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Front Cover Master Service Manual PMX45

Electric Low Lift Pallet Truck

Effective Serial Number PMX4531141001 - UP

WARNING Read and observe all warnings on this unit before operating it. WARNING DO NOT operate this equipment unless all factory installed guards and shields are properly secured in place. Part no: 311230-000

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Date: March 28, 2002

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Standard Codes Version no

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000

390

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 F-Code List PT

Powered Pallet Trucks

T-Code List No.

Model

390

PMX45

C-Code List No Function Group

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C-Code

Chassis

0000

Motors

1000

Drive Gear / Transmission

2000

Brake / Wheel System

3000

Steering System

4000

Electrical System

5000

Hydraulic / Pneumatic System

6000

Operating Function-lifting Cylinder

7000

Peripheral / Installation Equipment

8000

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390

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Optionals / Attachments

9000

Tools

10000

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Table of Contents Standard Codes ............................................................................................. 1 Warning Symbols ......................................................................................... 11 Warning Levels ......................................................................................... 11 Prohibitory Symbols .................................................................................... 12 Ordinance Symbols .................................................................................. 12 Safety ............................................................................................................ 13 General Safety .......................................................................................... 13 Battery Safety ............................................................................................... 17 Static Safety .................................................................................................. 22 Welding Safety ............................................................................................. 23 Introduction, Service Manual ...................................................................... 25 Contents, Section M ..................................................................................... 27 Machine Information ................................................................................. 27 General Product Information ...................................................................... 29 Truck Presentation. ................................................................................... 29 Truck Side Views ................................................................................... 29 Intended Truck Application .................................................................... 30 Prohibited Truck Application .................................................................. 30 Truck Data ............................................................................................. 30 Truck Dimensions .................................................................................. 31 Data Plate .............................................................................................. 32

Main Components ..................................................................................... 33 Inch and Metric (SAE) Fasteners ............................................................... 35 Introduction ............................................................................................... 35 Nomenclature, Threads ............................................................................ 36 Strength Identification ............................................................................... 37 Conversion of English and Metric Units .................................................... 44 Technical Service Data ................................................................................ 47 Ordering Spare Parts ................................................................................... 49 Contents, Section P ..................................................................................... 51 Planned Maintenance ............................................................................... 51 Introduction, Maintenance .......................................................................... 53

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Table of Contents Jacking Truck Off The Floor ..................................................................... 54 Elevate Rear of Truck ............................................................................ 54 Elevate Either Side of Truck .................................................................. 54

Lubricants ................................................................................................. 55 Standard ................................................................................................ 55 Corrosion ............................................................................................... 55 Cold Storage .......................................................................................... 56

Service Schedule ......................................................................................... 59 Planned Maintenance Schedule ............................................................... 59 Planned Maintenance Procedures ............................................................ 63 Services Performed Daily or Every 8 Operating Hours .......................... 63

Battery Discharge Indicator with lift interrupt (optional) .............. 63 Hydraulic System ....................................................................... 63 Frame/Sheet Metal ..................................................................... 64 Wheels/Tires .............................................................................. 64 Functions/Operations ................................................................. 64 Services Performed Monthly or Every 120 Operating Hours ................. 65

Inspection ................................................................................... 65 Transmission .............................................................................. 65 Brakes ........................................................................................ 65 Battery ........................................................................................ 65 Electrical Connections ................................................................ 66 Main Contactor ........................................................................... 66 Motor Brushes ............................................................................ 66 Drive Motor ................................................................................. 66 Hydraulic Reservoir .................................................................... 66 Frame Lube ................................................................................ 67 Pivot Points ................................................................................ 67 Services Performed Every 480 or 960 Operating Hours ........................ 68

Drive Motor ................................................................................. 68 Services Performed Annually or Every 1440 Operating Hours .............. 69

Inspection ................................................................................... 69 Transmission .............................................................................. 69 Battery ........................................................................................ 69 Hydraulic System ....................................................................... 70 Brakes ........................................................................................ 70 Lubrication Chart ......................................................................................... 71 Oil and Grease Specifications .................................................................... 72 Approved Oils and Grease ....................................................................... 72 Grease Location Points ............................................................................ 72 Contents, Section S ..................................................................................... 73 Service Instructions .................................................................................. 73

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Table of Contents Chassis/Lift Frame ....................................................................................... 75 Pull rod ...................................................................................................... 76 Removal ................................................................................................. 76 Inspection ............................................................................................... 77 Installation .............................................................................................. 78

Carrier Frame Bushings ............................................................................ 80 Inspection Covers ........................................................................................ 81 General Information .................................................................................. 81 Driver Controls ............................................................................................. 85 Decals ............................................................................................................ 87 Decal with Protective Sheet ...................................................................... 87 Decal without Protective Sheet ................................................................. 87 Motor Maintenance Schedule/Troubleshooting ........................................ 89 General Information .................................................................................. 89 Operating Conditions ................................................................................ 89 Troubleshooting ........................................................................................ 90 Pump Motor .................................................................................................. 97 Mounting Points ........................................................................................ 97 Removal ................................................................................................. 97 Installation .............................................................................................. 97

Pump Repair ............................................................................................. 98 Disassembly ........................................................................................... 99

Inspection and Troubleshooting ............................................................... 100 Drive End Head ..................................................................................... 100 Commutator End Head ......................................................................... 100 Bearings ................................................................................................ 100

Brush Inspection ...................................................................................... 101 Brush Replacement Determination ....................................................... 101 Replacement Procedures ..................................................................... 102

Drive Motor .................................................................................................. 105 Mounting Points ....................................................................................... 105 Drive Motor Brush ................................................................................. 106 Drive Motor Removal ............................................................................ 106 Drive Motor Installation ......................................................................... 108

Component Repair .................................................................................. 110 Motor Disassembly ............................................................................... 112

Motor Inspection ..................................................................................... 113 External Motor ....................................................................................... 113 Brush and Commutator ......................................................................... 113 Bearings ................................................................................................ 116

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Table of Contents Armature Electrical Check .................................................................... 116 Frame and Field Service Recommendation .......................................... 116 Assembly/Testing .................................................................................. 117

Transmission ............................................................................................... 119 System Description .................................................................................. 119 Troubleshooting ....................................................................................... 119 Transmission Mounting ............................................................................ 120 Wrap Around Bumper ........................................................................... 121 Guards .................................................................................................. 122 Removal ................................................................................................ 123 Installation ............................................................................................. 124

Transmission Repair ................................................................................ 125 Disassembly .......................................................................................... 126 Reassembly .......................................................................................... 127

Axle Seal .................................................................................................. 129 Removal ................................................................................................ 129 Installation ............................................................................................. 129

Parking Brake System ................................................................................ 131 Brake Theory of Operation ...................................................................... 132 Brake Adjustment .................................................................................... 133 Brake Shoe Removal / Installation ........................................................... 134 Drive Wheel .................................................................................................. 135 Removal ................................................................................................... 135 Installation ................................................................................................ 136 Tire Pressing Procedure .......................................................................... 137 Support/Swivel Wheel (Optional) ............................................................... 139 Maintenance and Adjustments ................................................................ 141 Caster Adjustment ................................................................................ 141

Troubleshooting ....................................................................................... 141 Stabilizing Caster .................................................................................. 141

Caster Replacement ................................................................. 141 Fork Wheels ................................................................................................. 143 Removal/Installation ................................................................................ 143 Steering ........................................................................................................ 145 Control Handle Head ............................................................................... 146 Removal ................................................................................................ 146 Installation ............................................................................................. 146

Driver Protection (Reverser) Assembly Replacement ............................. 147 Direction Control Switches ....................................................................... 149 Removal ................................................................................................ 149

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Table of Contents Installation ............................................................................................. 149

Raise, Lower, and Horn Switches ............................................................ 151 Removal ................................................................................................ 151 Installation ............................................................................................. 152

Potentiometer .......................................................................................... 153 Removal ................................................................................................ 153 Installation ............................................................................................. 154

Steering Stem .......................................................................................... 158 Removal ................................................................................................ 158 Installation ............................................................................................. 158

Electrical Functions .................................................................................... 159 General .................................................................................................... 159 Adjustable Settings: .............................................................................. 159 References ............................................................................................ 159 Key Switch S17 in the ON Position ....................................................... 159 Operating Arm in Drive Position, S10, Brake Switch Closed ................ 160 Travel Request, Fork First .................................................................... 160 Travel Request, Forks Trailing .............................................................. 160 Reversing/Motor Brake Forks First Direction to Forks Trailing Direction 160 Reversing/Motor Brake Forks Trailing Direction to Forks First Direction 161 Reverser switch .................................................................................... 161 Lifting Forks .......................................................................................... 161 Lowering Forks ..................................................................................... 161 Horn ...................................................................................................... 162 Lift Interrupt ........................................................................................... 162

Electrical Symbols ...................................................................................... 165 Electrical Schematics ................................................................................. 169 Battery .......................................................................................................... 173 Removal ................................................................................................... 173 Installation ................................................................................................ 173 Battery Maintenance ................................................................................ 174 Battery Inspection and Care ................................................................. 174 Battery Exterior Cleaning ...................................................................... 175 Charging ............................................................................................... 175

Storage .................................................................................................... 176 Battery History Record ............................................................................. 176 Swing Out Battery Pack .............................................................................. 177 Battery Cable Routing Diagram ............................................................... 179 Charger Diagram ..................................................................................... 181 Troubleshooting ....................................................................................... 182 Electrical Testing ................................................................................... 182

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Table of Contents Equipment required: .................................................................. 182 Instructions ................................................................................ 182 Battery Connector ....................................................................................... 189 Location ................................................................................................... 189 Inspection ................................................................................................ 189 Installation ................................................................................................ 190 Battery Controller/Hourmeter/ Lift Interrupt (Optional) ........................... 191 General Information ................................................................................. 191 Electrical .................................................................................................. 192 Voltage .................................................................................................. 192

Battery Controller (BC) ............................................................................ 193 General Information .............................................................................. 193

Discharge Adjustment ............................................................... 193 Reset ..................................................................................................... 195 Key Switch ............................................................................................ 195 Hourmeter ............................................................................................. 196

Troubleshooting ....................................................................................... 196 Battery Discharge Indicator (BDI) ......................................................... 196

No Reset ................................................................................... 196 Reset After Break in Power ....................................................... 196 No Discharge, Gauge Does Not Run Down .............................. 197 No Lockout ................................................................................ 197 No Lift ........................................................................................ 198 Early Lockout ............................................................................ 198 LEDs Do Not Light .................................................................... 198 Hourmeter ............................................................................................. 199

No Display ................................................................................. 199 Hourmeter Glass Icon Does Not Flash ..................................... 199 Hourmeter Glass Icon Always Flashes ..................................... 199 Battery Discharge Indicator / Hourmeter .................................................. 201 General Information ................................................................................. 201 Electrical .................................................................................................. 202 Voltage .................................................................................................. 202

Battery Discharge Indicator (BDI) ............................................................ 202 General Information .............................................................................. 202 Key Switch ............................................................................................ 202 Hourmeter ............................................................................................. 203

Troubleshooting ....................................................................................... 203 Battery Discharge Indicator (BDI) ......................................................... 203

No Reset ................................................................................... 203 Reset After Break in Power ....................................................... 204 No Discharge, Gauge Does Not Run Down .............................. 204 LEDs Do Not Light .................................................................... 204

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Table of Contents Hourmeter ............................................................................................. 205

No Display ................................................................................. 205 Hourmeter Glass Icon Does Not Flash ..................................... 205 Hourmeter Glass Icon Always Flashes ..................................... 205 Start/Stop Switches .................................................................................... 207 General .................................................................................................... 207 Test/Inspection ...................................................................................... 207

Master Control On/Off Switch (S21) ........................................................ 209 Inspection .............................................................................................. 209 Removal ................................................................................................ 209 Installation ............................................................................................. 209

Transistor Controller .................................................................................. 211 Basics Of Circuit Operation ..................................................................... 211 Control Features ................................................................................... 213

Maintenance ............................................................................................ 214 Safety .................................................................................................... 214 Cleaning ................................................................................................ 214

Motor Circuit ............................................................................................ 215 Control Circuit .......................................................................................... 216 Troubleshooting Guidelines ..................................................................... 217 General ................................................................................................. 219

Shorts to Frame Test ............................................................................... 220 Definitions ................................................................................................ 224 Diagnostics and Troubleshooting ............................................................ 225 Handset Diagnostics ............................................................................. 225 Troubleshooting .................................................................................... 225 Troubleshooting Chart .......................................................................... 227 Technical Specification ......................................................................... 232 Troubleshooting Chart Using Handset .................................................. 233

Transistor Controller Troubleshooting ..................................................... 235 Troubleshooting Chart Index ................................................................... 235 Troubleshooting Charts ........................................................................... 236 Hydraulic System ........................................................................................ 247 General .................................................................................................... 247 Troubleshooting ....................................................................................... 247 Schematic ................................................................................................ 249 Description ............................................................................................... 250 Lift ......................................................................................................... 250 Lower .................................................................................................... 250 Relief Pressure ..................................................................................... 250

Maintenance ............................................................................................ 251 Lift Limit Switch ........................................................................................ 251

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Table of Contents Hydraulic Pump ......................................................................................... 253 Removal ................................................................................................... 255 Disassembly ............................................................................................ 256 Inspection ................................................................................................ 257 Reassembly ............................................................................................. 258 Installation ................................................................................................ 260 Adjustments ............................................................................................. 261 Relief valve ........................................................................................... 262 Solenoid Operated Valve ...................................................................... 262

Lift Cylinder ................................................................................................ 263 Cylinder Repair ....................................................................................... 264 Removal ................................................................................................ 264 Disassembly .......................................................................................... 265 Inspection .............................................................................................. 265 Assembly .............................................................................................. 265 Installation ............................................................................................. 266

Battery Charger, Optima Pack ................................................................... 267 Handset Operation ...................................................................................... 269 Operating Modes ..................................................................................... 272 Revert to Previous Settings ..................................................................... 275 Handset Self Test .................................................................................... 275

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Warning Symbols T-code

000

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

1. Warning Levels Warning levels Warning text is 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 the instructions are not followed. 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 an accident or breakdown if the instructions are not followed.

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000

Prohibitory Symbols NO SMOKING If smoking occurs in situations where a restriction against 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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000

Safety 1. General Safety Do NOT operate or work on this truck unless trained, qualified, and authorized to do so and have read the Operator’s Manual.

Know truck controls and what they do.

Do NOT operate truck if it needs repair or if it is in any way unsafe.

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Operate truck only from the position of the Operator.

Before working on this truck always turn key switch to OFF and disconnect battery connector from truck (unless this manual states otherwise).

Do NOT wear watches, rings, or jewelry when working on truck.

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000

Follow the scheduled inspection steps.

lubrication,

maintenance,

and

Follow exactly the safety and repair instructions in this manual. Do NOT take “shortcuts”.

Do NOT Use an open flame near the truck.

Do NOT use gasoline or other flammable liquids for cleaning parts.

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Clean up any hydraulic fluid, oil, or grease that has leaked or spilled on the floor.

Always operate and park truck indoors.

Do NOT wash truck with a hose.

Do NOT add to or modify truck without written approval from BT Prime-Mover, Inc.

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Battery Safety T-code

000

Battery Safety WARNING As a battery is being charged, an explosive gas mixture forms within and around each cell. If the area is not properly ventilated, this explosive gas can remain in or around the battery for several hours after charging. Be sure there are no open flames or sparks in the charging area. An open flame or spark can ignite this gas, resulting in serious damage or injury. WARNING Battery electrolyte is a solution of sulfuric acid and water. Battery acid causes burns. Should any electrolyte come in contact with clothing or skin, flush the area immediately with cold water. Should the solution get on the face or in the eyes, flush the area with cold water and receive medical attention immediately. Read, understand and follow procedures, recommendations and specifications in the battery and battery charger manuals from the manufacturer.

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Wear personal protective equipment to protect eyes, face, and skin when checking, handling, or filling batteries. This equipment includes goggles or face shield, rubber gloves (with or without arm shields) and a rubber apron.

Make sure a shower and eyewash station are nearby in case there is an accident.

A battery gives off explosive gases. Never smoke, use an open flame, or use anything that gives off sparks near a battery.

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000

Keep the charger area well-ventilated to avoid hydrogen gas concentration.

Turn the key switch off before disconnecting the battery from the truck at the battery connector. Do NOT break live circuits at the battery terminals. A spark often occurs at the point where a live circuit is broken.

Do NOT lay tools or metal objects on top of battery. A short circuit or explosion could result.

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Keep batteries clean. Corrosion causes shorts and possibly sparks to the frame. Keep plugs, terminals, cables, and receptacles in good condition to avoid shorts and sparks.

Keep filler plugs firmly in place at all times except when the electrolyte level is checked, when water is added to the cells or when the specific gravity is checked. Make sure vent holes in filler plugs are open to allow gas to escape from the cells. Vent Plug

Do NOT allow cleaning solution, dirt, or any foreign matter to enter the cell.

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Make sure to install the correct size battery. A smaller or lighter weight battery could seriously affect truck stability. See the truck specification (data) plate for more information.

Never plug a battery charger into the truck battery connector. Plug battery charger ONLY into battery connector from battery.

Follow the charging procedures in the “Battery Instruction Manual” and in the “Battery Charger Instruction Manual”.

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PT Static Safety Version no

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000

Static Safety Electronic circuit board and devices used on the truck can be damaged by the discharge of static electricity, called electrostatic discharge. Static charges can accumulate from normal operation of truck as well as movement or contact between non-conductive materials such as; plastic bags, synthetic clothing, synthetic soles on shoes, styrofoam coffee cups, etc. Accumulated static can be discharged through human skin to a circuit board or component by touching the parts. Static discharge is also possible through the air when a charged object is placed close to another surface at a different electrical potential. Static discharge can occur without seeing or feeling it. Whenever working on or near static-sensitive electronics, always use static discharge precautions. 1. Place a static discharge wrist strap around the wrist. Connect the ground lead to the wrist strap connector. 2. Connect the ground clamp to an unpainted, ground surface on the truck frame. 3. If removing or installing static-sensitive components, place them on a properly grounded static mat. 4. To transport static-sensitive components, including failed components being returned, place the components in an antistatic bag or box. The wrist strap and associated accessories should be tested monthly to verify they are working properly. A defective static discharge wrist band will not alert that it is bad.

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Welding Safety T-code

000

Welding Safety WARNING Flame cutting or welding on painted surfaces may produce potentially harmful fumes, smoke and vapors. Prior to performing flame cutting or welding operations, it is recommended that the coating be removed in the vicinity where the operation(s) will be performed. WARNING Coating removal may be by mechanical methods, chemical methods or a combination of methods. Flame cutting and/ or welding operations should be carried out only in well ventilated areas using local exhaust if necessary. Before working on truck, make sure of the following: • Fire protection equipment is nearby. • Know where the nearest eyewash station is located.

