact results of the testing you have done. Authorized BT dealers may call the factory directly if necessary. © BT Products

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The First Steps of Any Troubleshooting Procedure are to: 1. Inspect the truck for physical damage or mechanical malfunction. Contactors must be free to move and the tips must not be welded or burnt. 2. Check for ground faults from the electrical system to the frame with an ohmmeter. A minimum of 20,000 ohms resistance from the frame to any and all wiring is acceptable. 3. Check that the battery is fully charged and connected. 4. Operate the truck in all modes to determine the exact symptoms. DO NOT forget that these systems are equipped with safety circuits that prevent operation in the event of improper operating procedures.

2. Basics Of Circuit Operation The Curtis® PMC SepEx model 1244 is a microprocessor based, programmable motor controller designed for separately excited motors. It is a true MultiMode controller capable of four distinct operating modes, or personalities, and is programmable with a Curtis® 1307 Programmer. In addition to programming the controller, the 1307 has Diagnostic and Test modes to display error codes and display the status of the controller’s inputs and outputs. The 1244 controller includes an armature controller and a field controller. Both of which regulate the voltage and current applied to the motor according to a preprogrammed motor control algorithm. This motor control algorithm allows the user to select programmable speed and torque profiles that can be tailored to almost any material handling vehicle traction system. The polarity and magnitude of the field current is also controlled to provide solid state, contactorless direction control and regenerative braking. The 1244 is energized by applying power to the keyswitch input, pin number 1. At that time the controller is powered up and performs an internal self test. The controller becomes active by applying power to the interlock input, pin number 2. At that time, the following start-up checks are performed: 146

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1. Checks to see if there is a short between M- and Ground. This insures that the M- output or power MOSFETs are not shorted. 2. Checks to see if there is continuity in the field coil. This also occurs each time forward or reverse is selected. 3. Checks to see if the main contactor coil has actually closed, when commanded, by checking for battery voltage at the B+ terminal. 4. Checks to see if the throttle is below 25 percent. 5. Checks to see if there is continuity in the emergency reverse wiring, if an emergency reverse switch is used. The controller applies a brief pulse from the emergency reverse check output, pin number 22. This pulse is read by the emergency reverse input, pin number 7. If the pulse is not present, there is an open circuit and the controller is disabled. This check first occurs during power up and runs continuously whenever the controller is powered. Selecting either forward or reverse will apply battery voltage to the respective input pin and select the direction of current flow in the field. Increasing throttle increases the voltage and current in the armature circuit. The field current will then follow a predetermined current map to match the armature current. In this manner, the motor is kept in its commutation range and arcing on the commutator is minimized. As the throttle is increased, and the motor speeds up the armature voltage will approach the battery maximum. If further increases in speed are commanded, the field will weaken automatically as directed by the field current map to provide the desired speed. Top speed is limited by limiting the minimum allowable field current. Further top speed limiting can be obtained by limiting the maximum armature voltage through the MAX SPEED Parameter. Regenerative braking is initiated by selecting the opposite direction and applying throttle. The amount of regen braking is regulated by controlling the field and, consequently, the armature current, based on the amount of throttle applied. In this manner, smooth controlled braking force is controlled by the operator. A feature called “neutral braking” provides automatic in neutral. Whenever neutral is selected (releasing © BT Products

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the throttle lever), a programmable amount of regen braking is automatically applied to bring the vehicle to a gentle stop. The neutral braking feature simulates the feel of compression braking in an internal combustion engine vehicle.

2.1. Control Feature

148

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•

Full bridge control of the motor field allows reversing without the use of direction contactors.

•

Fully compatible with the 1307 Programmer for programming, diagnostic and test information.

•

Armature current controlled at all times, reducing arcing and brush wear.

•

Regenerative braking increased usable battery energy and reduces motor heating.

•

Neutral braking provides automatic braking in neutral. Simulates the feel of compression braking. Braking level is adjustable.

•

MultiMode allows up to four user selectable vehicle operating profiles.

•

Programmable to match individual separately excited motor characteristics.

•

Meets or exceeds EEC fault detect requirements with circuitry and software to detect faults in the throttle circuit, MOSFET drive circuits, and emergency reverse wiring.