CAUTION Disconnect battery before attempting to inspect, service or repair truck. • Check for shorts to frame. If any shorts are detected, remove before proceeding with the welding operation. • Clean the area to be welded. • Protect all truck components from heat, weld spatter and debris.

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• Attach the ground cable as close to the weld area as possible.

• Disconnect all electrical cards before any type of electric resistance welding is done. • Do not perform any welding operations near the electrical components. • If welding must be done near the battery compartment, remove the battery from truck. • When welding is completed, perform all ground tests and electrical inspections before the vehicle is operated.

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PT M Introduction, Service Manual Version no

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390

Introduction, Service Manual The information in this Service Manual covers model PMX45. Federal and State laws require that operators be completely trained in the safe operation of trucks in accordance with OSHA regulation 1910.178. An Operator’s Manual is sent with every BT Prime-Mover 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

(563) 262-7700 This service manual is not a training manual. The information contained in this service manual is intended as a guide to help trained, qualified and authorized technicians safely service this truck. The Service Manual is divided into four separate sections, which cover needed information for servicing the truck type. 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 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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General Product Information 1. Truck Presentation. The PMX45 is a battery powered walkie pallet truck intended solely to be operated handling pallets or similar load carriers indoors. The trucks are equipped with a steering arm with all the controls for operating within easy access. The trucks have maximum lifting capacities of up to 4500 pounds (2041 kg). Review data plate on the truck to note the maximum lifting capacity. The truck is equipped with a 24 volt electrical system. Truck speed is regulated by means of a transistor controller to provide infinite control of acceleration and speed while driving. Chassis/lift frame is raised by means of a hydraulic unit. The control of the lift/lower is done electrically with the push button on the steering arm. The trucks can be fitted with a battery pack and can be specially equipped to work in cold conditions.

1.1. Truck Side Views The terms right-hand and left-hand used indicate the right and left side of the truck as viewed from the operator’s line of sight for proper operation of truck. Use this view when ordering parts to assure proper selection of parts.

Left Side

Forward

Rearward

Right Side

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

1.2. Prohibited Truck Application The trucks are designed for handling goods indoors. The use of trucks for other purposes is not permitted. Do not use the truck for the following: •As a towing tractor for trailers. •To tow other trucks. •To transport/lift passengers. •To drive on gravel or grass.

1.3. Truck Data The table below provides information regarding some technical data which is of value with daily use of the trucks. Truck data Lifting capacity rated load, lb/kg

4500/2041

Lift height, inches/mm

6/152.4

Operating speed without load, mph/k

3.7/5.96

Operating speed with load, mph/k

3.3/5.31

Service weight without battery, lb/kg

800/363

Service weight including battery (minimum battery weight 150 lb (68 kg) maximum 330 lb (149.6 kg)

Above + battery weight

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

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1.4. Truck Dimensions The following diagram shows external dimensions for the PMX45 truck in its standard design. 7.3” (185 mm)

27” (685 mm)

30.0” (762 mm)

77.6” (1971 mm)

26.1” (662 mm) 50° 12°

Battery Compartment 9” (228 mm)

46.5” (1181 mm)

48” (1219 mm)

32.1” (815 mm)

3.25” (82 mm) 6” (152 mm)

6.7” (170 mm)

54.4“(1381 mm) 4.6” (116 mm)

All Dimensions shown for 48” (1219 mm) long pallet

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

7.6 inch (193 mm) 9.0 inch (228 mm) 27.7 inch (703 mm) 28.5 inch (723 mm) (Consult Data Plate on truck)

For smaller industrial battery sizes, provide blocking to restrain the battery from moving not more than 0.5 inch (12 mm) in any horizontal direction. © BT Prime-Mover, Products Inc.

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

1 4 6

3 5

7 9

8 10

Legend 1 Truck model number 2 Truck serial number 3 Truck type 4 Truck capacity 5 Truck weight 6 Truck voltage 7 Use UL Class Battery type 8 Battery maximum AMP hours 9 Minimum battery weight 10 Maximum battery weight

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2. Main Components 1. Reverser switch The end of the control handle is equipped with a red automatic reversing switch which causes the truck to travel in the rearward direction when activated. 2. Travel speed/direction selection Selects the direction truck moves. The further in that direction the faster the truck moves. 3. Horn switch Horn sounds to warn others of truck position. 4. Fork raise switch Forks will raise when switch is pressed or until lift stops are reached. 5. Fork lower switch Forks will lower when switch is pressed or until lower stops are reached. 6. Battery 24 volt with different capacities and weights. 7. Load Wheel Lubricate load wheels to prevent wheels from locking up. 8. Drive unit with brake Fixed drive unit with a spring applied brake, drive motor, gear box, and drive wheel combined into a compact unit. The steering bearings are at the top of the drive unit. 9. Electric panel 24 volt electrical system. Truck speed is regulated by means of a transistor controller. 10. Circuit breaker 15A, Control circuit breaker 80A, Power circuit breaker 11. Cover Removable to provide access for servicing. 12. Steering pivot point Lubricate pivot point to prevent stiff steering. 13. Hydraulic unit Pump motor, pump, electric valves and oil tank integrated in a compact unit. 14. Hydraulic electric solenoid valve © BT Prime-Mover, Products Inc.

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For controlling lifting and lowering functions with electric solenoid valve. 15. Steering control handle Truck is controlled by the operator with 180 degree steering angle. The brake is applied in the upper and lower position of the steering control handle. 16. Key Switch (toggle switch) Shuts off electrical power to control system. 17. Gauge Combined hourmeter/battery indicator, hourmeter/battery indicator with lift cutout or hourmeter only. 18. Main on/off switch Stops all control functions 19. Emergency battery disconnect Pulling the battery connector shuts off all electrical power to truck. 2

Control handle in operating position

5 4 3

19 11 7

16 13

9 10 15

12 14

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M1.1 Inch and Metric (SAE) Fasteners Version no

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Inch and Metric (SAE) 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. Many 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 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 shank diameter of 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 UNC (Unified National Coarse) or UNF (Unified National Fine) is shown. This number of threads per inch is not shown because an 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

M12 x 1.75 x 50

A = Shank Diameter

A = Thread size

B = Number of threads per unit of length

B = Pitch

C = Type of thread

C = Length

D = Shank 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 marks that identify grades and property classes for different fasteners. WARNING When fasteners must be replaced new fasteners must be of same strength or greater than original fasteners. The new fasteners must also be the correct size. NOTE!

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Identification marks are according to bolt strength. The higher the number, or increase in number of marks, indicates increased bolt strength.

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Table 1. Bolt and Screw Designation

Types of Fasteners

Metric Fasteners

Inch Fasteners

Strength Levels: Property Classes

Strength Levels: SAE Grades

5.2

* Markings Not Required 8

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

Same As Above

Hex Head Flange Screws 5

12 Point Flange Screws Markings Not Required

8.8

12.9

8.8

12.9

Hex Socket Head Cap Screws 5.1

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

* Markings Not Required

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

5.8

8.8

9.8

10.9

12.9

9.8

10.9

12.9

Markings for size M5 and Larger

8.1 or

Studs

Optional Geometric Symbols for Size M5 through M11 ONLY.

Hex Nuts

Markings Not Required

Hex Slotted Nuts

Markings Not Required

Hex Flange Nuts

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Table 3. Torque Nut Designations

Types of Fasteners

Inch Fasteners

Strength Levels: SAE Grades

B B

C C

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

Inch Fasteners

Strength Levels: SAE Grades

Metric Fasteners

Strength Levels: Property Classes

Nylon Insert Prevailing Torque Nuts

Markings Not Required

or or

Markings Not Required

Nylon Insert Prevailing Torque Flange Nuts

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Table 5. Fastener Torque Values

Size and Pitch

Property, Class

8.8*

10.9**

12.9***

44-53 71-88 177-221

N•m 5-6 8-10 20-25

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

N•m 7-8 12-14 30-35

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

N•m 8-10 14-16 ------------

ft-lb

N•m

ft-lb

N•m

ft-lb

N•m

M8 x 1.25 M10 x 1.5

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

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

22-26 44-48

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

26-30 52-55

34-40 70-75

M12 x 1.75 M14 x 2

30-33 52-59

70-80 110-125

74-81 114-133

100-110 155-180

85-96 133-155

115-130 180-210

M16 x 2 M20 x 2.5

125-140 251-280

170-190 340-380

177-199 332-369

240-270 450-500

207-236 406-443

280-320 550-600

M24 x 3

428-479

580-650

590-664

800-900

664-774

900-1050

M30 x 3.5

848-959

1150-1300

1180-1328

1600-1800

1364-1549

1850-2100

M36 x 4

1479-1660

2000-2250

2065-2323

2800-3150

2397-2729

3250-3700

in-lb M5 x 0.8 M6 x 1 M8 x 1.25

in-lb

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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Truck Torque Specifications Description

Torque Specification

Pump motor brush screws Pump motor mounting bolts Pump motor terminal nuts Drive motor pinion gear nuts Drive motor mounting bolts Drive axle nut

5.9 ft-lb (8 N•m) 5.9 ft-lb (8 N•m) 10.33 ft-lb (14 N•m) 35 ft-lb (47 N•m) 35 ft-lb (47 N•m) 250 ft-lb (338 N•m)

“E” Drive motor terminals “E” Drive motor pole piece screws Transmission case brake cover bolts Transmission gear case cover bolts

140 in-lb (15 N•m) 250-300 in-lb (28-33 N•m) 35 ft-lb (47 N•m) 35 ft-lb (47 N•m) Loctite® 515-74®

Parking brake drum nut Hydraulic pump adaptor cap screws Hydraulic spool valve assembly Hydraulic solenoid coil

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35 ft-lb (47 N•m) 10-12 ft-lb (13-16 N•m) 35 ft-lb (47 N•m) 5 ft-lb (6 N•m)

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4. Conversion of English and Metric 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

Return

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)

TORQUE Multiply

To Get

Multiply

To Get

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

kilometer/hour

0.621

miles/hour (mph)

miles/hour

1.609

kilometer/hour (km/h)

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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Technical Service Data NOTE!

When the battery is fully charged, performance may vary due to motor and system efficiency tolerance. Technical service data represents nominal values obtained under typical operating conditions. Specifications are subject to change without notice.

DRIVE MOTOR Type Shunt wound Power 1.3 hp Duty factor 60 minutes Minimum brush length 0.60 inch (15 mm) Minimum commutator diameter 2.05 inch (52 mm) Minimum brush spring tension 35 oz (992 g) TRANSMISSION/GEAR Type Horizontal motor spiralbevel output Gear ratio 22:1 Oil volume 1½ pints (0.709 liter) Standard and corrosion continuous SAE 80 operation above 23° F (-5°C) (see page 55) Cold Storage (see page 56) Continuous operation 5° F(-15° C) ATF Intermittent operation -13° F (-25° C) WHEELS Drive wheel (inch/mm) 10.5 x 5 x 6.5 (267 x 127 x 165) Torque axle nut 250 ft-lb (338 N•m) Load wheel (inch/mm) 3.25 x 5 (82.55 x 127)

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HYDRAULIC UNIT Relief Pressure at rated load Relief Pressure at operating load Minimum brush length Minimum commutator diameter Minimum brush spring tension Pump flow Tank volume

3200 psi (22063 kPa) 2500 psi (17236 kPa) 0.699 inch (17 mm) 1.60 inch (40.8 mm) 35 oz (992 g) 1.6 cc/REV About 1 quart

Standard and corrosion continuous operation above 23° F (-5°C) (see page 55) Cold Storage (see page 56) Continuous operation 5° F(-15° C) Intermittent operation -13° F (-25° C)

Sunoco TH ATF

FUSES Circuit breaker Control circuit

80 Amp 15 Amp BATTERIES

Dimension W x L x H (inch/mm) Capacity (Max. Amp-hrs.) Weight (Minimum/Maximum)

28.5 x 9 x 24 (723.9 x 228.6 x 609.6) 510 200/600 lbs. (91/272)

DRIVING SPEEDS Without load With rated load

3.7 mph 3.3 mph LIFTING/LOWERING TIME

Lift with rated load Lower with rated load, electrical valve CURRENT CONSUMPTION Driving without load Lifting with rated load

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5.3 sec. 3.3 sec. 35 Amp 135 Amp

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Ordering Spare Parts 1. Locate fault on truck. 2. Locate truck model and serial number. Forward

3. The terms right-hand and left-hand used indicate the right and left side of the truck as viewed from the operator’s line of sight for proper operation of truck. Use this view when ordering parts to assure proper selection of parts.

Left Side Right Side Rearward

4. In the parts book, locate page with the exploded diagram and find the item number for the part required. 5. Locate item number in the table. Select column for actual truck model and serial number. The following is an explanation of a serial number:

PMX 45 3 1 265 001 Number of unit for that day Day of year (365) Year (2001) Decade (2000) Capacity (4500lb) Model (PMX)

CAUTION Although some trucks appear to be similar, component parts may not be interchangeable. If an incorrect part is used, the truck may malfunction. 6. Note part number. 7. Contact your local BT Prime-Mover Dealer and state the part number. 8. If truck model, serial number, or article number cannot be found, call your local BT Prime-Mover Dealer for assistance. © BT Prime-Mover, Products Inc.

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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

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Introduction, Maintenance The schedules of maintenance and lubrication given in this section of the Service Manual cover up to one year of operation of a truck. These schedules are based on hourly usage and can be adapted to suit most normal one shift pattern. The following hourly usage figures have been used when calculating the schedule: Single shift, 30 hours per week usage Double shift, 60 hours per week usage Triple shift, 90 hours per week usage The schedules are intended only as a guide, not as a rigid structure. Operator of truck may wish to adapt these schedules to local requirements. 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.

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•

Use only spare parts approved by BT PrimeMover.

•

Always clean the equipment and carry out a full safety check after service.

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1. Jacking Truck Off The Floor To perform maintenance that requires the truck to be lifted from the floor, observe the proper precautions as follows: 1. Lower the forks completely. Remove any load. 2. Turn key switch OF. Disconnect battery connector from truck. WARNING Use extreme care whenever the truck is jacked up for any reason. Keep hands and feet clear from beneath the truck while jacking. Use jack stands or solid blocks to support the truck, do not rely on jacks. 3. Place the jack under the designated jacking points. Jack only in these areas

1.1. Elevate Rear of Truck 1. Place the jack in the designated jacking position. 2. Jack the rear of the truck so the drive tire is off the floor no more than 3 inches (76 mm). 3. Block truck in place.

1.1. Elevate Either Side of Truck 1. Place the jack in the designated jacking position. 2. Jack the side of the truck so that the load wheel is off the floor no more than 0.50 inch (12.7 mm). 3. Block truck in place.

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2. Lubricants 2.1. Standard For trucks in their standard design under continuous operation, the recommended ambient temperature is 23° F (5° C). These trucks should apply to the following guidelines: •

Parked outside storage when not in use

•

Charging and maintenance work to be done outside storage

2.2. Corrosion In an environment where a damp, wet, or corrosive condition exits, these trucks apply to the following guidelines:

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•

All hardware coated with LPS Rust Inhibitor during and/or after assembly

•

Sealed components (switches, push/pull cables, sensors, etc.) where appropriate

•

Grease fittings provided on axle and other pivot points

•

Plated pins, shafts and linkage where required

•

All electrical connections coated with Dow Corning No. 4 compound during assembly

•

Lift chains coated with Libriplate chain protectant

•

Components coated with LPS Cold Galvanize where appropriate

•

Components (adjustable features, bearing races, etc.) coated with an anti-seizing compound where appropriate

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2.3. Cold Storage To prevent moisture contamination in the electrical system, trucks equipped with cold storage conditioning packages have electrical compound applied to all electrical connections during assembly. For cold storage reach trucks with continuous operation, the recommended ambient temperature is 5° F (-15° C). Cold storage trucks should apply to the following guidelines: •

Trucks completely dry prior to commencing the continuous stay in the cold storage

•

Parked inside the cold storage for operator breaks

•

Charging and maintenance work done outside the cold storage

•

Trucks completely dry before returning to continuous cold storage operation

For cold storage reach trucks with intermittent operation, the recommended ambient temperature is -13° F (-25° C). Trucks apply to the following guidelines: •

Surface condensation occurs, “wet” trucks should neither remain idle in the cold storage for no longer than 10 minutes nor operate inside the cold storage for extended periods

•

Condensation must not be allowed to freeze on the truck at any time

•

Park outside the cold storage for operator breaks

•

Charging and maintenance work to be done outside the cold storage

Items included in the cold storage package are as follows:

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All corrosion conditioning items

•

Sealed components used in all non-heated locations

•

Heavy-duty mechanical switches used where appropriate

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•

Thermostat controlled heaters used to prevent moisture buildup in electrical component areas

•

Heaters located around the electronic card, the drive and lift power controllers, the steering tachometer, and hydraulic control potentiometers

•

Windshield replaced with a screen

•

Hydraulic fluid in lift/auxiliary system changed to ATF

•

Anti-seizing compound used on the control console, vertical adjustment bar

•

Standard grease replaced with Mobiltemp SHC 32 lubricating grease

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Service Schedule 1. Planned Maintenance Schedule ITEM 0300 0300.1

0300.2 0300.3 0300.4 1700 1700.1 1700.2 1700.3 1700.4 1700.5 1700.6

1700.7 1700.8 2550 2550.1 2550.2

3300 3300.1 3300.2 3300.3

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WORK REQUIRED Interval in Hours Interval in Days/Weeks/Months Chassis Check that truck data plate and decals are legible (wear and fading depends on environment) Check for damage and cracks Retighten truck body bolts (to chassis) Check cover screws Motors Check for arcing due to poor connections Check tightness on all connections Clean motor of dirt and dust Check torque of motor bolts Check for abnormal noise in motor bearings Blow carbon, copper, and plastic particle accumulations from the motor using compressed air Check electrical armature (page 116) Check brushes (see page 101 or page 113) Drive Gear Check for oil leakage Check that toe guard is secured and at proper height (located at drive wheel) Brake Clean dust and debris Check brake shoes for wear Check correct clearance of brake shoes Master Service Manual

8 1d

30 1w

120 1m

360 3m

720 6m

1440 12 m

4320 36 m

X X X

X X

X X X

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ITEM 3300.4 3500 3500.1 3500.2 3500.3 3500.4 4100 4100.1 4100.2 5000 5000.1 5000.2 5000.3 5000.4 5000.5 5000.6 5000.7 5110 5110.1

5110.2 5110.3 5110.4 5300 5300.1 5400 5400.1

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WORK REQUIRED Interval in Hours Interval in Days/Weeks/Months Check brake operation Wheels Remove all string, wrapping and debris Check all wheels for wear Grease load wheel bearings Grease caster and caster wheels Steering Control handle Check fasteners Check ease of steering Electrical Control System Check key switch Check that travel direction/speed selectors are operational Check brake switch Check that horn button is operational Check that hydraulic buttons are operational Check control wiring harness for proper routing Check that main on/off switch is operational Battery Electrolyte level, 1/2 - 5/8 inch (12.7 - 15.875 mm) above cell plates Check all connections: battery, battery and charger plugs Check all cell and link covers intact Check battery specific gravity Instrument Panel Check battery indicator and hourmeter for correct operation Electrical Panel Clean and check mounting to chassis

8 1d X

30 1w

120 1m

360 3m

720 6m

1440 12 m

4320 36 m

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

X X

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ITEM 5400.2 5400.3 5400.4 5400.5 5400.6 6000 6000.1 6000.2 6000.3 6000.4 6000.5 6420 6420.1 6420.2

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WORK REQUIRED Interval in Hours Interval in Days/Weeks/Months Check tightness of connections Check contactor tips Check contactor tips for free movements Check all cable insulation for damage Check for connections in harness connectors Hydraulic System Check hoses and connections for leakage Check hoses for wear and damage Check oil tank for cracks, leaks and mounting Check correct oil level Change hydraulic oil Lift Cylinder Check for leakage Check mounting

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120 1m

360 3m

720 6m X X

1440 12 m

4320 36 m

X X X

X X X X X X X

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5110 5191

0850

6420 5192

5300

4110

6000

5230

1750 5430

3550 6100

4110

0340

3530 0300

3540

1760 2550

0340

5000

5460 3300

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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 Performed Daily or Every 8 Operating Hours Daily inspection is to be made by the operator prior to each operating shift. It is the responsibility of the operator to report any defects to the proper authorities. The truck should not be operated until it has been inspected and repaired by a trained, qualified, and authorized technician. The operator is ultimately responsible for the safe operation of the truck. 2.1.1. Battery Discharge Indicator with lift interrupt (optional) The battery guard indicates the current charge status of the truck 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 lift function when a predetermined charge level has been reached. This prevents overloading the battery and increases the operating economy of the truck. When the battery has reached a charge level equivalent to 70 percent discharge, a warning signal is given via flashing lights. A further 10 percent of the battery capacity can then be used before the battery guard cuts out the lift function. 2.1.2. Hydraulic System Inspect the entire truck for leaks, especially around the hydraulic pump assembly and lift cylinder. Any sign of oil on the floor under the truck is an indication that the truck may be leaking hydraulic oil or transmission fluid. Report any problems to the proper authorities. DO NOT operate the truck until it has been inspected and repaired by a trained, qualified, and authorized technician.