•

Vehicle speed is controlled and limited at top end through separate field and armature control.

•

Passive regen provides vehicle speed control at any throttle position when going down ramps.

•

Linear temperature cutback on armature and field drive current limits. No sudden loss of power under any thermal conditions.

•

Under voltage cutback reduces motor current to maintain the battery voltage above the undervoltage point.

•

PWM drivers for contactors are programmable for pull-in and holding currents to reduce power dissipation and

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allow the use of common contactors.

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•

HPD (high pedal disable) and SRO (static return to off) interlock options ensure proper start-up sequence.

•

Emergency reverse (belly button) input, upon activation, causes immediate braking, then drive in the reverse direction at high torque.

•

Integral fault LED provides a “controller operating properly” signal and flashes error code information when a fault occurs.

•

Fully protected inputs and outputs.

•

Active power on self test and continuous diagnostics during operation.

•

Internal watchdog circuits ensure proper software operation.

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3. Motor Circuit

Control plug J2

Handset plug J3 4-pins Control plug J1 F2 B+ F1

B-

M-

The transistor controller has three terminals for the high current circuits B-, M-, and B+. Two quick connect terminals are provided for the field winding connections F1 and F2.

4. Control Circuit Terminal

Connecting

B-

Negative connection to battery

B+

Positive connection to battery and motor armature A1

M-

Motor armature A2

Motor field

The transistor controller has an integrated 16-pin connector to provide the low power logic control connections. The designation of the pins are according to the table below. 150

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24 23 22

21 20 19 18

17 16 15 14 13

12 11 10

Pin number 1 is located on the bottom row on the right side looking at the fount of the controller. Pin No

Connecting

CONTACTOR DRIVERS P1

Key switch input

Brake switch input

Mode select 1

Not Used

THROTTLE CONNECTIONS P5

Not Used

BASIC CONTROL SIGNALS

Return

Coil return

P10

Drive steer wheel direction input

P11

Load wheel direction input

P12

Hourmeter

P13

Not Used

P14

Throttle pot low

P15

Not Used

P16

Throttle: wiper/resistor pot

P17

Negative main contactor

P18

Not Used

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Pin No

Connecting

P19

Not Used

P20

Not Used

P21

Not Used

P22

Not Used

P23

Not Used

P24

Not Used

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5. Diagnostics and Troubleshooting The controllers provide diagnostics information assist technicians in trouble shooting drive system problems. The diagnostics information can be obtained in several ways: observing the fault codes issued by the Status LED, observing the fault display driven by the controller's Fault 1 and Fault 2 outputs, or reading the appropriate display on the hand held programmer.

5.1. 1307 Programmer Diagnostics The programmer presents completed diagnostic information in plain language. Faults are displayed int Diagnostic Menu, and the status of the controller inputs/outputs is displayed in the Test Menu. Accessing the Diagnostic History Menu provides a list to the faults that have occurred since the diagnostic history file was last cleared. Checking (and clearing) the diagnostic history file is recommended each time the vehicle is brought in for maintenance. The following 4-step process is recommended for diagnosing and troubleshooting an inoperative vehicle: (1) visually inspect the vehicle for obvious problems; (2) diagnose the problem using the programmer; (3) test the circuitry with programmer; and (4) correct the problem. Repeat the last three steps as necessary until the vehicle is operational. Example: A vehicle that does not operate in fork direction “forward” is brought in for repair. Step1: Examine the vehicle and its wiring for any obvious problems, such as broken wires or loose connections. Step2: Connect the programmer, select the Diagnostics Menu, and read the displayed fault information. In this example, the display shows “No Faults Present,” indicating that the controller has not detected anything out of the norm. Step 3: Select the Test Menu, and observe the status of the inputs and outputs in the forward direction. In this example, the display shows that the forward switch did not close when “forward” was selected, which means © BT Products

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the problem is either in the forward switch or the switch wiring.

5.2. Troubleshooting Chart The controller has a Status LED built into the controller that is visible through a window in the label. This LED displays fault codes whenever there is a problem with the controller or the inputs to controller. During normal operation with no faults present, the Status LED will flash steadily on and off. If the controller detects a fault a 2 digit code (see table below) is flashed continuously until the fault is corrected. Example, Code “3.2” -- main contactor welded -- appears as:

LED Codes

2,2

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Programmer Fault LCD Display Category

Explanation

(3,2) Possible Cause

Controller or microprocessor fault

1,3

(3,2)

solid on

2,1

1,2

(3,2)

No power or defective controller

1,4

1,1

LED off

0,1

No known faults

Controller operational; no fault

Current shunt fault

Current sensor error

1. Controller defective

HW fail-safe 1-2-3

Self- or watchdog fault

1. Controller defective

M- shorted

Internal M- short to B-

1. Controller defective

Field open Arm sensor Field sensor

Field winding fault Armature current sensor fault Field current sensor fault

1. Motor field wiring loose. 2. Motor field wiring open. 3. Controller defective

Throttle fault 1 Throttle fault 2

Wiper signal out of range Pot low fault

1. Throttle input wire open 2. Throttle input wire shorted to B+ or B3. Throttle pot defective 4. Wrong throttle type selected

SRO

SRO fault

1. Improper sequence of KSI, brake and direction inputs. 2. Wrong SRO type selected 3. Brake or direction switch open 4. Sequencing delay too short

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LED Codes

Programmer Fault LCD Display Category

2,3

HPR

HPD sequencing fault

1. Improper sequencing of KSI, brake and throttle inputs. 2. Wrong HPD type selected 3. Misadjusted throttle pot

2,4

E/R wiring check

Emergency reverse wiring fault

1. Emergency reverse wire open 2. Emergency reverse check wire open

3,1

Contactor coil / FLD short

Contactor driver output overcurrent

1. Contactor coil shorted

3,2

Main Contactor welded

Welded main contactor

1. Main contactor stuck closed 2. Main contactor drive shorted

3,3

Precharge fault

Internal voltage too low at startup

1. Controller defective 2. External short, or leakage path to B- on external B+ connector.

3,4

Missing contactor

Missing contactor or did not close

1. Main contactor coil open 2. Wire to main contactor open

4,1

Low battery

Low battery voltage

1. Battery voltage is above undervoltage cutback limit. 2. Corroded battery terminals 3. Loose battery or controller terminal

4,2

Overvoltage

1. Battery voltage is below undervoltage shutdown limit. 2. Vehicle operating with charger attached. 3. Battery disconnected during regen braking

4,3

Thermal cutback

Over / under-temperature cutback

3. Temperature below 85°C or above 25°C 4. Excessive load on vehicle 5. Improper mounting of controller 6. Operation in extreme environments.

4,4

Anti-tiedown

Mode 2 or Mode 4 selected at start-up

1. Mode switches shorted to B+ 2. Mode switches “tied down” to select Mode 2 or Mode 4 permanently.

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Test Menu THROTTLE

Throttle reading, as % of full throttle

ARM CURRENT

Motor armature current, in amps

FIELD CURRENT

Motor field current, in amps

ARM PWN

Motor armature applied duty cycle, as %

FIELD PWM

Motor field applied duty cycle, as %

BATT VOLTAGE

Battery voltage across the capacitors

CAP VOLTAGE

Capacitor voltage

HEATSINK °C

Heatsink temperature

FORWARD INPUT

Forward switch: on/off

REVERSE INPUT

Reverse switch: on/off

MODE

Controller operating mode: 1 to 4

INTLCK INPUT

Interlock switch: on/off

PEDAL INPUT

Pedal switch: on/off

EMR REV INPUT

Emergency reverse switch: on/off

MOTOR RPM

Tachometer input: pulser per second

MAIN CONT

Main contactor: open/closed

AUX DRIVER

Auxiliary driver: open/close

REV OUTPUT

Reverse drive status: on(low)/off(high)

BRAKE OUTPUT

Brake drive status: on(low)/off(high)

FAULT 1 OUTPUT

Fault 1 driver status: on(low)/off(high)

FAULT 2 OUTPUT

Fault 2 driver status: on(low)/off(high)