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2.1.3. Frame/Sheet Metal Inspect the truck for loose, damaged or missing parts. All shields must be in place and functional. Report any problems to the proper authorities. DO NOT operate the truck until it has been inspected and repaired by a trained, qualified, and authorized technician. 2.1.4. Wheels/Tires Inspect wheels and tires for wear and damage. Trash that is wrapped around the 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. Apply lubricant through grease fitting to lubricate grease load wheel bearings. Remove cover and apply lubricant in frame opening to grease fitting to lubricate caster assembly. 2.1.5. Functions/Operations Test truck for proper operation of all functions including travel controls, lift and lower functions, brakes and emergency disconnect button. Safety devices must be operational. Report any problems to the proper authorities. DO NOT operate the truck until it has been inspected and repaired by a trained, qualified, and authorized technician.

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2.2. Services Performed Monthly or Every 120 Operating Hours The monthly planned maintenance service should be performed by a trained, qualified, and authorized technician 2.2.1. Inspection All 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 transmission fluid level. The level check point is a plug on the side cover of the transmission about 4 inches (102 mm) above the bottom of the transmission case. Remove plug and inspect the level of the fluid inside the transmission case. The fluid level should come to about 0.375 inch (10 mm) below the plug and should never be above the level of the plug. 2.2.3. Brakes Truck at full speed with rated load must stop in its own length. The brakes should be fully released when the control handle is moved down 12 degrees from the fully raised position and should apply at 28 degrees above the fully lowered position. 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.

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2.2.5. Electrical Connections All electrical connections should be clean and tight. Plug-in connectors should be unplugged and plugged back in to clean the terminals. If the truck is equipped with any of the cold-storage use or corrosive environment application packages, the di-electric compound in the plug-in connectors should be renewed. 2.2.6. Main Contactor With a voltmeter, check to make sure main contactor has not welded close. Replace contactor if welded close. 2.2.7. Motor Brushes Inspect the drive and pump motors for brush wear and condition of the commutator. For minimum brush lengths see page 47. It is recommended that the brushes be replaced if the brush spring is within 0.0625 inch (1.59 mm) of touching the brush holder. 2.2.8. Drive Motor Blow out the drive motor fan and vents. Check for any signs of oil on the drive motor air vents. Check for any damage to the air vents. WARNING Compressed air used for cleaning MUST be reduced to less than 30 psi (206 kPa) and then only with effective chip-guarding and personal protective equipment worn. 2.2.9. Hydraulic Reservoir Check the fluid level in the hydraulic reservoir.

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P2.0 Service Schedule

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2.2.10. Frame Lube The pressure type grease fittings (zerk fittings) should be lubricated with grease (see page 72). The total number of grease fittings depends on truck options when built (see page 72). Cold-storage use application package will have more grease fittings than a standard truck. Look for fittings on the load wheel axles. Regular grease fittings are found on the transmission pivot bearings. 2.2.11. Pivot Points There are other pivot points and items that need to be lubricated but do not have grease fittings. These include, but are not limited to, the control handle mounting shaft. Lubricate non-greasable wear points with a drip oil can using 10 weight machine oil.

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2.3. Services Performed Every 480 or 960 Operating Hours The planned maintenance service should be performed by a trained, qualified, and authorized technician. 2.3.1. Drive Motor Since the operating environment of material handling equipment varies widely, the following recommendations are suggested for periodic maintenance inspections for the drive motor armature. •

Normal Service 8 hours per day operation Routine inspection every 960 hours (8 months).

•

Severe Service 24 hours of daily operation 1. Dusty or sandy locations; such as cement plant, lumber or flour mills, coal dust or stone-crushing areas. 2. High temperature areas; such as steel mills, foundries, etc. 3. Sudden temperature changes (continuous indooroutdoor movement) such as refrigeration plant, etc.

•

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Routine inspection every 480 hours (4 months).

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2.4. Services Performed Annually or Every 1440 Operating Hours The annual planned maintenance service will take a longer period of time to complete than does the monthly service. This would be a good time to arrange other repairs that have been noted on the monthly service. 2.4.1. Inspection All 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. 2.4.2. Transmission The transmission fluid should be drained once a year. The drain port is located on the lower portion of the side cover opposite the drive tire. Remove bolt to drain transmission fluid. Flush transmission case. Pour a cleaning solution into the fill port accessed from the battery compartment. With the drive tire off the floor, allow solution to run out of drain port while transmission is running. Stop flushing when the solution runs clean. Allow the solution to drain well before replacing drain plug. Replace drain plug bolt. Refill transmission with proper clean oil before operating truck. 2.4.3. 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 trained, qualified, and authorized technician.

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2.4.4. Hydraulic System The hydraulic system should be drained, flushed and refilled, and the pressure relief valve setting should be checked and adjusted. WARNING Before siphoning oil from reservoir, make certain siphon is clean. To drain reservoir, remove reservoir filter assembly. Siphon oil from reservoir and purge oil out of the hydraulic system. Fill reservoir with proper clean oil. Operate the raise and lower function several times to purge air from the system. Check oil level. Put rated truck capacity load on forks and adjust pressure relieve valve, if necessary, so that the truck will lift rated load. 2.4.5. Brakes Follow procedures for brake removal before inspecting. Remove brake assembly and inspect friction disc for wear. The friction disc should be replaced once thickness is 0.25 inch (6 mm) or less. The armature and magnetic coil should be adjusted if truck will not meet stopping and holding specifications. The air gap should not exceed 0.018 inch (0.46 mm) and should remain within 0.003 inch (0.076 mm) throughout the circumference.

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P3.0 Lubrication Chart

Version no

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Lubrication Chart Pos. No.

Service Point

Interval/Running Hours 360 h

1 2 3 4 5 6 7

Wheel bearings Handle pivot Lifting linkage Hydraulic system Steering bearings Drive gear Drive gear drain

720h

1440 h

Lubricant (See “Approved Oils and Grease” on page 72.)

L L L C C C L= Lubrication

C = Check

O L O

A A A B C C C

O = Oil change

6 1 7

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Oil and Grease Specifications 1. Approved Oils and Grease

Lubricant

Specification Standard and Cold Storage Corrosion Continuous Continuous Operation Operation To 23° F (-5° C) Above Intermittent Operation 23° F (-5° C) To -13° F (-25° C)

Grease

Mystik JT-6

Hydraulic oil

Sunoco TH

ATF

Transmission oil

SAE 80

Application area

Bearings and bushings Hydraulic system Gears

2. Grease Location Points On lube and cold storage trucks ONLY.

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S Contents, Section S T-code

000

Contents, Section S 1. Service Instructions NO FUNCTION GROUP

C-CODE

CHASSIS

0000

MOTORS

1000

DRIVE GEAR / TRANSMISSION

2000

BRAKE / WHEEL SYSTEM

3000

STEERING SYSTEM

4000

ELECTRICAL / PNEUMATIC SYSTEM

5000

HYDRAULIC SYSTEM

6000

LIFTING CYLINDER

7000

PERIPHERAL / INSTALLATION

8000

EQUIPMENT

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OPTIONS / ATTACHMENTS

9000

TOOLS

10000

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S0.1 0300 Chassis/Lift Frame

Version no

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Chassis/Lift Frame 2 4

1 3

21 27 26 5

25 23 14 18 22 11

8 21 28

11 4

20 11

4 17

Item No.

Description

15 4

Item No.

Description

Item No.

Description

Frame, lift

Bushing, iron

Screw, transmission stop

Nut

Rod, pull

Screw, shoulder

Screw, socket head

Screw, locking

Nut, jam

Fitting, grease

Link, upper

Pin, wheel fork pivot

Pin, lower link

Bushing, iron

Pin, lower link

Frame, carrier

Pin, load wheel

Pin, outside lower

Fitting, grease

Screw, set

Pin, inside lower

Nut, locking

Pin, pull rod

Screw, locking

Grease fitting

Fork, wheel

Skid

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PT S0.1 Chassis/Lift Frame Version no

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000

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0300

1. Pull rod To replace pull rods and/or bushings it is best to work with the truck in the upright position. It is necessary to block or jack the truck off of the floor and have forks in the fully upright position to work in the upright position.

1.1. Removal WARNING Block all wheels to prevent truck from rolling. 1. Park truck on a level surface and make sure parking brake is applied and load wheels are blocked to prevent accidental movement. 2. Release pressure in hydraulic system by pressing the lowering button on steering control handle. 3. Disconnect battery connector from the truck. Remove battery from unit to prevent accidental operation. 4. Remove cover. WARNING Compressed air used for cleaning MUST be reduced to less than 30 psi (206 kPa), and then only with effective chip-guarding and personal protective equipment. NOTE!

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

5. Before disassembly, thoroughly clean exterior in a cleaning solution to remove all contamination. 6. Remove set screw (8) and pin (5) connecting wheel fork (10) to frame (1). This allows the wheel fork and pull rod (12) to drop. 7. Remove setscrew (8) and pin (9) connecting the pull rod (12) to wheel fork (10). 8. Remove lower link stationary pivot pin (14) by removing locking screw (13).

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S0.1 0300 Chassis/Lift Frame

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9. With lower links (17) and (18) out of lift frame channels, the links can be separated and pull rod (12) removed from link pin (15). Each link has one pin attached at opposite ends. Link can be separated without removing additional set screws. 10.Remove all bushings and discard. Replace with new bushings.

1.2. Inspection WARNING Compressed air used for cleaning MUST be reduced to less than 30 psi (206 kPa), and then only with effective chip-guarding and personal protective equipment. NOTE!

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

1. Thoroughly clean all parts and remove all nicks and burrs with emery cloth. 2. Inspect pull rods (12) for excessive wear or bending. No cracks are allowed in pull rods (12) and must be replaced as a pair. If heavy wear or bending is found replace both pull rods (12). 3. Inspect wheel forks (10) for excessive wear or cracks. If cracks are found replace both wheel forks (10). 4. Inspect all pins for nicks, scratches, or scoring. If heavy scoring is found or scratches that can not be removed with emery cloth, replace pin. 5. Replace all bushings with new.

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PT S0.1 Chassis/Lift Frame Version no

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0300

1.3. Installation WARNING Compressed air used for cleaning MUST be reduced to less than 30 psi (206 kPa), and then only with effective chip-guarding and personal protective equipment. NOTE!

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

1. All parts should be cleaned and dried thoroughly. Metal parts should be lightly oiled prior to reassembly. 2. Press new bushings in pull rod (12). 3. Assemble pull rods (12) on lower links (17) and (18) and press links together to fit in frame channel. 4. Install pivot pin (14) and retaining screw (13) in lower links (17) and (18). 5. Install pin (9) connecting pull rod (12) to wheel fork (10). 6. Install pins (5) in wheel fork (10) and frame (1). Replace setscrew (8). 7. Lubricate all grease fittings. 8. Install battery on truck. Connect battery connector to truck. WARNING DO NOT use your hands to check for hydraulic leakage. Use a piece of cardboard or paper to search for leaks. Escaping fluid under pressure can penetrate the skin causing injury. Relieve pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Keep hands and body away from pinholes and nozzles which eject fluids under high pressure.

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9. Operate the truck’s hydraulic system and check operation of system as a whole. Look for a leak in tight places on the lifting linkage. 10.Replace cover.

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2. Carrier Frame Bushings Bushing on upper links (24) of the carrier frame (26) can be replaced by removing link from one side at a time and pressing in new bushings.

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S0.2 0340 Inspection Covers

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

5 3

8 11 7

9 10

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0340

Item No.

Return

Description

Item No.

Description

Screw

Washer

Retainer

Screw, cap

Nut

Bracket

Screw

Bracket, key switch

Cover, inner

Cover, outer

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Inspection Covers (“EE” electric box) Item No.

Return

Item No.

Description

Cover

Relief strain

Box

Screw

Control, panel assembly

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0340

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S0.3 0640 Driver Controls

Version no

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Driver Controls The truck is controlled by the operator with 180 degree steering angle. The steering control handle is used to provide hand brake, direction, speed, and horn on the truck. The brake is activated mechanically by the steering control handle/brake control. Rotating control in the forward and rearward direction will select the direction of travel. A thumb control and optional picking knob for speed and direction control is equipped on the truck. Speed is controlled based on the position of the directional controls lever. The horn sounds as long as the button is pressed. The fork raise switch activates a contactor to start the pump motor with lifting.

Steering Control Handle

Fork Lower Switch

Fork Raise Switch

Steering Control Handle Horn Switch Rearward Reverse Switch

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Directional Controls

Forward

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PT S0.3 Driver Controls

0640

Version no

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000

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S0.4

0850 Decals

Version no

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000

390

Decals Remove and replace any decals that are damaged. Replace any missing decals. Remove a damaged decal by using a sharp edge to peel decal from the surface. Use caution not to scratch or damage paint on lift truck when removing decal. Replacement of warning decals are free from BT PrimeMover. Using the required cleaning solution, thoroughly clean surface of the truck before applying a new decal. Allow the surface to completely dry, be sure that there is no residue. Touch up paint in area of decal, as required.

1. Decal with Protective Sheet To install this style, peel off backing, place decal into position, and press decal into place. Do not wrinkle decal. Rub over protective over-sheet with a firm, straight, plastic edge to remove air bubbles and any wrinkles. Peel off the over-sheet.

2. Decal without Protective Sheet To install decal without protective sheet, peel off backing, place decal into position, and press decal into place. Do not wrinkle decal. Smooth decal into place using clean fingers. Be sure all edges are secured to the surface.

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S0.4

0850

Version no

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2 1 3

Item No. 1 2 3 4 5 6 7

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Description Plate, DATA Decal, DO NOT STEAM CLEAN Decal, NO RIDING Decal, PRIME-MOVER LOGO Decal, U.L. Label Decal, WARNING Decal, PMX

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Motor Maintenance Schedule/ Troubleshooting 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 for long-life and trouble-free 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)

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3. Troubleshooting When a motor has trouble in operation, a reasonable decision has to be made as to the proper corrective course of action. A review of the many troubleshooting guides has been conducted and have been reduced to a few which seem to be the most effective Symptom/Cause relationships and are listed on tables 1 and 2.

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Table 1

Unsatisfactory brush performance.

Table 2

Primary sources performance.

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brush

2002-02-13

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Table 1. Unsatisfactory Brush Performance Indications Sparking

Etched or burned bands on brush face Pitting of brush face Rapid brush wear

Glowing at brush face

Copper in brush face Flashover at brushes Chattering or noisy

Immediate Causes Commutator surface condition Overcommutation Undercommutation Too rapid reversal of current Faulty machine adjustment Mechanical fault in machine Electrical fault in machine Bad load condition Poor equalized parallel operation Vibration Chattering of brushes Wrong brush grade Fluctuating contact drop Overcommutation Undercommutation Too rapid reversal of current Glowing Embedded copper Commutator surface condition Severe sparking Imperfect contact with commutator Wrong brush grade Embedded copper Faulty machine adjustment Severe load condition Bad service condition Wrong brush grade Commutator surface condition Bad service condition Wrong brush grade Machine condition Bad load condition Lack of attention Commutator surface condition Looseness in machine Faulty machine adjust High friction Wrong brush grade

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Primary Faults 1-2-3-43-44-45-46-49-59-60 7-12-31-33 7-12-30-32 7-12-30-32 8-9-11 6-14-15-16-17-18-19-20-21-28 29 25-27-28-29-38-39-40-41-42 7-13-23-34 51-52 See “Chattering or Noisy” 55-57-59 50 7-12-31-33 7-12-30-32 7-12-30-32 See “Glowing at brush face” See “Copper in brush face” See specific surface fault in evidence. Also see 50. See “Sparking” 11-14-15-16-51-52 54-58 See “Copper in brush face” 7-12 38-39-41-42 46-47 57-61-62 2-3 43-46-47-48-49 59-61 14-35 38-39-41-53 5-11 See specific surface in evidence 15-16-17 10-11 6-43-45-49-52-58-59 55-58-59

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Table 1. Unsatisfactory Brush Performance Indications Brush chipping or breakage

Rough or uneven surface Dull or dirty surface Eccentric surface High commutator bar Low commutator bar streaking or threading of surface Bar etching or burning Bar marking at pole pitch spacing Bar marking at slot pitch spacing Flat spot Discoloration of surface Raw copper surface Rapid commutator Wear with blackened surface Rapid commutator Wear with bright surface Copper dragging

Return

Immediate Causes Commutator surface condition

Sparking Sparking Copper or foreign material in brush face Glowing Sparking Flashover Sparking

Primary Faults See specific surface fault in evidence 15-16-17 52 See “Chattering or Noisy” 14 1-2-3-4-17 5-44-60 1-19-22-52 17 2-25 2-3-43-44-45-46-49-47-48-5961 See “Glowing at Brush Face” 2-3-7-12-30-31-32-33 5-11-14-35-38-39-41-53 25-37

Sparking

7-12-30-57-60

Sparking Flashover Lack of attention High temperature Atmospheric condition Wrong brush grade Embedded copper Bad service condition Wrong brush grade Burning Severe sparking

19-23-25-41-53 5-11-14-35-38-39-41-53 1-5-11 See “Heating at commutator” 44-46 60 See “Copper in brush face” 43-45-47-49 59-61 2-3-11-14 See “Sparking”

Foreign material in brush face Wrong brush grade Brush vibration

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

Looseness in machine Vibration Chattering Sluggish brush movement

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Table 1. Unsatisfactory Brush Performance Indications Heating in windings

Heating at commutator

Heating at brushes

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Immediate Causes Severe load condition Unbalanced magnetic field Unbalanced armature currents Poorly equalized parallel operation, lack of ventilation Severe load condition Severe sparking High friction Poor commutator surface Depreciation High contact resistance Severe load condition Faulty machine adjustment Severe sparking Raw streaks on commutator surface Embedded copper Wrong brush grade

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2002-02-13

Primary Faults 38-41-42-53 18-19-20-21-27-28-29 8-19-22-25-27-28-29-37 7-13-23-24 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 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

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Table 2. Primary Sources of Unsatisfactory Brush Performance Preparation and Care of Machine 1.