CONTROL STATE

Controller state: 0 to 7

SPARE 1

Not used

MODSEL 1

Mode select 1

MODSEL 2

Mode select 2

SPARE ANALOG

Not used

Special Program Menu

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RESET ALL SETTING

Revert to original settings

CONT SETTINGS > PROG

Save controller settings in programer

PROG SETTINGS > CONT

Load programmer settings in controller

CLEAR DIAG HISTORY

Clear diagnostics history memory

CONTRAST ADJUSTMENT

Adjust display contrast

LANGUAGE SELECTION

Select displayed language

PROGRAMMER INFO

Display programmer information

CONTROLLER INFO

Display controller information

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Controller parameter settings Parameter

Setting

M1 Drive Current Limit

400

M2 Drive Current Limit

400

M3 Drive Current Limit

400

M4 Drive Current Limit

400

M1 Brake Current Limit

200

M2 Brake Current Limit

200

M3 Brake Current Limit

200

M4 Brake Current Limit

200

M1 Neutral Brake Percent

M2 Neutral Brake Percent

M3 Neutral Brake Percent

M4 Neutral Brake Percent

M1 Acceleration rate

0.5

M2 Acceleration rate

0.5

M3 Acceleration rate

0.5

M4 Acceleration rate

0.5

M1 Maximum speed

Maximum setting 40

M2 Maximum speed

Maximum setting 80

M3 Maximum speed

Maximum setting 40

M4 Maximum speed

Maximum setting 90

M1 Brake Rate

0.5

M2 Brake Rate

0.5

M3 Brake Rate

0.5

M4 Brake Rate

0.5

All adjustment are made through PMC handset (See section 5710 Handset Operation).

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5.3. Technical Specification The technical specification for the BT-version of the Curtis 1244 transistor controller is according to the table below. PARAMETER

RANGE

STD SETTING

UNITS

DESCRIPTION

M1 Drive C/L

200 - 400

400

Amp

Main current limit

M1 Brake C/L *

100 - 400

200

Amps

Brake current limit

M1 Neut Brk % *

0 - 50

% of braking C/L

Neutral braking %

M1 Accel Rate *

0.1 - 5.0

0.5

Sec

Acceleration rate

M1 Max Speed *

0 - 44

% PWM duty cycle

Maximum speed

Seconds

Time to reach full drive output from zero output

M1 Brake Rate

158

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0.1 - 5.0

0.5

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5.4. Troubleshooting Chart Using the Handset Disable Controller When

Recover When

Fault

Test When

BB circuit check (BB = Belly Button)

Continuous after brake release

Circuit found open

Brake released

Coil open/shorted driver

Entering and in neutral, before allowing PWM out, after brake released

Immediate

Cycle Brake S10

Contactor driver overcurrent

Continuously while contactor being driven

Immediate

Cycle Brake S10

Overvoltage

Continuous after brake released

Immediate

Cycle Brake S10

Power supply out of range

Once upon activating S17 and continuous after brake release

Immediate

Cycle Brake S10

M-fault

PWM output (0+) percent to 85 percent. After brake release and not in emergency reverse

Immediate

Cycle Brake S10

M-circuit check

Brake released

Immediate

Cycle Brake S10

Start-up checks

Once upon activating S17

RAM & EEPROM failure only

Cycle S17

Throttle fault

Continuous after brake released

Set throttle input to zero, decel output PWM to zero

Condition clears

Under voltage, Severe

Once upon activating S17 and continuous after brake release

Immediate

Cycle Brake S10

Current sensor fault

Continuous while PWM on

Immediate

Cycle Brake S10

Vds over current

Continuous while PWM on

Immediate

Cycle Brake S10

Watchdog, Ext.

Continuous while S17 on

Immediate

Cycle Brake S10

Watchdog, Int.

Continuous while S17 on

Immediate

Cycle Brake S10

Welded contactor

Continuous while brake released Immediate & no contactor driven

Cycle Brake S10

Parameter block check

Initiating serial communication

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Reinitiating serial interface

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The following are indicated and handled similarly:

Fault

160

Test When

Action

Recover When

Emergency reverse

BB pressed forces E/R

E/R action (see text)

BB re-applied or brake released

HPD

Depends on type, see text

Disable PWM output

throttle cycled

Thermal cutback

Brake released

See text

Undervoltage

Continuous while S17 on

Immediate

Condition clears

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PS S5.6 5461 24 Volt, 400 Amp Transistor Controller Troubleshooting Version no

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24 Volt, 400 Amp Transistor Controller Troubleshooting 1. Troubleshooting Chart Index

Return

Dead truck, nothing operates. No travel, no horn.

No travel, line contactor does not close. Horn function okay.

No reverse travel (load wheels leading). Line contactor closes when control handle is pulled down to operating position. Forward travel and the horn functions work okay.

No forward travel (load wheels trailing). Line contactor closes when control handle is pulled down to operating position. Reverse travel and the functions work okay.

Truck travel speed does not respond to controls properly. Speed control is sluggish or erratic.

No high speed travel.

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2. Troubleshooting Charts The following troubleshooting charts describe a course of testing and repair for each problem listed. If the given test is NOT successful perform the repair listed with the test. If the given test IS successful move on directly to the next test or follow the special instructions given. 1.

Dead truck, nothing operates. No travel, no horn. Conditions for testing: Truck raised and blocked with drive tire off floor. Battery fully charged and connected to truck. S21 in the “RUN” position. S17 turned “ON”. Test for battery voltage at: A. Positive side of F50, wire number 28. Repair open wire number 28 between battery and F50. B. Negative side of F50, wire number 26. Replace F50. C. Positive side of S21, wire number 26. Repair open wire number 26 between F50 and S21. D. Negative side of S21, wire number 27. Replace S21. E. Positive side of S17, wire number 27. Repair broken wire number 27 between S21 and S17. F. Negative side of S17, wire number 6. Replace key switch.

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G. If truck is not functioning re-evaluate symptoms and troubleshoot individual functions. 2.

No travel; line contactor does not close. Horn functions work okay. Conditions for testing: Truck raised and blocked with drive tire off floor. Battery fully charged and connected to truck. S21 in the “RUN” position. S17 turned “ON”. Brake released and S10 closed. Test for battery voltage at: A. Plug J1-1, wire number 6 on transistor controller. Repair open wire number 6 between S17 and A1. B. Positive side of K10 coil, wire number 6. Repair open wire number 6 between S17 and K10. C. Positive side of S10, wire number 6. Repair open wire number 6 between S17 and S10. D. Negative side of S10, wire number 7. Adjust or replace S10. E. Plug J1-2; wire number 7 on A1. Repair open wire number 7 between S10 and A1. F. Negative side of K10 coil. If battery voltage is NOT measured here then verify line contactor coil and replace line contactor coil. G. Test with handset

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H. Replace A1. 3.

No reverse travel (load wheels leading). Line contactor closed. Forward travel and horn functions work okay. Conditions for testing: Truck raised and blocked with drive tire off floor. Battery fully charged and connected to truck. S21 in the “RUN” position. S17 turned “ON”. Brake released and S10 closed. Travel controls operated to travel in the reverse direction (load wheels leading), and horn operates properly. Test for battery voltage at: A. Positive side of S15, wire number 7. Repair open wire number 7 between S10 and S15. B. Negative side of S15, wire number 3. Adjust or replace S15. C. Plug J1-11, wire number 3, A1. Repair open wire number 3 between S15 and A1. D. Power circuit breaker positive side of F1. Repair power cable between battery positive and F1. E. Power circuit breaker negative side of F1. Replace F1. F. Power circuit positive side of K10.

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Repair power cable between F1 and K10. G. Power circuit negative side of K10. If battery voltage is NOT measured here then verify line contactor operation and replace line contactor. H. B+ terminal on A1. Repair open power cable between K10 and B+ at the transistor controller. I. A1 terminal on drive motor. Repair open A1 cable between K10 and M1. J. M- terminal on A1: Voltage should be battery voltage in neutral and decrease with throttle input down approximately 1 volt. K. A2 terminal on drive: Voltage should be battery voltage in neutral and decrease with throttle input down approximately 1 volt. L. Test with handset M. Replace A1. 4.