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

Brushes in wrong position

Unequal brush spacing

Poor alignment of brush holders

10.

Incorrect brush angle

11.

Incorrect spring tension

12.

Interpoles improperly adjusted

13.

Series field improperly adjusted Mechanical Fault in Machine

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14.

Brushes tight in holders

15.

Brushes too loose in holders

16.

Brush holders loose at mounting

17.

Commutator loose

18.

Loose pole pieces or pole-face shoes

19.

Loose or worn bearings

20.

Unequal air gaps

21.

Unequal pole spacing

22.

Dynamic unbalance

23.

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Table 2. Primary Sources of Unsatisfactory Brush Performance 24.

Commutator too small Electrical Fault in Machine

25.

Open or high resistance connection at commutator

26.

Poor connection at shunt terminal

27.

Short circuit in field or armature winding

28.

Ground in field or armature winding

29.

Reversed polarity on main pole or interpole Machine Design

30.

Commutating zone too narrow

31.

Commutating zone too wide

32.

Brushes too thin

33.

Brushes too thick

34.

Magnetic saturation of interpoles

35.

High bar-to-bar voltage

36.

High ratio of brush contact to commutator surface area

37.

Insufficient cross connection of armature coils Load or Service Condition

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38.

Overload

39.

Rapid change of load

40.

Reversing operation of non-interpole machine

41.

Plugging

42.

Dynamic braking

43.

Low average current density in brushes

44.

Contaminated atmosphere

45.

“Contact poisons”

46.

Oil on commutator or oil mist in air

47.

Abrasive dust in air Master Service Manual

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Table 2. Primary Sources of Unsatisfactory Brush Performance 48.

Humidity too high

49.

Humidity too low

50.

Silicone contamination Disturbing External Condition

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51.

Loose or unstable foundation

52.

External source of vibration

53.

External short circuit or very heavy load surge

54.

“Commutation factor” too high

55.

“Commutation factor” too low

56.

Contact drop of brushes too high

57.

Contact drop of brushes too low

58.

Coefficient of friction too high

59.

Lack of film forming properties in brush

60.

Lack of polishing action in brush

61.

Brushes too abrasive

62.

Lack of carrying capacity

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S1.1

1750 Pump Motor

Version no

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Pump Motor 1. Mounting Points Pump Motor

1.1. Removal WARNING Block all wheels to prevent truck from rolling. 1. Park truck on a level surface and make sure load wheels are blocked to prevent accidental movement. 2. Disconnect battery connector from the truck. 3. Disconnect all connections to pump/motor assembly. Disconnect hydraulic hose. 4. Remove battery from truck. 5. Remove pump motor mounting screws from battery box compartment. 6. Remove pump/motor assembly from truck.

1.2. Installation WARNING Compressed air used for cleaning MUST be reduced to less than 30 psi (206 kPa), and then only with effective chip-guarding and personal protective equipment. 1. Thoroughly clean all parts. Air dry all parts. 2. Install pump/motor assembly on truck. 3. Install screws to battery box compartment. 4. Install battery on truck. 5. Reconnect hydraulic hose. Connect connections to pump/motor assembly.

all

6. Remove block. Connect battery connector to truck. Test operation of truck.

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1750

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2. Pump Repair 2

1 3

Item No.

Return

Description

Item No.

Description

Pump motor assembly

Bearing

Holder, brush

Armature

Brush and spring

Bolt

Stator

End head, commutator

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S1.1

1750 Pump Motor

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2.1. Disassembly 1. Remove pump motor from truck (see page 97). 2. Remove commutator end cover. 3. 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. 4. Scribe or center punch locating marks in the end head and frame. Although locating marks are not always necessary, they can save time when the motor does not have locating pins. 5. Remove commutator end head retaining screws. Most motors have a slip fit bearing at the commutator end, and the end head can be removed with very little trouble. On motors that have a shaft extension on both ends of the armature, the attachment on the commutator end of the shaft must be removed before the end head can be separated from the motor. 6. Remove the drive end head retaining screws if necessary. Some smaller pump motors retain the drive end head with the motor through bolts. Separate the armature (3) and commutator end (5) as an assembly from the frame and field coil assembly. CAUTION Use caution, and DO NOT damage the armature during removal. If the shaft, coupling, or spline is damaged when removing the end head, the armature or the drive spline has to be replaced. 7. Separate the armature (3) from commutator end (5). This operation is usually done by pressing the armature out of the commutator end bearing. On some of the larger motors, the end head and bearing will have to be removed with a puller. When a puller is used, protect the end of the armature shaft with a nut or a thick flat washer.

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1750

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8. Separate the bearing from the end head. On larger motors, the bearing is retained with a snap ring. Remove the snap ring and press the bearing out of the end head.

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

3.1. 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.

3.2. 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.

3.3. Bearings 1. Check bearings by turning them with your fingers. Feel for binding or gritty effects and excessive looseness or wobble. A good bearing should also have a small amount of drag or stiffness caused by the lubrication but should turn smoothly. If the bearing turns very freely, it should be replaced. Bearings should also be changed, if worn out, damaged or removed from armature shaft. 2. Ball bearings that have been pulled off a shaft, pressed out of end head, 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

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1750 Pump Motor

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brinelled and will fail within a relatively short period of service.

4. Brush Inspection When the performance of the motor changes, it must be immediately inspected. One of the most common reasons for trouble is from some form of malfunction in the area of the brushes, resulting in arcing. Brushes can be worn out or stuck in their brush holders. In either case an insufficient electrical contact between brushes and commutator can lead to damage of the commutator surface.

4.1. Brush Replacement Determination Pump motor manufacture guarantees the motors for at least 50,000 cycles (S3 duty cycle at nominal power). More than 200,000 cycles may be experienced at the same ratings. Service is recommended after 50,000 cycles. At this time all brushes should be replaced if the following appear: 1. Any brush can not move freely in its brush holder. To establish this the brush carrier must be removed from the brush rigging. The force of the brush spring should push the brush as far out of the carrier as it is allowed by the cable. 2. Any brush is at the end of it useful length. The length of the brushes should never fall below 0.28 inch (7 mm) (length of new brush is 0.699 inch (17 mm). An alternative method to measure the length of the brush is to measure the difference between the cable wire and the end of the slot in the brush holder. This should be at least 0.039 inch (1 mm). If this measurement is slightly greater than this dimension, it is recommended that the brushes be replaced because the remaining life of the used brush may be less than the time to the next inspection.

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PT S1.1 Pump Motor

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4.2. Replacement Procedures Replace brushes as an assembly, which include the brush, brush holder and spring.

SCREW TERMINAL NUTS REAR BRACKET

1. Stand motor on the drive end. 2. Release terminal nuts. 3. Remove rear bracket. Terminals should stay in position. If terminals remain located in the rear casting, a gentle blow will release them. 4. Disconnect all four brushes by loosening screws. Push each brush assembly towards the commutator. Remove it from the brush rigging. 5. Replace old brush assembly with new. To avoid confusion, it is recommended that each brush be changed in order. Make sure each brush assembly is replaced with the correct part that has the brush cable on the same side. Service kits consists of two matching pairs of brush assemblies.

BRUSH SCREWS

BRUSH RIDGING SPRING BRUSH HOLDER BRUSH

COMMUTATOR

Internal view of brush rigging

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6. Retighten screw with a torque of 5.9 ft-lb (8 N•m). 7. Insert through bolts and remount motor. Tighten bolts to a torque of 5.9 ft-lb (8 N•m). 8. Retorque terminal nuts to 10.33 ft-lb (14 N•m). 9. Install pump motor on truck (see page 97)

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Drive Motor 1. Mounting Points 1

2 6

45 8

25 26

24 23 22 21 20

19 16 17

Drive Tire Item No.

Description

Item No.

Description

Item No.

Description

Screw, socket

Brake assembly

Cam

Cover, brake

Screw, socket

Screw, hex locking

Spring, brake

Motor, drive

Bearing

Rod, brake

Transmission assembly

Bolt, special

Nut, jam

Screw, socket

Retainer

Yoke assembly

Screw, cap

Arm, brake

Anchor, brake spring

Clamp

Washer, flat

Key

Bracket, brake switch

O ring

Nut, flanged

Bushing

Drum, brake

Pin, roll

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1760

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1.1. Drive Motor Brush WARNING Block all wheels to prevent truck from rolling. 1. Park truck on a level surface and make sure load wheels are blocked to prevent accidental movement. 2. Turn key switch OFF and disconnect battery connector from the truck. 3. Drive motor brushes are accessible by removing brake cover (2) and turning steering control handle. 4. Remove shields around motor end cover to expose brushes. 5. Remove screws holding brush lead. 6. Lift spring off brush. Remove brush from holder.

1.2. Drive Motor Removal WARNING There is no brake on the truck when drive motor is removed from transmission assembly. Block all wheels to prevent truck from rolling. 1. Park truck on a level surface and make sure load wheels are blocked to prevent accidental movement. 2. Turn key switch OFF and disconnect battery connector from truck. 3. Remove brake cover (2) located over drive tire. 4. Remove brake spring (3). Disconnect brake linkage at clevis and remove yoke assembly (6). 5. Disconnect brake interlock switch and remove mounting bracket from transmission case.

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WARNING When removing all four socket screws (12), the drive motor will be loose and can fall injuring personnel or damaging other equipment. 6. Disconnect power cables from drive motor, noting their proper position. Remove four drive motor mounting socket screws (12). 7. Remove drive motor (13) from transmission assembly (14). Place drive motor assembly (13) on a bench to continue disassembly. 8. At drive end armature shaft, remove locknut and pinion gear from drive motor (13). 9. At commutator end armature shaft, remove locknut and brake drum (10) from drive motor (13). 10. The brake assembly (11) can be removed without disassembling. Remove brake assembly (11) by lifting one brake shoe at a time just high enough to remove mounting screws (15). 11. Remove and discard old O ring between drive motor (13) and transmission assembly (14). 12. To repair drive motor see page 112.

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1.3. Drive Motor Installation The drive motor can be installed transmission gear case cover.

without removing

WARNING Compressed air used for cleaning MUST be reduced to less than 30 psi (206 kPa), and then only with effective chip-guarding and personal protective equipment. 1. Thoroughly clean all parts. Air dry all parts. 2. Install brake assembly (11) by lifting one brake shoe at a time and installing mounting screws (15). 3. Install brake drum (10) on drive motor armature shaft over the key. 4. Install pinion gear on drive motor over the key and tighten locknut. Place wrench on nuts (9) and tighten to 35 ft-lb (47 N•m). NOTE!

Always make sure that O ring has been lubricated with petroleum jelly before installation.

5. Coat new O ring (28) with petroleum jelly (such as Vaseline) before installation. 6. Slide drive motor (13) in transmission assembly (14) and work it around until motor lines up with intermediate gear. 7. Install four motor mounting bolts (12) and torque screws to 35 ft-lb (47 N•m). 8. Connect power cables to their proper terminals. 9. Install brake interlock switch and connect wires. NOTE!

Wire number 6 connects to the common terminal and switch and wire number 7 connects to the normally open terminal.

10. Reinstall drive tire. Torque drive axle nut to 250 ftlb (350 N•m).

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11. Connect brake linkage (4), (5), and (6) and stretch spring brake (3) across mount. 12. Adjust brake linkage (4), (5), and (6) for proper adjustment. (See “Brake Adjustment” on page 133.) 13. Install brake cover (2) on transmission case over drive tire and secure with screws (1). 14. Remove blocks. Connect battery connector to truck. Test operation of truck.

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2. Component Repair 1

E” Drive Motor 3

6 5

12 14

Item No.

110

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Description

Item No.

Description

Drive motor assembly

Spring, brush

Seal

Brush box assembly

End head, drive

Brush assembly

Bearing

Ring, retainer

Washer, wave

Armature

End head, commutator

Kit, field coil

Cover plate assembly

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“EE” Drive Motor 3 6

4 5

13 15

9 8

Item No.

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Description

Item No.

Description

Drive motor assembly

Spring, brush

Seal

Brush box assembly

End head, drive

Brush assembly

Bearing

Ring, retainer

Washer, wave

Armature

End head, commutator

Kit, field coil

Headband, commutator end

Headband, drive end

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2.1. Motor Disassembly 1. Remove drive motor from truck (see page 106). 2. Remove head band from commutator end of motor, if equipped. 3. Use a brush hook to reach into the motor and lift the brush springs. Pull the brush assembly out of the brush holders. Either position brush assembly outside the motor or remove brush from the motor. 4. Scribe or center punch locating marks in the end head and frame. Although locating marks are not always necessary, they can save time when the motor does not have locating pins. 5. Remove commutator end head retaining screws. Most motors have a slip fit bearing at the commutator end, and end head can be easily removed. 6. Remove drive end head retaining screws if necessary. Separate armature and drive end head as an assembly from the frame and field oil assembly. CAUTION Use caution and DO NOT damage armature during removal. If shaft, coupling, or spline is damaged when removing the drive end head, the armature or the drive spline must be replaced. 7. Separate armature from the drive end head, by pressing the armature out of the drive end bearing. Remove bearing with a puller, protecting the end of the armature shaft with a nut or a thick flat washer. 8. Separate bearing from drive end head. Press the bearing out of the end head. Remove retaining ring from bearing. 9. After the motor has been separated into all its major subassemblies, the components should be cleaned and inspected for wear or damage.

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3. Motor Inspection A good planned maintenance program will save many hours of future “down time” on a truck. Maintenance schedule should consist of periodic routine inspections of motors, battery and wiring circuitry.

3.1. External Motor Routine motor inspection should include the following: 1. Check for clean, tight terminal studs and mounting bolts. 2. Cooling holes must be kept free of any debris or restriction, which would prevent proper airflow and hamper cooling. 3. Internal and external spline drives must be periodically lubricated in accordance with the original manufacturer’s recommendation. 4. Check for any sign of oil leaks. 5. Make visual inspection of brush and commutation area. Headband, if equipped, should be removed for clear, proper viewing.

3.2. Brush and Commutator An important part of any planned maintenance schedule is the brush and commutator inspection. By recognizing undesirable commutator and/or brush conditions, corrective action can be taken before a major component is damaged beyond serviceability. Brush and commutator inspection can usually be accomplished by removing the cover band (if equipped) from the commutator end of the motor. The brushes and commutator should be inspected for even wear and good commutation. Good commutation will be indicated by a dark brownish, polished commutator and an evenly polished brush wearing surface. If the commutator appears rough, pitted, scored or has signs of burning or heavy arcing between the commutator bars, the motor should be removed for servicing.

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For a detailed inspection of the commutator, the motor should be disassembled. With the armature supported on both bearing journals, check run-out of commutator with a dial gauge. Total indicated run-out should not exceed 0.003 inch (0.0762 mm) or 0.001 inch (0.0254 mm) bar to bar. If the readings fall outside this limit, commutator must be turned and reundercut. After the commutator has been undercut, the armature should be placed in a lathe and the commutator lightly sanded with No. 00 sandpaper. This will remove any burrs left from the undercutting operation. Clean commutator with dry compressed air and recheck commutator run-out. mica

segments

GOOD UNDERCUT 0.04 inch deep mica segments mica segments

BAD UNDERCUT Brushes should be inspected for uneven wear and signs of overheating such as discolored brush shunts and brush springs. See “Table 1. Unsatisfactory Brush Performance” on page 91. Check the brush holders for physical damage and make sure they are not loose on the end head or the brush holder plate. Check the brush springs for correct alignment on the brush. A brush spring that does not apply equal pressure on the center of the brush will cause the brush to wear unevenly. Check for correct clearance and freedom of brush movement in the holder. If any of the brushes are worn to the point that replacement is necessary, the complete brush set should be replaced. Do not replace just one or two brushes. When brush service is required on the motor, lift brush spring over holding bracket before removing brush.

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Put Spring In This Position For Brush Removal

Do not substitute brushes. The brushes are matched to the motor type and application to provide the best service. Substituting brushes of the wrong grade can cause commutator damage or excessive brush wear. WARNING Compressed air used for cleaning MUST be reduced to less than 30 psi (206 kPa) and then only with effective chip-guarding and personal protective equipment worn. NOTE!

Blow stone dust out with dry compressed air.

After the installation of new brushes, the motor should be bench tested at 12 Volts, no load and brushes seated to the commutator with a dressing stone. Remove stone dust. Minimum commutator diameter before armature needs to be replaced is specified on the original manufacturer’s test specification.

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3.3. Bearings After the motor has been disassembled, it is recommended that new bearings be installed. Bearings may have been damaged during removal. Although the bearings may appear and feel good, the bearing races could be brinelled and fail within a relatively short period of service.

3.4. Armature Electrical Check Before the armature is reassembled into the motor, the following test should be performed. 1. Check armature for grounded circuits by placing one test lead of a Dielectric Breakdown Tester on the commutator and the other lead at the armature shaft. If the test light comes on, the armature is grounded. 2. For short circuit connection, one armature is tested on a growler using a hacksaw plate to locate any shorted windings. 3. All motor armatures are wave wound and can be short circuit tested. For helpful maintenance guides for proper servicing of motors, see page 68.

3.5. Frame and Field Service Recommendation Motors disassembled for servicing should also include a complete inspection of the frame and field assembly. It is not uncommon that the frame and field of a motor becomes exceptionally dirty after many hours of operation. This may result in a grounding condition due to dirt, grease and other foreign materials. In this case it is recommended to clean the complete frame and field in a cleaning solution. After cleaning, the frame and field must be oven-cured for one hour at 300°F (148°C). Add a coat of water soluble class H type of varnish for proper insulation protection. A similar air-dry varnish may also be used providing it has a Class H thermal specification.