No forward travel (load wheels trailing). Line contactor closed. Reverse travel and horn functions work okay. Conditions for testing: Truck raised and blocked with drive tire off floor. Battery fully charged and connected to truck. S21 in the “RUN” position. S17 turned “ON”. Brake released and S10 closed. Travel controls operated to travel in the forward direction (load wheels trailing).

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Test for battery voltage at: A. Positive side of S16, wire number 7. Repair open wire number 7 between S10 and S16. B. Negative side of S16, wire number 2. Adjust or replace S16. C. Plug J1-10, wire number 2, A1. Repair open wire number 2 between S15 and A1. D. Power circuit breaker positive side of F2. Repair power cable between battery positive and F1. E. Power circuit breaker negative side of F1. Replace F1. F. Power circuit positive side of K10. Repair power cable between F1 and K10. G. Power circuit negative side of K10. If battery voltage is NOT measured here then verify line contactor operation and replace line contactor. H. B+ terminal on A1. Repair open power cable between K10 and B+ at the transistor controller. I. A1 terminal on drive motor. Repair open A1 cable between K10 and M1. J. M- terminal on A1: Voltage should be battery voltage in neutral and decrease with throttle input down approximately 1 volt. K. A2 terminal on drive: Voltage should be battery 166

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voltage in neutral and decrease with throttle input down approximately 1 volt. L. Test with handset M. Replace A1 5.

Truck travel speed does not respond to controls properly. Speed control is sluggish or erratic. Conditions for testing: Truck raised and blocked with drive tire off floor. Battery fully charged and connected to truck. S21 in the “RUN” position. S17 turned “ON”. Brake released and S10. Travel controls to be operated from neutral to full speed in both directions as tests are made. A. Test voltage at plug J1-16, wire number 9, on A1. This voltage should start out between 3 and 4 volts in neutral and decrease smoothly to less then 0.2 volts at high speed in both directions. If voltage does not change repair open wire number 9 or number 19 connected to accelerator potentiometer. If voltage changes but not smoothly or not below 0.5 volt then adjust or replace accelerator potentiometer. B. Transistor controller may be in thermal cutback. Allow controller to cool and retest. C. Test handset D. Replace A1.

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No high speed travel.

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Conditions for testing: Truck raised and blocked with drive tire off floor. Battery fully charged and connected to truck. S21 to the “RUN” position. S17 turned “ON”. Brake released and S10. Stand on platform to close S14. Travel control to be operated from neutral to full speed in both direction as tests are preformed. Test for voltage at: Special Instructions: If truck is NOT equipped with Speed Dropout System continue with test “A”. If truck IS equipped with Lift Interrupt System follow test “1 through 3". (1)

Test for battery voltage at pin 3 on back of BDI gauge, wire number 2. Repair open wire number 2 between S16 and BDI gauge.

(2). Test for battery voltage at negative pin 4 on back of BDI gauge, wire number 23. If battery voltage is NOT measured here verify that battery voltage is sufficient for Speed Dropout System to allow high speed function to operate. Replace BDI gauge which contains the Speed Dropout System. (3)

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Continue testing with test A.

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A. Positive side of S14. Repair open wire number 2 between S16 and S14. B. Negative side of S14. Replace S14. C. J1-3 on A1. Repair open wire number 35, J1-3 on A1. D. Test with handset. E. Repair A1.

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PS Version no

Section

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S5.14 5710 Handset Operation T-code

000

Handset Operation The PMC handset allows you to program, test, and diagnose the transistor controller. The handset is powered by the host controller, via a 4-pin connector located on the controller. When the handset is first plugged into the controller, it displays the controller’s model number, date of manufacture, and software revision code. Following this initial display, the handset displays a prompt for further instructions.

Item Number

Part Number

Description

306415-000

PMC handset

306416-000

Cable

A 4-line LCD display is presented in this window.

The LED in the corner of the key lights up to identify the mode of operation.

Choose the Program, Test, or Diagnostics Mode with one of these three keys.

Scroll the 4-line display (up or down) with these two keys.

Change the selected item’s value (up or down) with these two keys.

Receive more information about selected items with this key. Also, use this key in combination with other keys to put the programmer in Special modes.