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If new field coils are installed the cross-over connection should be brazed for a good sound connection and to prevent breakage due to vibration. It is not recommended that connections be soldered. Motor terminals should be torqued to 140 inch-lbs (15.82 N•m). Pole piece screws should be torqued to 250-300 inch-lbs (28-33 N•m). NOTE!

Do not use a torch for the crossover connection. The insulation of the field coils will be easily damaged by this method.

A high capacity resistance power unit with a plier-type handpiece may be used for brazing field connections.

3.6. Assembly/Testing Refer to the following drawing whenever a bearing is installed into an end head or shaft. Press Ram

Pipe Same Size As Inner Race

Bearings Inner Race

End Head Armature Shaft

Snap Ring

1. Press against the race that is absorbing the pressure. 2. Use a new bearing when servicing a motor. 3. After assembly, the motor should be tested per the original motor manufacturer.

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WARNING Do not run motor NO LOAD at full motor voltage 4. In the event no dynamometer is available for testing, the motor should be tested against a NO LOAD POINT outlined on the specification. 5. Install drive motor on truck (see page 108).

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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. 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 Oil Type Oil Capacity Drive Tire Size

22:1 SAE80 1½ pints (0.709 liter) 10.5 inch x 5 inch x 6.5 inch (267 mm x 127 mm x 165 mm)

2. Troubleshooting Because of the uncomplicated nature of the 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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3. Transmission Mounting 1 2 3

4 5

6 7

Item No. 1 2 3 4

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Description

Item No.

Description

5 6 7

Ring, nilos Transmission assembly Bumper

Nut Ring, nilos Bearing Bearing

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3.1. Wrap Around Bumper A wrap around bumper is installed on the transmission as an optional protective feature. 3

5 Item No. 1 2 3 4 5

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Description Bumper Frame, carrier Frame, lift Nut Screw

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3.2. Guards Guards are installed on the transmission as a protective feature.

5 6 5 1 2

4 3

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Item No.

Description

Item No.

Description

1 2 3

Guard, wheel Guard, rubber Strip

4 5 6

Screw Screw Washer, flat

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3.3. Removal WARNING Block all wheels to prevent truck from rolling. NOTE!

An overhead lifting device capable of lifting 4000 lbs (1814 kg) is required.

1. Disconnect battery connector from truck. Remove battery from truck. Block truck with drive tire off floor approximately 1 inch (25.4 mm). 2. Remove plastic covers from truck. 3. Disconnect control wiring harness and power cables from electrical panel. 4. Remove pivot bearing retaining nut with a spanner wrench. NOTE!

A pry bar may be needed to separate the transmission from the pivot frame.

WARNING Transmission assembly may fall free from mounting. 5. Remove transmission through pivot frame.

assembly

lowering

6. Remove control wiring harness and power cable through transmission pivot mount. 7. Remove bearing cups in pivot frame.

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3.4. Installation 1. Install bearing cups in pivot frame. 2. Install larger nilos ring and bearing cone on the neck of transmission case. 3. Pull control wiring harness and power cables up through transmission pivot mount. 4. Install transmission assembly through pivot frame. Install smaller bearing cone and smaller nilos ring. 5. Install nut on transmission pivot tube. Tighten nut as far as possible with truck jacked up. 6. Pack bearings using grease zerk. NOTE!

Using a grease gun, pack the bearings with grease before installing.

7. Lube transmission pivot bearings with grease gun while slowly rotating the transmission. Only fill the space between the bearings. 8. Lower truck and finish tighten transmission nut until snug. Back nut off 1/4 turn and try steering. If steering feels free, lock nut with Loctite® 290®. If steering still feels snug, back off another 1/4 turn before applying Loctite®. 9. Install plastic covers on truck. 10.Install battery on truck. Connect battery connector to truck. Turn key switch ON and test operation of truck.

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4. Transmission Repair 1 Torque nut to 250 ft/lb (338 N•m) while turning wheel. 2 3 16 4 8 5

11 12

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

14 13

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10 2

Item No.

Description

Item No.

Description

1 2 3 4 5 6 7 8 9

Transmission assembly Screw, socket head Case, gear Pin, dowel Key Gear, pinion Nut, flange Cover, gear Plug, fill/level pipe

10 11 12 13 14 15 16 17

Washer, sealing Bearing Idler gear set Bearing Ring, spacer Seal Nut, axle Drive axle & intermediate gear

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4.1. Disassembly 1. Remove drain plug (9) and drain gear case lubricant. Thoroughly clean outside with a noncorrosive cleaning fluid. Air dry all parts and proceed with disassembly of transmission as follows. 2. Remove transmission from truck (see page 123). 3. Pry off gear case cover (8).

4. Block transmission with gear case side down. Allow room for gears to drop between blocks (not shown).

5. Press drive axle through seal/spacer and bearing. Drive axle and intermediate gear (17) will come out together, noting that idler gear set (12) may also drop out. 6. Remove old bearings and races from gears and case. Clean transmission case.

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4.2. Reassembly 1. Heat bearing cone on bearing heater to facilitate installation. 2. Install new bearings (13) on intermediate gear. 3. Install new inner bearing cone on drive axle. NOTE!

Bearing cups are slip fit in the transmission case.

4. Position transmission on work bench with gear case side up. 5. Install larger bearing cup in transmission case. 6. Place drive axle and intermediate gear (17) in case as a unit with gears meshed. Because of gear size and bearing interference, these pieces cannot be installed separately. 7. Reposition transmission case so that it rests on gear case cove side. 8. Install outer drive axle bearing cup cone and spacer ring. a. Place bearing cone over shaft. Use a standard M24 nut and bearing installation tool (see page 128) to push bearing on drive axle. At this time, the bearing will not seat on the shoulder of drive axle. Remove nut and pusher. b. Install drive axle seal (15) in transmission case. c. Install ring on drive axle. Use bearing installation tool and nut to press ring on shaft. This should also press bearing down to seat on shoulder. NOTE!

Failure to use a new nut could result in damage to the wheel and/or transmission.

9. Turn axle shaft while torquing nut to 250 ft-lb (350 N•m). Control the drive axle turning by holding brake lever on drive motor.

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10.Use Loctite® 515-74® “gasket eliminator” on mating surface, and install gear case side covers. Be sure that two dowel pins are in the case to position cover. Tap cover into position. Torque cover bolts to 35 ft-lb (47 N•m).

0.12” (3 mm) x 30°

7.25” (184 mm) 5.88” (149 mm) 5.75” (146 mm) 3.00” (76 mm) 1.636” (41mm)

1.50” (38 mm)

1.88” (47 mm) ± 0.01”

1.606” 1.384” (35 mm) (40mm)

2.25” (57 mm)

Bearing Installation Tool

128

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5. Axle Seal The drive axle seal (15) can be replaced without removing the gear case cover. Before starting disassembly of any parts, thoroughly clean outside of assembly with a non-corrosive cleaning fluid. Air dry all parts.

5.1. Removal 1. Drain transmission oil. WARNING Block all wheels to prevent truck from rolling. 2. Disconnect battery connector from truck. Block truck with drive tire off floor about 1 inch (25.4 mm). 3. Remove drive axle nut (16) from drive tire. Remove drive tire. 4. Remove drive axle seal (15) with seal puller or pry out with pry bar. Take care not to damage sealing surface or mounting bore.

5.2. Installation 1. Visually inspect threads on shaft for damage. Replace drive axle (17) if threads are damaged. 2. Install new oil seal (15). NOTE!

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

3. Turn drive axle shaft while torquing nut to 250 ft-lb (350 N•m). Control the drive axle turning by holding brake lever on drive motor.

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4. Lower truck off blocks. 5. Refill transmission case with new oil (see page 72).

Fill with oil to this level

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C-code

S3.0 3300 Parking Brake System

Version no

T-code

000

390

Parking Brake System 1

2 6

45 8

25 26

24 23 22 21 19

16 17

Item No.

Description

Item No.

Description

Item No.

Description

Screw, socket

Brake assembly

Cam

Cover, brake

Screw, socket

Screw, hex locking

Spring, brake

Motor, drive

Bearing

Rod, brake

Transmission

Bolt, special

Nut, jam

Screw, socket

Retainer

Yoke assembly

Screw, cap

Arm, brake

Anchor, brake spring

Clamp

Washer, flat

Key

Bracket, brake switch

O ring

Nut, flanged

Bushing

Drum, brake

Pin, roll

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PT S3.0 3300 Parking Brake System Version no

T-code

000

390

1. Brake Theory of Operation The brake is of a spring-applied and mechanically-released design. The brake has a drum that is mounted on the drive motor armature shaft. 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 a spring on a cam arm. The cam forces the brake shoes against brake drum. This action clamps the brake shoes against the drum and provides braking any time the handle is in the static position (fully raised or lowered). When the brake is released, the cam arm forces the cam to rotate to the neutral position. Springs on the brake shoes pull the brake shoes away from brake drum. This releases the brake and allows the drum to turn with the drive motor armature shaft.

132

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2002-02-13

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Section

C-code

S3.0 3300 Parking Brake System

Version no

T-code

000

390

2. Brake Adjustment WARNING Block all wheels to prevent truck from rolling. 1. Disconnect battery connector from truck. Block drive wheel off floor. 2. Remove brake cover above drive tire. 3. Fully raise control handle. Remove brake spring, allowing the brakes to release. Remove clevis pin from yoke assembly. 4. Lower the control handle to the operating position so brake linkage is on top of operating cam. 5. Adjust clevis so pin goes in the brake cam arm. Install pin. 6. Install spring and test braking ability. Truck at full speed with rated load must stop in its own length. If brakes are inadequate, then shorten the linkage on clevis to get adequate braking. 7. Install brake cover above drive tire. 8. The brake drum may be removed and the operating cam arm moved one “spline tooth” to compensate for brake shoe wear.

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133

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Section

C-code

PT S3.0 3300 Parking Brake System Version no

T-code

000

390

3. Brake Shoe Removal / Installation WARNING Block all wheels to prevent truck from rolling. 1. Disconnect battery connector from truck. Block truck with drive tire about 1 inch (25.4 mm) off floor. 2. Remove brake cover above drive tire. 3. Disconnect main spring of brake. 4. Move steering control handle to “BRAKE RELEASED” position, and disconnect clevis from brake cam arm. 60°

5. Loosen nut (9) and remove brake drum (10). 6. Lift to center one shoe at a time to remove mounting bolts. 7. During assembly, the brake lever should be checked to see it is set at 60 degrees and brake drum nut (9) is torqued to 35 ft-lb (47 N•m). WARNING Before adjustments are made disconnect battery from the truck to prevent accidental operation. 8. Adjust brake linkage and brake interlock switch (See “Brake Adjustment” on page 133). 9. Install brake cover above drive tire.

Item No.

3 4

Description

Cam

Plate

Lever

Clip

Spring

Shoe

Brake Drum/Disc Assembly 134

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2002-02-13

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Section

C-code

S3.1

3530 Drive Wheel

Version no

T-code

000

390

Drive Wheel 1. Removal WARNING Block all wheels to prevent truck from rolling. The drive wheel can be removed, without removing the transmission by the following steps: 4

1. Park truck on level surface and block truck from moving. 2. Turn key switch to OFF. Disconnect battery connector from truck. 3. Hoist machine and securely block truck with drive tire about 1 inch (25.4 mm) off floor. NOTE!

If hub is rusted to axle, two bolts threaded in the holes on the hub can be used to push the hub from the axle.

4. Remove axle hub and wheel drive retaining nut (4). Pull tire and wheel from axle. 5. Press drive tire (2) from drive wheel (3).

Item No.

1 3

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Description

Wheel assembly

Tire

Wheel, drive

Nut

Transmission assembly

2002-02-13

135

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Section

C-code

PT S3.1 Drive Wheel

3530

Version no

T-code

000

390

2. Installation NOTE!

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

1. Press drive tire (2) onto drive wheel (3). This is usually done while pressing off old tire. Press hub to center of tire. 2. Install drive tire and hub on axle. Secure with new wheel drive retaining nut (4). Torque nut to 250 ft-lb (350 N•m).

136

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Section

C-code

S3.1

3530 Drive Wheel

Version no

T-code

000

390

3. Tire Pressing Procedure 1. Check the inside surface of metal insert on new tire. Remove any scaling or rust with sandpaper. Clean the inside of metal insert and lubricate with a soapy solution. Outside of Hub and Tire Assembly New Tire Worn Tire

Circular Ram Press Table

2. Place a circular ram on a press table. The length of ram must be longer than the width of old tire to allow complete removal of the old tire. The outside diameter of ram must be small enough to fit loosely in the insert of tire, but large enough to rest squarely on the flat surface on the outer edge of the hub. 3. If the outside edge of hub is not flush with the edge of the metal insert in old tire, measure how far hub is recessed inside the tire. The new tire must be placed in the same position the old tire was installed on the hub. Use a spacer (slightly smaller in diameter than the inside diameter of tire insert and the same thickness as the depth of the recess) to obtain proper amount of recession. 4. Position hub assembly with old tire on top of circular ram so the outside of the wheel is positioned upward. The outside edge of hub has a chamfer to help guide the new tire onto the wheel. The chamfered edge must always be the leading edge when a tire is pressed onto hub. 5. Center hub assembly on top of ram and make sure they mate squarely. 6. Position new tire with its chamfered insert facing hub. Align new tire and hub so they are concentric.

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137

F-code

Section

C-code

PT S3.1 Drive Wheel

3530

Version no

T-code

000

390

CAUTION Any misalignment of tire and hub while tire is being pressed onto hub can cause damage to hub. For this reason, chamfers have been provided on the outside edge of hub and on the end of the inside diameter of tire’s metal insert. The chamfers help to center the hub and tire during the pressing operation and reduce the possibility of misalignment. To prevent damage, the hub must be installed on circular ram with its chamfered side up. NOTE!

If new tire does not press on with a minimum of 5 tons (4535 kg) force, replace hub.

7. Begin pressing new tire onto hub and old tire off hub. Run press slowly for the first few inches of travel, because this is the critical stage of the operation. If tire begins to cock to one side, stop press and realign tire. A sharp jar with a softheaded mallet will usually realign tire on hub. 8. Release the press. Remove wheel, tire assembly, and old tire from the press table. Inspect wheel and tire assembly. 9. Install wheel assembly following the procedure for the specific type of wheel.

138

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F-code

Section

C-code

PT S3.2 3540 Support/Swivel Wheel (Optional) Version no

T-code

000

390

Support/Swivel Wheel (Optional)

21 20

2 3 4 5 7

11 12 14

8 6

9 10

19 17

14 18

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139

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Section

C-code

PT S3.2 3540 Support/Swivel Wheel (Optional) Version no

T-code

000

390

Item No.

140

Return

Description

Item No.

Description

Frame, lift

Lockwasher

Screw, set

Guard

Nut

Bearing, ball

Spring

Bumper

Bushing

Screw, socket head

Caster assembly

Wheel, caster

Screw, cap

Tube

Bushing

Screw, cap

Cap

Screw, socket head

Fork, caster wheel

Fitting, grease

Nut

Frame

Master Service Manual

2002-02-13

F-code

Section

C-code

PT S3.2 3540 Support/Swivel Wheel (Optional) Version no

T-code

000

390

1. Maintenance and Adjustments Normal maintenance of the truck frame consists of lubricating the casters periodically (see “Planned Maintenance Schedule” on page 59). If optional lube or cold storage package has not been fitted on the truck during production, lubricate by dripping 10 weight machine oil onto pivot points to soak into bushings. In a wet or corrosive environment it is necessary to reduce time between planned maintenance intervals.

1.1. Caster Adjustment 1. Loosen nut (3) and set screws (2). New free length is 6.45 inch (164 mm)

2. Tighten cap screw (7) until they contact the cap (9), then tighten to get spring compression.

2. Troubleshooting Worn free length is 6.00 inch (152 mm) or less

Very little troubleshooting is necessary on frame assembly. Most faults can be found by visual inspection. These usually are evidenced by hard steering or loss of traction.

2.1. Stabilizing Caster 2.1.1. Caster Replacement WARNING Risk of injury. Spring pressure is under spring base when unbolted spring base may fly free and cause an injury or possibly death. Release spring tension before removing spring base mounting bolts. CAUTION Spring tension does still exist. NOTE!

Replace caster wheel when caster spring can no longer be adjusted.

1. Release spring tension before removing spring base mounting bolts.

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141

F-code

Section

C-code

PT S3.2 3540 Support/Swivel Wheel (Optional) Version no

T-code

000

390

2. Remove two cap screws (19) mounting caster base plate to guard (13). 3. Replace caster assembly as needed, and adjust spring tension.

142

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F-code

Section

C-code

S3.3

3550 Fork Wheels

Version no

T-code

000

390

Fork Wheels 1

Item No. 1

Description Bearing

Item No. 2

Description Wheel, load

1. Removal/Installation WARNING Block all wheels to prevent truck from rolling. 1. Park truck on level surface and apply brake. 2. Hoist truck so load wheels are approximately two inches (50 mm) off the floor and securely block. 3. Remove set screw from the under side of fork. 4. Remove axle and load wheel assembly from fork. 5. Inspect bearings. 6. Install new load wheel (2) and bearing (1) as needed. 7. Install load wheel assembly in fork. Install axle and set screw. © BT Prime-Mover, Products Inc.

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143

F-code

Section

C-code

PT S3.3 Fork Wheels

3550

Version no

T-code

000

390

144

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2002-02-13

F-code

Section

C-code

S4.0

4100 Steering

Version no

T-code

000

390

Steering

17 16

1 2 5 15 14 12

13 11

1 9 8 7

Figure 1. Control Head Assembly Item No. 1 2 3 4 5 6 7 8 9

Return

Description Screw, flat head Bracket, switch Nut Clamp, cable Cover Pin, roll Screw, shoulder Guard Screw, flat head locking

Master Service Manual

Item No. 10 11 12 13 14 15 16 17 18

2002-02-13

Description Block Screw, socket Bushing Grip, twist Pin Housing, switch Screw, flat head Washer Grip, fixed

145

F-code

Section

C-code

PT Steering

S4.0

4100

Version no

T-code

000

390

1. Control Handle Head 1.1. Removal WARNING Block all wheels to prevent truck from rolling. 1. Park truck on a level surface. 2. Release pressure in the hydraulic system by pressing the lowering button on the steering control handle. 3. Turn key switch to OFF. Disconnect battery connector from truck. 4. Remove six flat head screws (1, figure 1) from outer edge of the switch cover (5). NOTE!

Do not remove center screw (1) and nut (3).

5. Lift switch cover (5) off and move to one side. 6. Remove two socket head screws (11) from inside head that bolts the head and handle together. 7. Remove harness clamp at the base of the handle stem to gain access to disconnect harness. 8. Lift entire head assembly away from the 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 (11) inside head assembly and secure head assembly to handle stem. 3. Move switch cover (5) plate assembly back in place and secure with screws (1). 4. Connect battery connector to truck. Turn key switch to ON. Test operation of control handle functions. 146

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F-code

Section

C-code

S4.0

4100 Steering

Version no

T-code

000

390

2. Driver Protection (Reverser) Assembly Replacement The driver protection (reverser) assembly is mounted on top of the head assembly. WARNING Block all wheels to prevent truck from rolling. 1. Park truck on a level surface and make sure parking brake is applied. 2. Disconnect battery connector from truck. 3. Lift switch cover (5, figure 1) assembly plate off assembly and lay to one side. 4. Remove screws (2, figure 2) holding reverser assembly (1) to head assembly. 5. Remove reverser assembly (1) and replace with new assembly. Secure with screws (2) 6. Connect battery connector to truck. Test operation of control handle functions.

Figure 2. Driver Protection (Reverser) Assembly Item No. 1 2

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Description Reverser assembly Screw

2002-02-13

147

F-code

Section

C-code

PT Steering

S4.0

4100

Version no

T-code

000

390

8 4

9 12

Figure 3. Direction Control Switches Item No. 1 2 3 4 5 6

148

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Description Spring, return Switch, lift Switch, lower Kit, switch Screw, machine Switch, rearward

Master Service Manual

Item No. 7 8 9 10 11 12

Description Spacer Switch, forward Bracket Lockwasher Nut Screw

2002-02-13

F-code

Section

C-code

S4.0

4100 Steering

Version no

T-code

000

390

3. Direction Control Switches 3.1. Removal The direction control switches are mounted in the control handle head. It is not necessary to remove the head to change switches. WARNING Block all wheels to prevent truck from rolling. 1. Park truck on a level surface, make sure parking brake is applied, and wheels are blocked to prevent accidental movement. 2. Release pressure in the hydraulic system by pressing the lowering button on steering control handle. 3. Turn key switch to OFF. Disconnect battery connector from truck. NOTE!

Do not remove center screw (1) and nut (3).

4. Remove screws (1, figure 1) from outer edge of switch cover (5). 5. Lift switch cover (5) assembly plate off assembly and lay to one side. 6. Remove screws (12, figure 3) holding forward/ rearward switch bracket (9) to housing. 7. Remove control handle head (see page 146). 8. Remove switch wires from wire harness plug and remove bracket (9) with switches (6) and (8).

3.2. Installation 1. Reconnect switch wires and reinstall bracket (9) in housing. 2. Install control handle head (see page 146).

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149

F-code

Section

C-code

PT Steering

S4.0

4100

Version no

T-code

000

390

3. Test switch operation and adjust bracket (9) before installing switch cover (5, figure 1) assembly plate. 4. Move switch cover (5) plate assembly back in place and secure with screws (1). 5. Connect battery connector to truck. Turn key switch to ON. Test operation of control handle functions.

Figure 4. Horn

150

Return

Item No.

Description

1 2 3 4 5

Switch, horn Spring, return Screw, socket head Horn Spacer (Cold storage)

Master Service Manual

2002-02-13

F-code

Section

C-code

S4.0

4100 Steering

Version no

T-code

000

390

4. Raise, Lower, and Horn Switches 4.1. Removal Raise, lower, and horn switches are mounted in the switch cover plate on the control handle head. The switches in the control handle are molded in the switch bar so the switch bar and switch will be replaced together as a single part. It will be necessary to remove the head to change switches. WARNING Block all wheels to prevent truck from rolling. 1. Park truck on a level surface, make sure parking brake is applied, and wheels are blocked to prevent accidental movement. 2. Release pressure in hydraulic system by pressing the lowering button on steering control handle. 3. Turn key switch to OFF. Disconnect battery connector from truck. NOTE!

Do not remove center screw (1) and nut (3).

4. Remove screws (1, figure 1) from outer edge of switch cover (5) assembly plate. 5. Lift switch cover (5) assembly plate off assembly and lay to one side. 6. Remove center screw (1) and nut (3) securing switch bracket (2) to switch cover (5). Switch bars (2, 3, figure 3 and 1, figure 4) and springs (2) will now be free to be removed. 7. Remove control handle head (see page 146). NOTE!

Mark wire terminal positions when removed to make installation easier.

8. 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. © BT Prime-Mover, Products Inc.

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151

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Section

C-code

PT Steering

S4.0

4100

Version no

T-code

000

390

4.2. Installation 1. Install switch bars (2, 3, figure 3 and 1, figure 4) in switch cover (5, figure 1), making sure switch bars are placed in their proper location. 2. Install return springs (1, figure 3) in wells on each of the switch bars (2, 3, figure 3 and 1, figure 4). Place switch bracket (2, figure 1) on springs (2, figure 4), making sure spring aligns with dimples in switch bracket and wires from switches go though holes. Secure assembly with one screw (1, figure 1), clamp (4), and nut (3) placed in the center. 3. Test switch operation that switch bars (2, 3, figure 3 and 1, figure 4) return and do not bind before installing switch cover (5, figure 1) plate assembly on head. 4. Install new switch wire terminals in head wiring harness plug. 5. Install control handle head (see page 146). 6. Install switch cover plate assembly back in place and secure with screws (1). 7. Connect battery connector to truck. Turn key switch to ON. Test operation of control handle functions.

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F-code

Section

C-code

S4.0

4100 Steering

Version no

T-code

000

390

1 2

Figure 5. Speed Controls Item No.

Description

1 2 3

Potentiometer bracket assembly Gear Screw

5. Potentiometer 5.1. Removal The accelerator potentiometer is accessible inside the control handle head by removing the switch plate. This operates off a gear toothed shaft (rack) that is moved when travel controls are twisted. WARNING Block all wheels to prevent truck from rolling. 1. Park truck on a level surface, make sure parking brake is applied, and wheels are blocked to prevent accidental movement. © BT Prime-Mover, Products Inc.

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153

F-code

Section

C-code

PT Steering

S4.0

4100

Version no

T-code

000

390

2. Release pressure in hydraulic system by pressing the lowering button on steering control handle. 3. Turn key switch to OFF. Disconnect battery connector from truck. NOTE!

Do not remove center screw (1) and nut (3).

4. Remove screws (1, figure 1) from outer edge of switch cover (5). 5. Lift switch cover (5) assembly plate off assembly and lay to one side. NOTE!

Mark wire terminal positions when removed to make installation easier.

6. Remove control handle head (see page 146). 7. 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. 8. Remove two screws (3, figure 5) securing potentiometer bracket assembly (1) to the control head housing (15, figure 1). Remove and discard potentiometer bracket assembly (1, figure 5) and gear (2). Replace with new.

5.2. Installation 1. Install new potentiometer bracket assembly (1) and gear (2) on the control head housing (15, figure 1) and hold in place with screws (3, figure 5). Do Not tighten completely. 2. Connect ohmmeter leads to potentiometer wires. 3. While holding potentiometer assembly bracket (1, figure 5) against control head housing (15, figure 1), make sure the gear (2, figure 5) on potentiometer are engaged with the return (3, figure 6) gear teeth. In neutral the ohmmeter 154

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Section

C-code

S4.0

4100 Steering

Version no

T-code

000

390

reading should be 5500 ohms and will reduce to below 50 ohms as travel controls are rotated to high speed. By sliding potentiometer bracket assembly (1, figure 5) up or down as necessary taking measurements and make adjustments. 4. If slotted holes in potentiometer assembly bracket (1, figure 5) do not allow enough adjustment, the bracket may be lifted slightly and the potentiometer drive gear (2) can be rotated by one tooth. 5. Tighten potentiometer bracket assembly (1, figure 5) mounting screws (3) and install potentiometer wire terminals in head wiring harness plug. 6. Test operation of potentiometer gear (2) and return (3, figure 6) by moving travel controls before installing switch cover (5, figure 1) plate assembly on head. 7. Install control handle head (see page 146). 8. Install switch cover plate assembly back in place and secure with screws (1, figure 1). 9. Connect battery connector to truck. Turn key switch to ON. Test operation of control handle functions.

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155

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Section

C-code

PT Steering

S4.0

4100

Version no

T-code

000

390

1 2

4 5 1

Figure 6. Driver Controls (speed and direction) Item No.

156

Return

Description

Item No.

Description

Pin, roll

Bushing

Cam

Shaft, cam

Return

Control, thumb

Spring, return

Pin, threaded

Master Service Manual

2002-02-13

F-code

Section

C-code

S4.0

4100 Steering

Version no

T-code

000

390

9 8

10 5 6

11 13

Figure 7. Steering arm/wheel (stem)

Return

Item No.

Description

Item No.

Ring, retainer

Chain

Nut, clip

Handle, lower

Anchor, chain

Clamp

Tube, plastic

Nut, jam

Screw, cap

Spring

Sheave

Link, connector

Master Service Manual

Description

2002-02-13

Item No.

Description

157

F-code

Section

C-code

PT Steering

S4.0

4100

Version no

T-code

000

390

6. Steering Stem 6.1. Removal The control handle stem acts as the steering control for the operator. It is attached to the lower front of the drive unit allowing the wheel direction to be rotated in proportion to the left and right movement of the control handle stem. WARNING Block all wheels to prevent truck from rolling. 1. Park truck on a level surface, make sure parking brake is applied, and wheels are blocked to prevent accidental movement. 2. Turn key switch to OFF. Disconnect battery connector from truck. 3. Remove the control handle head (see page 146). 4. Remove chain from chain anchor. 5. Remove chain anchor (12, figure 7) and set aside. Place a wire through chain anchor to prevent chain from sliding into handle stem. 6. Remove bolts from brake cover. Remove roll pin from cam pivot (see page 131). 7. Carefully remove cam pivot shaft from transmission assembly. Remove control handle stem.

6.2. Installation 1. Hold new handle stem in position while carefully inserting the cam pivot shaft. Install a new roll pin in cam pivot shaft 2. Install brake cover and secure with bolts. 3. Reattach chain anchor to transmission assembly. Attach upper end of handle stem spring to its proper position. 4. Attach control handle head. 5. Connect battery connector to truck. Turn key switch to ON. Test operation of control handle functions. 158

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Section

C-code

S5.0 5000 Electrical Functions

Version no

T-code

000

390

Electrical Functions 1. General 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.

1.1. Adjustable Settings: Std. value 200A

Min. value 200A

Max. value 200A

200

300

Neutral Brake Current Limit (%)

200

Acceleration (sec.)

0.1

3.0

Maximum speed (%)

100

Setting Brake Current

limit (amp)

1.2. References For more information about adjustment of the speed potentiometer, the transistor controller, and the connection card, see “Troubleshooting Chart” on page 227. The description is divided into different phases which correspond to the operational sequence steps.

1.3. Key Switch S17 in the ON Position When S17 closes, battery voltage is supplied to A1 J1-16. 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.

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PT S5.0 Electrical Functions Version no

T-code

000

390

C-code

5000

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 the brake has been released can be cleared by cycling S10.

1.4. 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; at the same time the brake is mechanically released. Voltage is supplied to A1 J1-15.

1.5. Travel Request, Fork First When the thumb control is activated for driving in the fork first 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.

1.6. Travel Request, Forks Trailing When the thumb control is activated for driving in the forks trailing 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 J1-12. 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.

1.7. Reversing/Motor Brake Forks First Direction to Forks Trailing Direction S15 returns to open position before S16 closes.

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S5.0 5000 Electrical Functions

Version no

T-code

000

390

1.8. Reversing/Motor Brake Forks Trailing Direction to Forks First Direction S16 returns to open position before S15 closes.

1.9. Reverser switch Possible breaks in the wiring for the reverser switch is continuously checked by the transistor controller. It sends a small pulsed current through the circuit from J1-13 wire number 11A, S20, wire number 11B and J1-10. When S20 is activated J1-13 becomes positive. A1 now interrupts the inputs at J1-12, at the same time it provides a positive at J1-11. The motor will now be connected for motor braking at a maximum current limit 200 amp, and subsequently accelerate in forks first direction until S20 returns to its neutral position. When S20 returns to the neutral position, positive disappears from J1-11 and the truck will stop. In order to be able to start again if S16 is still activated, the transistor controller must be returned to the inactive position. This is accomplished by letting the speed potentiometer return to the neutral position, after which a new direction of travel can be chosen.

1.10. Lifting Forks The micro switch S34 closes. K30 receives positive voltage through wire number 5, lift limit switch, wire number 17. Negative returns through wire number 13. K30 closes and the pump motor M3 starts.

1.11. Lowering Forks When the micro switch S41 closes, the lower valve Y10 receives voltage through wire number 4. Negative returns through wire number 13. Y10 energizes and forks lower.

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PT S5.0 Electrical Functions Version no

T-code

000

390

C-code

5000

1.12. Horn When micro switch S18 is activated, the horn (H1) receives positive voltage through wire number 8. Negative returns through wire number 13.

1.13. Lift Interrupt When equipped with lift interrupt, negative return is through wire number 20, lift interrupt, wire number 13, K30 closes and the pump motor M3 starts. Battery voltage must be sufficient for the lift interrupt system to allow lift function to operate.

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S5.0 5000 Electrical Functions

Version no

T-code

000

390

Electrical Panel Components 2

Item No.

Return

Master Service Manual

Description

Harness

Suppressor, pump coil

Suppressor, lower valve coil

Fuse, 15 AMP

Suppressor, horn

2002-02-13

163

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Section

PT S5.0 Electrical Functions Version no

T-code

000

390

164

Return

C-code

5000

Master Service Manual

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S5.1 5000 Electrical Symbols

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390

Electrical Symbols

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Symbol

Description

Function

Transistor regulator

Drive motor

Transistor regulator

Pump motor

Battery

E21

Heater

Handle

E22

Heater

Handle

E23

Heater

Brake Switch

E24

Heater

Lift Limit Switch

E25

Heater

100W Comp.

E26

Heater

Lift Pump Contactor

Circuit breaker

Power circuit

80 amp

F50

Fuse

Control circuit

15 amp

Horn

K10

Contactor

Main

K30

Contactor

Pump motor

K102

Contactor

Cold storage

Motor

Drive

Motor

Pump

Indicator Option

Hourmeter

Indicator Option

Battery discharge indicator

Indicator Option

Hourmeter/battery indicator

Potentiometer

Speed

S10

Switch

Brake

Master Service Manual

Remark

24 volt

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5k - 0 Ohm

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166

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Symbol

Description

Function

Remark

S15

Switch

Load wheel direction

Forks first

S16

Switch

Steer wheel direction

Forks trailing

S17

Switch

Key

S18

Switch

Horn

S20

Switch

Reverser

S21

Switch

Main On / Off

S34

Switch

Raise

S36

Switch

Lift limit

S41

Switch

Fork lower

S60

Thermostat

Heater

V11

Suppressor

Pump coil suppressor

V12

Suppressor

Lower valve coil suppressor

V13

Suppressor

Horn suppressor

Y10

Coil

Lower valve

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S5.1 5000 Electrical Symbols

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Electrical Symbols Symbol

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Symbol

Description

Battery

Brake (coil)

Contactor

Diode

Emergency stop

Fuse

Horn

Inductive sensor (normally closed)

Inductive sensor (normally open)

Key switch

Magnet switch (normally closed)

Magnet switch (normally open)

Motor

Potentiometer

Description

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Electrical Symbols Symbol

Description

Symbol

Push button switch (normally closed)

Description Push button switch (normally open)

Resistor

Switch

Switch (normally closed)

Switch (normally open)

Valve

168

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S5.2 5000 Electrical Schematics

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Electrical Schematics

Return

First number = Previous page wire was found.

Sh. = Sheet or page of Diagram

Legend

Circuit Diagram 1(3)

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First number = Previous page wire was found.

Sh. = Sheet or page of Diagram

Legend

Circuit Diagram 2(3)

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Return

First number = Previous page wire was found.

Sh. = Sheet or page of Diagram

Legend

Circuit Diagram 3(3)

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172

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S5.3

5110 Battery

Version no

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000

390

Battery CAUTION Before working on the battery, review Battery Safety, beginning on page 17. Batteries may weigh more than 200 pounds (90 kg). Use extreme care during replacement. Use a suitable battery replacement device or hoist for lifting.

1. Removal WARNING Block all wheels to prevent truck from rolling. 1. After the truck is stopped and the control handle is returned to full up position, turn key switch to the OFF position. 2. Disconnect battery connector from truck. 3. Remove the batteries in accordance with the manufacturer’s recommendations.

2. Installation 1. With a fully charged and tested battery on the lifting device, position the lifting device at the truck according to the manufacturer’s recommendations. 2. Position the battery in the compartment. Be sure the battery has no more than 0.50 inch (13 mm) of “free play” movement in the battery compartment. 3. Move lifting device from the area. 4. Connect battery connector to truck. Turn key switch ON and test operation of truck.

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PT Battery

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3. Battery Maintenance The following information does not supercede or replace information supplied by the battery and battery charger manufacturer. Read, understand, and follow the procedures in the manual supplied with the battery and battery charger. Notify your supervisor if there are any concerns or questions regarding battery safety or procedures.

3.1. Battery Inspection and Care NOTE!

Read, understand, and follow procedures, recommendations, and specifications in the battery and battery charger manufacturer’s manuals.

Batteries in industrial trucks pick up various kinds of dirt and dust depending on their surroundings and the types of material handled. If cells are overfilled and electrolyte collects on the covers, the following occurs: 1. The top of the battery becomes wet and stays wet, since the acid in the electrolyte does not evaporate. 2. This moist surface, in combination with certain kinds of dirt, becomes electrically conductive and permits stray currents to flow externally over the top of the battery. This degrades battery performance and truck operation. 3. The acid also causes corrosion of cell posts, nuts, connectors and the steel battery case. When inspecting batteries, check the following: 1. Wet covers can indicate overfilling, leaky seals at posts, or excessive gassing during charge. If covers are wet, determine the cause and correct the problem. 2. Make sure batteries cannot move more than 0.5 inch (12 mm) in any horizontal direction. Shim or block to restrain them.

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3.2. Battery Exterior Cleaning Refer to recommended battery manufacturer’s guidelines for details.

3.3. Charging OSHA regulations require that battery charging installations be located in areas designated for that specific purpose. Such areas must provide for flushing and neutralizing spilled electrolyte, fire protection, protecting charging equipment from damage by trucks and adequate ventilation of fumes from gassing batteries. To charge a battery, direct current is passed through the battery cells in the direction opposite that of discharge. Charging time is 5% to 20% longer than discharge time.

Read, understand, and follow procedures, recommendations and specifications in the battery and battery charger manufacturer’s manuals.

CAUTION NEVER plug the battery charger into the truck. This will severely damage the truck’s electrical system. Plug the charger ONLY into the connector from the battery.

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4. Storage Before storing battery, make sure the electrolyte is at the proper level in all the cells, the filler plugs are tight, and the battery is fully charged. Store battery in a clean, cool, dry location away from radiators and other sources of heat. Check electrolyte level and specific gravity every 30 days during storage. Whenever specific gravity is less than 1.230, charge the battery.