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CHANGE VALVE

The handset is operated via an 8-key keypad. Three keys select operating modes (Program, Test, Diagnostics), two scroll the display up and down, and two change the values of selected parameters. The eighth key, the MORE INFO key, is used to display further information about selected items within any of the three standard modes. In addition, when pressed together with the PROGRAM or the DIAGNOSTICS key, the MORE INFO key selects the Special Program mode or the Special Diagnostics mode. The display window presents a 4-line LCD display. The display is visible even in bright sunlight. You can adjust the display contrast in the Special Program mode. When one of the menu keys is pressed, the LED at the corner of the key lights up, identifying the mode of handset operation. For example, if the TEST key is pressed, the LED at the corner of the key indicates that the handset is now in the Test mode, and the Test Menu is displayed. Four lines of a menu are displayed at a time. The item at the top of the display window is the selected item. To select an item, scroll within the menu until the desired item is positioned at the top of the display window. The selected item is always the top line. (In Program mode, the selected item is highlighted by a flashing arrow.) To modify a parameter or obtain more information about it, it must be scrolled to the top position in the display window.

SCROLL DISPLAY

To scroll up and down within a menu, use the two SCROLL DISPLAY arrow keys. The SCROLL DISPLAY arrow keys can be pressed repeatedly or be held down. The scrolling speed increases the longer the key is held. A small scroll bar at the left of the display window provides a rough indication of the position of the four displayed items within the entire menu. That is, when the bar is at the top of the window, the top of the menu is displayed. As you scroll through the menu, the bar moves downward. When the bar is at the very bottom of the window, you have reached the end of the menu. This sample display is from the Program Menu:

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Scroll bar

M1 ACCEL RATE M1 ACCEL RATE M1 DECEL M1 DECEL

1.5 2.0 1.0 1.0

Selected item

The two CHANGE VALUE arrow keys are used to increase or decrease the value of the selected menu item. Like the SCROLL DISPLAY arrow keys, the CHANGE VALUE arrow keys can be pressed repeatedly or can be held down. The longer a key is held, the faster the parameter changes. This allows rapid changing of any parameter. An LED on each CHANGE VALUE arrow key indicates whether the key is active and whether change is permissible. When the value of a parameter is being increased, the LED on the “up” CHANGE VALUE key is on until you reach the maximum value for that parameter. When the LED goes off, you cannot increase the value. The MORE INFO key has three functions: (1) to display more information about the selected item, (2) to access the Special Program and Special Diagnostics mode (when used together with the PROGRAM and DIAGNOSTICS keys), and (3) to initiate certain commands (such as the Self Test). “More information” is available in all of the handset operating modes. After using the MORE INFO key to display additional information about the selected item, press the MORE INFO key again to return to the original list.

1. Operating Modes Program, test diagnostics, special program, special diagnostics

PROGRAM

In the Program mode, accessed by pressing the PROGRAM key, all the adjustable parameters and features of the controller are displayed (four at a time), along with their present settings. The setting of the selected item----the item at the top of the display with the flashing arrow----can be changed using the two CHANGE VALUE keys. The LED’s on these keys indicate whether there is still room

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for change. When the upper limit of a parameter’s range LED on the “up” key no longer lights up, the present value cannot be increased. When the lower limit is reached, the LED on the “down” key no longer lights up. The MORE INFO key, when used in the Program mode, displays a bar graph along with the minimum and maximum values possible for the selected parameter. Parameters can be changed either from the main Program Menu or after the MORE INFO key has been pressed and the additional information is being displayed (see example below). Selected Set value parameter MODE 1 ACCELERATION Bar graph

RATE,

SECS

1.3 MIN 0.2

MAX 3.0

Maximum value

Minimum value Some parameters on some controllers are dependent on other parameters. This means that the available settings for one parameter may be dependent on the limits of another parameter. For example, your controller may not allow the reverse speed to be set below the Mode 1 minimum speed. In this example, if you attempt to reduce the reverse speed below the M1 minimum speed, a message will be displayed indicating that the minimum reverse speed is dependent on the M1 minimum speed. The Program Menu is presented in C-code 5460. NOTE! Some items may not be available on all models.