5. Battery History Record A battery record system is essential because battery failure can cause production slowdowns and increased battery operating costs. A properly supervised record system can detect and call attention to such operating irregularities as the following: • Overcharging • Undercharging • Over-discharging • Excessive water consumption • Excessive dirt and corrosion • Worn-out batteries • Excessive current consumption of trucks Records should be kept for each battery. Your battery supplier should be able to provide maintenance record sheets. Each report should contain the following: • Battery number, type, serial number, and service data • Specific gravity and voltage readings for each cell • Temperature of the air and electrolyte • Electrolyte • Amperes • Condition of connectors, covers, sealing compound and tray • General cleanliness • Number of total cycles • Average specific gravity drop • Watering frequency • User comments and observations 176

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S5.4 5110 Swing Out Battery Pack

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Swing Out Battery Pack 3

19 7

8 9

4 10 16

12 11

18 13

14 15

Battery Specifications Exide type GC-3 6 volt 75-91 AMPS Trojan type T-90 or T-1900 6 volts 75-91 AMPS

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Item No.

178

Return

Description

Item No.

Description

Wrapper

Screw, cap

Door

Washer, flat

Screw, truss head

Lockwasher

Nut, flange

Battery

Decal, warning

Case, battery

Edging

Nut, clip

Charger, battery

Tray, battery

Cable assembly

Tray, battery

Decal instruction

Decal, warning

Screw, cap

Pin, cotter

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1. Battery Cable Routing Diagram 4 2

5 6

7 3 5

11 5

Battery Specifications Exide type GC-3 6 volt 75-91 AMPS Trojan type T-90 or T-1900 6 volts 75-91 AMPS

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Item No.

180

Return

Description

Item No.

Description

Connector assembly

Washer, flat

Tie, cable

Cable

Grommet

Cable

Boot, terminal

Battery

Nut

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2. Charger Diagram

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Timer Motor

Timer Switch

Fuse

Capacitor

Transformer

Diode

Ammeter

Circuit Breaker - 50 Amp

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3. Troubleshooting The charger incorporates a very simple and reliable design which makes troubleshooting relatively easy. The repair procedure involves testing the output of the charger and then testing individual components. The test procedures follow a logical sequence of electrical flow through the circuit. Only standard hand tools and an AC/DC volt/ohm meter are required. A battery hydrometer is recommended. WARNING Before checking charger, disconnect AC power supply, unplug batteries, and discharge capacitor with an insulated screwdriver. All tests should be made with extreme caution when a test calls for the power to be “on” at the charger.

3.1. Electrical Testing 3.1.1. Equipment required: 1. Common hand tools. 2. AC/DC volt/ohm meter. 3. Battery connector with + to - loop (use on charger only). 4. Battery hydrometer. 3.1.2. Instructions 1. Check condition of batteries (check each cell). a. Specific gravity, before and after charging. Acceptable values: Dead battery - 1.180 Fully charged battery - 1.280 Any cell that is different by more then 20 points indicates a suspect battery. b. Volts per cell, open circuit, before and after charging. Acceptable values: Dead battery - 1.9 v/cell 182

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Fully charged - 2.2 v/cell c. Charging rate DC amps, at start and finish of charge cycle. Acceptable values 24 volt system

Start 15 amps

Finish at 2.5 VPC 0.5 amps or less

d. Charging rate at battery DC volts, at start and finish. Acceptable values 24 volt system

Start

Finish

25.6 volts

30.0 volts

2. Visually inspect disconnected.

charger

with

all

power

a. Inspect AC power supply circuit breaker, wall, outlet, plug, cord. b. Inspect charger for physical damage. c. Inspect internally for loose or discolored connections and wires damaged due to overheating. d. Inspect transformer discrepancies.

coils

for

obvious

e. Inspect the charger’s internal AC power fuse. It should be 10 amp rated. NOTE!

If the AC power fuse is blown, it could indicate a shorted diode on the DC output circuit.

3. Testing the DC output circuit. NOTE!

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If the AC power fuse blows or the DC 1 x circuit breaker trips, check for reverse polarity of the battery connection.

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a. Open circuit voltage test. With the batteries disconnected and the charger turned on, the DC output voltage should be 1-1/2 times the rated DC voltage. System voltage

Short circuit output voltage

24 volts

36 volts

b. Short circuit amperage test. With the charger output battery connector short circuited (positive to negative jumper connector plugged into charger output connector), and the charger turned on, the DC output amps should be 80 percent of the normal DC amps. System voltage

Short circuit output voltage

24 volts

approximate 12 amps

(1) With the charger in the OFF position, connect AC power cord to appropriate AC power supply, connect with the + to - loop to the charger. (2) Turn on the battery charger and note the amp gauge reading. It should be as stated on the chart above. Leave the charger on for five minutes while watching the amp gauge. The amp gauge should remain steady. This verifies the condition of the circuit breaker and any loose connections. (3) Turn the charger off before disconnecting the jumper connector.

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4. Testing components WARNING Before checking components disconnect AC power supply, unplug batteries, and discharge capacitor with an insulated screwdriver. All tests should be made with the charger disconnected unless otherwise stated. Use extreme caution when a test calls for the power to be “on” at the charger. a. Diodes (1) A quick test for shorted diodes may be made by connecting the leads of the ohmmeter to the charger battery connector terminals and testing for continuity in each direction. If the test shows open, the DC circuit breaker, may be open. To bypass an open DC circuit breaker, connect the test leads to the positive and negative lugs behind the circuit breaker and reverse the ohmmeter probes. A shorted diode will show continuity in both directions. Retest the diodes individually to determine which diode is faulty. (2) Disconnect the diode flexible leads to isolate the diodes from the circuit. (3) Use the ohmmeter to test the continuity of each diode in both directions. A shorted diode will show continuity in both directions and an open diode will show no continuity in either direction. A good diode will show continuity in only one direction. (4) Reconnect diode leads in charger. b. Capacitor (1) Discharge capacitor. (2) Disconnect capacitor leads. (3) Set ohmmeter R x 10,000 scale and connect ohmmeter leads to terminals on

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capacitor. When needle (or display) quits moving, reverse leads. On a good capacitor, the needle will deflect to the right (low resistance) and then deflect back to the left (high resistance) each time the meter leads are reversed. On a shorted capacitor, the needle will deflect to the right (low resistance) and remain there. On an open capacitor, the needle will not deflect (stationary display). (4) Reconnect capacitor leads in the charger. (5) Set AC voltmeter on a scale to read at least 500 volts AC. Connect meter leads to the capacitor terminals. A shorted capacitor will indicate 0 volts AC. An open capacitor will indicate about 300 volts +/-20 volts AC. This is the same as the capacitor transformer winding voltage without a capacitor connected in circuit. (6) Turn on charger power. WARNING Before checking components, disconnect AC power supply, unplug batteries and discharge capacitor with insulated screwdriver. All tests should be made with the charger disconnected unless otherwise stated. Use extreme caution when a test calls for the power to be “on” at the charger. c. Timer The timer can be tested by rotating the timer knob clockwise to the one hour mark. With the AC power connected, the charger should turn off in one hour. 5. Overcharging problems Most complaints about charging problems can be remedied by following the above procedures. Overcharging problems may not be the fault of the charger. Often, overcharging is caused by faulty

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batteries or poor connections. The following items should be checked to resolve problems of overcharging or failure of charging amps to taper down. a. Charger and battery not properly matched. Check specifications on both batteries and charger (see “Battery Charger, Optima Pack” on page 267). Battery pack (GNB or Optima) has been designed for a specific size and type of battery. If another battery has been installed, be certain that it is comparable to the original batteries. Automotive type batteries will not function properly in this application. b. Excessive battery temperatures suppressed battery voltage.

causing

Allow batteries to cool. c. Defective battery or poor DC connection. Check battery voltage while charger rate is controlled by the battery state of charge. This will adjust the output to the proper level if the battery is in good condition. If the voltage does not come up to finish rate, this may indicate a bad cell within a battery or a marginal DC connection between the battery and the charger. Carefully inspect the connections for excessive heat. Test the battery cell voltages and specific gravity.

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S5.5 5191 Battery Connector

Version no

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Battery Connector 1

Item No.

Description

Screw, cap

Connector, SB-175

Cable, Positive

Cable, Negative

1. Location The battery connector is located on the left side of the truck, above the battery. f

2. Inspection 1. Turn the key switch OFF and disconnect the battery at the battery connector. 2. Check battery connector for damaged cables. © BT Prime-Mover, Products Inc.

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C-code

5191

3. Check to see if battery cables are pulling out of the connector. 4. Check cables at battery terminals. Connections should be tight, with no corrosion. 5. Check inside connector at internal contacts for damage, dirt, or corrosion. DO NOT use a metal object to clean connector.

3. Installation The cables to either half of connector have a lip on the forward end. This lip snaps over a spring-loaded retainer which is part of the connector. To remove a cable from connector, push retainer down while pulling battery cable towards the rear and out of the connector. NOTE!

Battery charger unintentionally connected to battery connector at chassis would lead to prevent premature, unwarrantable failure. Installation of spacer block onto battery connector would prevent a battery charger to truck connection.

1. Disconnect power supply to battery charger. 2. Attach spacer block to the topside of battery connector from the battery charger using two cap screws and two hex nuts. NOTE!

Verify spacer block is installed correctly by attempting to connect the battery charger connector to truck battery connector. If properly installed, the spacer block will not allow the battery charger connector to slide against chassis and will prevent a connection of battery charger and truck battery connector.

3. Reconnect supply to battery charger (see “Battery Charger, Optima Pack” on page 267).

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PT S5.6 5230 Battery Controller/Hourmeter/ Lift Interrupt (Optional) Version no

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Battery Controller/Hourmeter/ Lift Interrupt (Optional) 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 if there is a current passing through the relay contacts when the instrument registers empty battery contacts stay closed until current ceases. There will be no lockout of lift during 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

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2. Electrical 2.1. Voltage This instrument is supplied as a pin selectable dual voltage unit with low voltage of 24V or high voltage of 36V.

Contact Voltage and Current Ratings for Switching Resistive Loads. Open Contact Voltage

200

VDC

Max

Closed Contact Current

ADC

Max

Volt Ampere Product

Max

Memory Retention The instrument contains an internal battery, 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.

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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 light. 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 the battery should be recharged. 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 truck type. The given settings are approximate and might need to be fine tuned to get a 100 percent correct lockout for a specific application. Battery Ah 180 210 240

L-M M-N N-O

L-M - an adjustment is needed on the line between L and M. N-O - an adjustment is needed on the line between N and O. A 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 it starts to flash at higher specific gravity the discharge U potentiometer should be turned counterclockwise (towards

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K). If two LEDs start to flash at a specific gravity below 1.14, turn potentiometer clockwise (towards P). The letter designations for voltage per cell (VPC) multipliers at empty battery are specified as tabulated below. .

O P Q R S K DISCHARGE T

N M L

Setting

VPC

Setting

VPC

1.57

1.82

1.63

1.84

1.68

1.86

1.73

1.91

1.78

1.93

Pin No:

194

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Function

Hourmeter (-)

Key switch (+)

Relay arm (+)

Relay NC (-)

Battery (-)

Hourmeter (+)

24 Volt (+) low

Not used

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NOTE!

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The discharge adjustments can be made at any time during a working cycle before the lift lockout. Discharge potentiometer adjustments made late in a working cycle have little or no effect in delaying the lift lockout in the particular working cycle. Normally the discharge potentiometer adjustments are made before or at the beginning of a working cycle to effectively change the discharged profile of the 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 to a voltage greater than 2.09 volts per cell and connected to the truck.

3.3. Key Switch The electronics of the BC and LCD of the hourmeter are energized as long as machine battery remains connected to gauge. The display of the BC is turned on and off by the key switch. 200 AMP Controllers The key switch also enables timing function of the hourmeter. With key switch ON, the hourmeter can be activated by connection number 6 at the rear of BC. With key switch OFF, the hourmeter will not respond to the connection number 6, and LCD of the hourmeter will be off.

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3.4. Hourmeter Hourmeter operation is indicated by flashing of the hourglass icon on the face of 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.

4. Troubleshooting 4.1. Battery Discharge Indicator (BDI) 4.1.1. No Reset 1. Using the open circuit reset, the instrument must first have a break in power and then measure a voltage greater than 2.09 volts per cell across its pin 7 or 8 and pin 5. Verify leakage voltage is not present across terminals by disconnecting one of the lines supplying battery voltage to the instrument. Replace the connection and measure the voltage across the gauge at pin 7 or 8 and pin 5. The reading must be above 2.09 volts per cell or the gauge does not reset to indicate full charge and the instrument is defective. 2. Using the high voltage rest to reset, the instrument 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 voltage across the pins and verify it is greater than 2.35 volts per cell. Verify that it remains above this level for a minimum of six minutes. If the two conditions are met, and the instrument does not reset, it is defective. 4.1.2. Reset After Break in Power If 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 or its memory cell is depleted. This will not affect the discharge function of the instrument if it is always connected 196

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to a fully charged battery and allowed to track its discharge without a break in power. NOTE!

New instruments are shipped from the factory with a full reading in its memory. The first time the instrument is connected to the truck 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 (typical 10 year battery life).

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 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 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 proceed as follows: 1. Remove wire leading to pin 3 when at lockout. 2. Replace 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 lift switch. After replacing wire, if lift operates, the instrument is defective.

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4.1.5. No Lift Verify gauge is not at lockout with its two red LEDs alternately flash. The relay outputs should be closed above lockout and should read zero ohms with an ohmmeter across pins 3 and 4. If not at lockout, test lift switch and contactor. 4.1.6. Early Lockout It is very important the instrument is installed so 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 meter negative lead on pin 7 or 8 (whichever pin B+ is connected to). Load battery and record measurement. 2. Repeat procedure with voltmeter’s positive lead on pin 5 and its negative lead on battery negative terminal. Record voltage measured. 3. Add 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 keyswitch, pin 2. Verify battery voltage is present across pin 2 and pin 5. If voltage is present and LEDs do not light, the instrument is defective.

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4.2. Hourmeter 4.2.1. No Display The LCD of hourmeter will light when power is applied at pin 7 or 8 and pin 5. If battery voltage is measured across the pins and LCD does not turn on, instrument is defective. 4.2.2. Hourmeter Glass Icon Does Not Flash If 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 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 truck key switch off. This should remove voltage from pin 2 of the instrument. If the voltage is not present at pin 2 and the hourmeter’s icon continues to flash, the instrument is defective.

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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

Battery negative Power pin 5

Key switch

1 10

Hourmeter LCD

Brake switch (Hourmeter input)

Not Used

BDI Gauge No Used

Ground, Wire 13 Input, Wire 6

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2. Electrical 2.1. Voltage This instrument is supplied in two configurations as a dual voltage unit for 24/36 volt DC. 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”. For location of wiring see circuit diagrams on page 169 through page 171.

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 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 80 percent discharged, the two LEDs from the left will flash alternately to warn the operator that the battery needs recharging.

3.2. Key Switch The electronics of the BDI and the LCD of the hourmeter are energized as long as the truck battery remains connected to the gauge. The display of the BDI is turned on and off by the key switch. 400 AMP Controllers Drive transistor controller enables timing function of the hourmeter, whenever there is current going to the drive motor. Also, timing function is enabled whenever S52 raise switch is closed.

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3.3. Hourmeter Hourmeter operation is indicated by flashing of the hourglass icon on the face of 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.

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 to reset the instrument, it must first have a complete break in the power and then measure a voltage greater than 2.09 volts per cell across pin 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 the horn button for a few seconds will sometimes drop the charge in capacitors to zero volts and allow the instrument to reset when it reads 2.09 volts per cell or above.

Replace this connection and measure the voltage across the gauge at pins 5 and 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 pins 5 and 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

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for a minimum of six minutes. If the 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. 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 (typical 10 year battery life).

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 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.

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4.2. Hourmeter 4.2.1. No Display The LCD of the hourmeter will illuminate when power is applied at pins 5 and 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 5 must be connected to battery positive, and one or both of the hourmeter lines must be active. If the key switch is on, 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. If voltage is not present at pin 3 and the hourmeter’s icon continues to flash, the instrument is defective.

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Start/Stop Switches 1. General To identify the electrical circuit location of switches see diagrams page 169 through page 171.

1.1. Test/Inspection Examine switch for signs of arcing, overheating, discoloration, cracking, or other physical damage. Replace switch if necessary. To test switch, isolate it from the electrical circuit. Remove all connections from the switch, making sure all wires are labeled and identified for reconnection. Use an ohmmeter set to a low resistance scale to measure resistance across the switch. In a closed position, the switch should be less than 1 ohm. In an open position, switch should show a resistance greater than 10 megohms. With the battery connected, use a voltmeter to check for voltage on both the positive and negative side of the switch while in the closed position. The voltage must be the same on both sides of the switch. If not, the switch is defective.

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4 5

Item No. 1 2 3 4 5 6 7 8 9

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Description Switch, disconnect Gauge Switch, key Screw, round Switch, brake interlock Nut, twin Switch, lift limit Screw, machine Nut, twin

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2. Master Control On/Off Switch (S21) The master control on/off switch (S21) is located on the top left-hand side of the frame carrier exterior. This switch will stop all control functions.

2.1. Inspection With the battery plugged in and the master control on/off switch in the closed position, battery voltage B+ should be present on both terminals of the switch. If not, the switch is defective. Test master control on/off switch with an ohmmeter after removing it from the electrical system. In the OFF position, ohmmeter should read greater than 10 megohms. In the ON position, ohmmeter should read less than 1 ohm. Replace switch if readings are not within ranges.

2.2. Removal 1. Turn the key switch OFF. Disconnect battery connector from truck. 2. Disconnect electrical harness from base of master control on/off switch. 3. Use a small screwdriver to pry tabs to allow the switch to be pulled out of the key switch bracket. 4. Repair or replace as necessary.

2.3. Installation 1. Push master control on/off switch into the key switch bracket. 2. Reconnect electrical harness to base of master control on/off switch. 3. Connect battery connector to truck. 4. Test truck operation, then return to service.

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Transistor Controller 1. Basics Of Circuit Operation The controller is a microprocessor based, programmable motor controller designed for separately excited motors. It is capable of four distinct operating modes or personalities and is programmer. In addition to programming the controller, it has diagnostic and test modes to display error codes and display the status of the controller's inputs and outputs. The controller includes an armature and a field. These both 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 truck traction system. The polarity and magnitude of the field current is also controlled to provide solid state, contactor-less direction control and plug braking. The controller is energized by applying power to the key switch input, pin number 16. At that time, the controller is powered up and performs an internal self test. The controller becomes active by applying power to the brake input, pin number 15. At that time, the following start-up checks are performed:

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A short between M- and Ground. (Insures the M- output or power MOSFETs are not shorted.)

•

Continuity in the field coil. (Occurs each time forward or reverse is selected.)