TEST

278

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In the Test mode, accessed by pressing the TEST key, realtime information is displayed about the status of the inputs, outputs, and controller temperature. For example, when the status of the reverse input is displayed, it should read “On/ Off/On/Off/On/Off” as the switch is repeatedly turned on and off. In the Test mode, the item of interest does not need to be the top item on the list. It only needs to be among the four items visible in the window. The Test mode is useful for checking out the operation of the controller during initial installation, or for troubleshooting should problems occur. Service Manual

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The MORE INFO key, when used in the Test mode, causes additional information to be displayed about the selected item (top line in the window). The Test Menu is presented in C-code 5460. NOTE! Some items may not be available on all models. In the Diagnostics mode, accessed by pressing the DIAGNOSTICS key, currently active faults detected by the controller are displayed. DIAGNOSTICS

The MORE INFO key, when used in the Diagnostics mode, causes additional information to be displayed about the selected item. A list of the abbreviations used in the Diagnostics display is included in C-code 5460.

* MORE INFO

PROGRAM

The Special Program mode allows you to perform a variety of tasks, most of which are self-explanatory. Through the Special Program Menu, you can revert to earlier settings, save controller settings into the handset memory, load the controller settings from the handset into a controller, clear the controller’s diagnostic history, adjust the contrast of the handset’s LCD display, select the language to be displayed by the handset, and display basic information (model number, etc.) about the controller and the handset. To access the Special Program mode, first press the MORE INFO key. Then, while continuing to hold the MORE INFO key, press the PROGRAM key. The LED on the PROGRAM key will light, just as when the handset is in Program mode. To distinguish between the Program and Special Program

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modes, look at the menu items in the display. CONTROLLER CLONING Two of the Special Program Menu items----Save Controller Settings in Handset Load Handset and Settings into Controller----allow you to “clone” controllers. To do this, simply program one controller to the desired settings. Save these settings in the handset, and load them into other similar (same model number) controllers, thus creating a family of controllers with identical settings. The MORE INFO key is used initially to access the Special Program mode. Once you are within the Special Program mode, it is used to perform the desired tasks. To adjust the contrast in the display window, for example, select “Contrast Adjustment” by scrolling until this item is at the top of the screen. Then press MORE INFO to find out how to make the adjustments. In the Special Diagnostics mode, the controller’s diagnostic history file is displayed. This file includes a list of all faults observed and recorded by the controller since the history was last cleared.

* MORE INFO

PROGRAM

NOTE! The maximum and minimum temperatures recorded by the controller are included in the Test Menu. Each fault is listed in the diagnostic history file only once regardless of the number of times it occurred. To access Special Diagnostics, first press MORE INFO key. Then, while continuing to hold the MORE INFO key, press the DIAGNOSTICS key. The LED on the DIAGNOSTICS key will light just as when the handset is in Diagnostics mode. The MORE INFO key, when used within the Special Diagnostics mode, causes additional information to be displayed about the selected item.

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To clear the diagnostic history file, put the handset into the Special Program mode, select “Clear Diagnostic History”, and press the MORE INFO key for instructions. Clearing the diagnostic history file also resets the maximum/minimum temperatures in the Test Menu.

2. Revert to Previous Settings Each time the handset is connected to the controller, it acquires all the controller’s parameters and stores them in its temporary memory. You can revert back to these original settings at any time during a programming session via the Special Program Menu. Select “Revert to Previous Settings” by scrolling it to the top of the display window, press the MORE INFO key, and follow instructions displayed. Any inadvertent changing of parameters can be “undone” using this procedure ---- even if you can’t remember what the previous settings were --- as long as the handset has not been unplugged and power has not been removed from the controller.

3. Handset Self Test SCROLL DISPLA

!’#$%&’()*+,-./ 0123456789:;<=>? @ABCDEFGHIJPLMNO PQRSTUVWXYZx - °

…

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You can test the handset by displaying two special test screens. Press the MORE INFO key while the handset is powering up. During the Self Test, you can toggle between the two test screens by pressing the SCROLL DISPLAY keys. The first screen turns on every LCD element, and the second screen displays all the characters used in the various menus. As part of Self Test, you can also test the keys by pressing each one and observing whether its corner LED lights up. To exit the Self Test, unplug the handset or turn off the controller, and then repower it without holding the MORE INFO key.

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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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