•

Main contactor coil has actually closed when commanded. (Completed by checking for battery voltage at the B+ terminal.)

•

Throttle is below 25 percent.

•

Continuity in the emergency reverse wiring. (Controller applies a brief pulse from the emergency reverse check output, pin number 10. This pulse is read by the emergency reverse input, pin number 13. If the pulse is not present, there is

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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 rearward 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 confining the minimum allowable field current. Further top speed limiting can be obtained by limiting the maximum armature voltage through the MAX. SPEED Parameter. Plug braking involves reversing the travel control to the opposite direction without applying the brake causing the truck to decelerate smoothly. The operator may choose to continue holding the controls in the opposite direction. This will start the truck moving in that direction or the operator may release the handle and allow the truck to come to a complete halt. Releasing the steering control handle will allow the parking brake to become automatically applied. THE CONTROL HANDLE MUST NOT BE PLACED IN THE BRAKE POSITION DURING THE PLUG BRAKING OPERATION. When using plug braking the operator may regulate, within the programmed capabilities, the degree of the plugging force and distance travelled during plugging. For the lightest plugging force, and the longest distance, the travel control should be operated only to the creep position in the opposite direction. For the strongest plugging power, and the shortest distance, the travel control should be operated to full speed in the opposite direction. Plug braking may be regulated with the control handle at any point between the creep position and full speed.

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1.1. Control Features

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

•

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

•

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

•

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.

•

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.

•

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

•

Truck acceleration and response are controlled through programmable parameters.

•

Linear temperature cutback on motor current limit. No sudden loss of power under any thermal conditions.

•

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

•

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.

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Active power on self test and continuous diagnostics during operation.

•

Internal watchdog circuits ensure proper software operation

2. 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 recommended that the controller exterior be cleaned periodically. Cleaning the controller gives a good opportunity to check the controller’s diagnostic history file with the handheld terminal, if available. (See “Handset Operation” on page 269.)

2.1. Safety NOTE!

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

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

2.2. Cleaning Although the controller requires virtually no maintenance if properly installed, the following is recommended on a regular basis of 360 hours. 1. Remove power by disconnecting the battery. 2. Discharge capacitors in the controller by connecting a load (such as a contactor coil or horn)

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across the controller’s B+ and B- terminals before doing any work on the controller. 3. Remove all dirt or corrosion from the bus bar area. The controller should be wiped clean with a moist rag. Allow 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.

3. Motor Circuit

Handset plug 4-pins

B-

M-

Control wire plug 16-pins

B+

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 S1 and S2.

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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.

Pin number 1 is located in the block row right side as you look at the logic. Pin No

Connecting

CONTACTOR DRIVERS P1

Not Used

Negative main contactor

THROTTLE CONNECTIONS P5

Not Used

Throttle; wiper/resistive pot.

Throttle: pot low

Not Used

BASIC CONTROL SIGNALS

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Not Used

P10

Emergency reverse output

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Connecting

P11

Drive fork direction input (Fork first)

P12

Drive steer wheel direction input (Fork trailing)

P13

Emergency reverse input

P14

Not Used

P15

Brake switch input

P16

Key switch input

5. Troubleshooting Guidelines Troubleshooting can be broken down into two sections: (1) mechanical and (2) electrical circuits. Electrical circuits can be broken down into control circuit and power circuit. Many hours of troubleshooting time can be saved by knowing the exact operational symptoms. If the proper switch operates for the chosen direction and speed, the problem can be found in the controller or the power circuit of that function. Voltage tests are made with the negative lead of the voltmeter connected to battery negative if the negative lead is connected to a negative terminal on the electrical panel. 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), the controller may not operate properly. 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 the component that is farthest electrically from the battery positive terminal. It is possible, and in many cases desirable, to measure battery voltage at both the positive and negative side of a component.

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Proper operation of this truck is with forks trailing when possible. Steering the truck is easier with the forks trailing. Always look in the direction of travel. Keep both hands within the handle guard and always look in the direction of travel.

TRAVEL

After the final test is completed, the truck should be repaired and operating properly. If it is not, then verify test results and possibly re-evaluate failure symptoms. If truck is still not repaired, then call your local authorized BT Prime-Mover Dealer for assistance. The following information is required when placing a service call: •

Truck model and serial number

•

Service hour meter

•

Actual battery voltage at open circuit

•

Actual battery voltage at open circuit at hydraulic operation under full load

•

Operating symptoms

•

Exact results of the testing performed

Perform the following steps before starting all troubleshooting procedures: 1. Inspect truck for physical damage or mechanical malfunction. Contactors must be free to move. Tips must not be welded or burnt. 2. Check for ground faults from electrical system to frame with an ohmmeter. A minimum of 20,000 ohms resistance from frame to any and all wiring is acceptable.

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3. Check that the battery is fully charged and connected. 4. Operate truck in all modes to determine the exact symptoms. DO NOT forget that systems are equipped with circuits that prevent operation in the event of improper operating procedures.

5.1. General Many problems are caused by a faulty or dirty battery. Make sure battery is clean. Check the electrolyte level and state of charge. CAUTION Be sure to block truck whenever a troubleshooting procedure requires turning key switch (S17) ON. This will avoid accidents caused by unexpected truck travel. CAUTION Unless otherwise directed, disconnect battery connector when checking electrical circuits or components with an ohmmeter. Electrical current can damage the ohmmeter. For transistor controller parameters see page 231. For troubleshooting the transistor controller see page 227. Visually inspect all wiring and electrical components for the following: •

Loose connections or connectors

•

Loose or broken terminals

•

Damaged terminals, blocks, or strips

•

Broken wiring and shorted conditions (especially those that are close to metal edges or surfaces)

Use an ohmmeter to check for wiring continuity.

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6. Shorts to Frame Test “Shorts to frame” is an industry term for unintentional current leakage paths between normally isolated electrical circuits and their metal enclosures. Shorts to frame may be metallic connections, such as a wire conductor contacting metal through worn insulation. More often, shorts to frame are resistive “leakage” paths caused by contamination and/or moisture. These leakage paths can result in unwanted electrical noise on the metallic truck structure and may result in improper operation. Shorts to frame can be caused by the following: •

Accumulation of dirt

•

Battery electrolyte leakage

•

Motor brush dust

•

Motor brush leads touching housing

•

Breakdown in insulation

•

Bare wires

•

Pinched wiring harness

•

Improper mounting of circuit cards

Shorts to frame can occur at numerous locations on truck include:

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Batteries

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Motors

•

Cables, wiring, and harnesses

•

Heat sinks

•

Bus bars

•

Solenoids

•

Contactors

•

Terminal strips

•

Switches

•

Power panel insulation

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Circuit card mounts

To test for shorts to frame: 1. Turn the key switch OFF and disconnect the battery from the truck. 2. To test the battery for shorts to case, connect a 12volt test light to battery case from battery B+, and then to battery case from battery B-. If it lights at all, even momentarily, there is a problem with the battery, either external contamination or internal damage. DO NOT continue until this condition is corrected. Meter may be damaged if proceeding before correcting condition. Install another battery in the truck and repeat procedure from step 1. If the test light does not light, continue to the next step. 3. With the battery disconnected from the truck, use a digital volt/ohm/ammeter on the ampere function to measure the leakage current from the battery case to battery B+ and from battery case to battery B-. Begin measuring at the highest Ampere scale and work toward the lowest. A reading of more than 0.001 ampere (1 mA) indicates a short. DO NOT continue until this condition is corrected. The meter may be damaged if proceeding before correcting condition. Install another battery in the truck and repeat procedure from step 1. If current is less than 0.0002 ampere (0.2 mA), go to step 4. If current is greater than 0.0002 ampere (0.2 mA) and less than 0.001 ampere (1 mA), remove battery from the truck, and continue with step 4. Ensure battery case does not touch truck frame during the remaining tests. 4. With battery disconnected (or removed and disconnected) from the truck, use a digital ohmmeter to measure the resistance from truck frame to truck B+, to truck B- (NOT battery B+ and B-), and to all fuses and motors. A reading of less than 1000 ohms indicates a short. DO NOT continue until this condition is corrected. Meter

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may be damaged if proceeding before correcting condition. a. To identify cause of short to frame, disconnect circuit components until the low resistance condition disappears. Do not reconnect components one at a time, but leave disconnected until the low resistance reading disappears. Prevent disconnected terminals or connectors from touching truck frame or other conductive surfaces. b. The most likely areas to check include: •

Motors

•

Heat sinks

•

Power cables

•

Power circuit components

•

Control circuit components

c. Repair or replace the component causing the low resistance condition, then repeat Step 4. d. Reconnect all other components previously disconnected, one at a time, measuring resistance between steps. If a reading is less than 1000 ohms when reconnecting a component, that component or its wiring is defective; repair or replace as appropriate. e. After all components are reconnected and readings are greater than 1000 ohms, continue with the next step. 5. Connect battery connector to the truck and turn key switch ON. If battery was previously removed, ensure battery case does not touch truck frame. 6. Use a volt/ohm/ammeter on the current function meter to measure leakage current to truck frame from B+, B-, and all fuses and motor terminals. Begin measuring at the highest ampere scale and work toward the lowest. If current is less than 0.001 ampere (1 mA), go to step 7. If current is greater than 0.001 ampere (1 mA), continue with the step below. 222

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a. To identify the cause of the short to frame, disconnect circuit components until leakage current reads less than 0.001 ampere (1 mA). Do not reconnect components one at a time, but leave disconnected until leakage current reads less than 0.001 ampere (1 mA). Prevent disconnected terminals or connectors from touching truck frame or other conductive surfaces. b. The most likely areas to check are as follows: •

Motors

•

Heat sinks

•

Power cables

•

Power circuit components

•

Control circuit components

c. Repair or replace the component(s) causing the leakage current. Repeat step 6. d. Reconnect all other components previously disconnected, measuring current between steps. If reading is greater than 0.001 ampere (1MA) when reconnecting a component, component or its wiring is defective. Repair/ replace as appropriate. 7. After all components are reconnected, reading is less than 0.001 ampere (1 mA) there is no short to frame condition with truck or battery. If the battery was previously removed from truck, reinstall battery.

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7. Definitions Continuity A continuous and uninterrupted path between two or more locations in an electrical circuit, typically having a resistance of less than 1 ohm. Open Circuit A lack of a continuous path between two or more electrical connections. Generally, when such a circuit is tested, it will have a resistance greater than ten megohms. Overtemperature (Power Amplifier) Overtemperature of the motor power amplifier is from 185o F (85o C) and above. At overtemperature, the drive current limit is linearly decreased from full set current down to zero. Plug current is not reduced to provide full vehicle braking under all thermal conditions. Pulse Width Modulation Pulse Width Modulation (PWM), also called “chopping,” controls the speed of the motor by switching the battery voltage to the motor on and off very quickly. Short Circuit or “Short” A short circuit is an unspecified path in a circuit that provides unwanted full or partial continuity between two or more locations in an electrical circuit. Example: Two insulated wires are physically next to each other and the insulation has been worn off each of the wires. Because the conductors inside each wire are now touching each other, there is a short circuit. Example: A power cable from the battery to a junction post in the truck has had the insulation worn away. Because the wire conductors are touching the tractor frame, there is a short circuit of the battery cable. Undertemperature When the power amplifier is operating at less than −13° F (−25° C), the current limit is cut back resulting in reduced travel speed.

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8. Diagnostics and Troubleshooting The controllers provide diagnostic information to assist technicians in troubleshooting drive system problems. The diagnostic information can be obtained by reading the appropriate display on the PMC handset (see “Handset Operation” on page 269). The information can also be obtained by looking at the status LED built in the controller that is visible through the window label.

8.1. 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 on page 230. 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. For complete operating instructions for the PMC handset see “Handset Operation” on page 269. Refer to the troubleshooting chart for suggestions covering a wide range of possible faults (see page 235).

8.2. Troubleshooting Troubleshooting can be broken down into three sections: 1. Handset 2. Status LED on the controller 3. Electrical circuits These sections can be further 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. 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 (see “Troubleshooting Chart” on page 227.) Then © BT Prime-Mover, Products Inc.

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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, 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. 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 the 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 forks trailing. Rearward direction refers to travel with the forks first. The control handle operating position is between 10 degrees below fully raised and 20 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, verify test results and possibly re-evaluate the failure symptoms. If the truck still has not been repaired, then call your local BT Prime-Mover Dealer for assistance. When placing a 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 completed. Authorized BT Prime-Mover Dealers may call the factory directly if necessary.

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The first steps of any troubleshooting procedure include: 1. Inspect truck for physical damage or mechanical malfunction. Contactors must be free to move and 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 systems are equipped with safety circuits that prevent operation in the event of improper operating procedures.

8.3. 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

(3,2)

Programmer Fault LCD Display Category

Explanation

(3,2) Possible Cause

LED off

1. No power or defective controller.

Solid on

1. Controller or microprocessor fault.

0,1

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No known faults

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1. Controller operational; no fault.

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LED Codes

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Programmer Fault LCD Display Category

Explanation

Possible Cause

1,1

Current shunt fault

Current sensor error

1. Controller worn or faulty.

1,2

HW fail-safe

Hardware fail-safe fault

1. Controller worn or faulty.

1,3

M- shorted

Internal M- short to B-

1. Controller worn or faulty.

1,4

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.

2,1

Throttle fault 1

Wiper fault

1. Throttle input wire open. 2. Throttle input wire shorted to B+ or B-. 3. Throttle pot defective. 4. Wrong throttle type selected.

2,2

E/R wiring check

Emergency reverse wiring fault

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

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

Throttle fault 2

Pot low broken or shorted

1. Throttle pot low wire open. 2. Throttle pot low wire shorted. 3. Wrong throttle type selected.

3,1

Contactor coil / FLD short

Contactor driver output overcurrent

1. Contactor coil shorted. 2. Field winding shorted.

3,2

Main Contactor welded

Welded main contactor

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

3,3

Field open

Motor field windings open

1. Field winding connection open. 2. Field winding open.

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Explanation

C-code

S5.9 5460 Transistor Controller

Possible Cause

3,4

Missing contactor

1. Main contactor coil open. 2. Main contactor missing. 3. Wire to main contactor open.

4,1

Low battery

Low battery voltage

1. Battery voltage is less than under voltage cutback limit. 2. Corroded battery terminals. 3. Loose battery or controller terminal.

4,2

Overvoltage

1. Battery voltage is greater than under voltage shutdown limit. 2. Vehicle operating with charger attached.

4,3

Thermal cutback

Over / under-temperature cutback

1. Temperature below 85° C (185o F) or above 25° C (77o F). 2. Excessive load on vehicle. 3. Improper mounting of controller. 4. Operation in extreme environments.

4,4

Anti-tiedown

Mode 4 selected at start up

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

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Test Menu THROTTLE %

Throttle reading, as % of full throttle

FIELD CURRENT

Motor field current, in amps

ARM CURRENT

Motor armature current, in amps

FIELD PWM

Motor field applied duty cycle, as %

ARM PWN

Motor armature applied duty cycle, as %

BATT VOLTAGE

Battery voltage across the capacitors

HEATSINK °F (°C)

Heatsink temperature

FORWARD INPUT

Forward switch: on/off

REVERSE INPUT

Reverse switch: on/off

MODE INPUT A

Mode select 1 switch: on/off

MODE INPUT B

Mode select 2 switch: on/off

INTERLOCK

Bake 1 switch: on/off

EMR REV INPUT

Emergency reverse switch: on/off

MAIN CONT

Main contactor: open/closed

AUX CONT A

Auxiliary driver: open/closed

SYS MODE

Function truck is operating in

Special Program Menu

230

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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

200

M2 Drive Current Limit

M3 Drive Current Limit

M4 Drive Current Limit

M1 Brake Current Limit

200

M2 Brake Current Limit

M3 Brake Current Limit

M4 Brake Current Limit

M1 Neutral Brake Percent

M2 Neutral Brake Percent

---

M3 Neutral Brake Percent

---

M4 Neutral Brake Percent

---

M1 Acceleration rate

M2 Acceleration rate

---

M3 Acceleration rate

---

M4 Acceleration rate

---

Quick start

M1 Maximum speed

M2 Maximum speed

M3 Maximum speed

M4 Maximum speed

M1 Creep speed

M2 Creep speed

---

M3 Creep speed

---

M4 Creep speed

---

All adjustment are made through PMC handset (see “Handset Operation” on page 269.)

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8.4. Technical Specification The technical specification for the BT-version of the transistor controller is according to the table below. Parameter

Range

STD Setting

M1 Brake C/L *

50A to Rated

200

Amps

Brake current limit

M1 Neut Brk % *

0 - 100

% of braking C/L

Neutral braking %

M1 Accel Rate *

0.1 - 3.0

Sec

Acceleration rate

M1 Max Speed *

0 - 100

% PWM duty cycle

Maximum speed

N/A

Emr Rev C/L

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8.5. Troubleshooting Chart Using Handset Fault

Point to Disable Controller

Conditions for Testing

Recovery Point

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 & no contactor driven

Immediate

Cycle Brake S10

Never - disable serial interface

Reinitiating serial interface

Parameter block check Initiating serial communication

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The following are indicated and are handled in a similar manner:

Fault

234

Conditions for Testing

Action

Recover Point

Emergency reverse

BB pressed forces E/R

E/R action (see “E/R wiring check” on page 228)

BB re-applied or brake released

HPD

Depends on type (See “HPD sequencing fault” on page 228.)

Disable PWM output

throttle cycled

Thermal cutback

Brake released

See “Thermal cutback” on page 229

Undervoltage

Continuous while S17 on

Immediate

Condition clears

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Transistor Controller Troubleshooting 1. Troubleshooting Chart Index 1. Dead truck, nothing operates. No travel, no lift, no lower, no horn. 2. No travel, line contactor does not close. Lift, lower, and horn function. 3. No rearward travel (forks first). Line contactor closes when control handle is pulled down to operating position. Forward travel and the lift, lower, and horn function. 4. No forward travel (forks trailing). Line contactor closes when control handle is pulled down to operating position. Rearward travel and the lift, lower, and horn function. 5. Truck travel speed does not respond to controls properly. Speed control is sluggish or erratic. 6. Improper operation of emergency reverse circuit; truck will not move in forks first direction when emergency reverse button is pressed. 7. Lift function does not operate. 8. Lift motor does not turn off at full lift height. 9. Lowering function does not operate.

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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 lift, no lower, 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. G. If truck is not functioning re-evaluate symptoms and troubleshoot individual functions.

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2. No travel; line contactor does not close. Lift, lower, and horn function. 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”. Control handle pulled down to operating position with brakes released and S10 closed. Test for battery voltage at: A. Plug J1-16, wire number 6 on transistor controller (A1). Repair open wire number 6 between S17 and A1. B. Positive side of K10, 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 J1-15; wire number 7 on A1. Repair open wire number 7 between S10 and A1. F. Negative side of K10 coil. If battery voltage is measured here, verify line contactor operation; and replace line contactor. G. Test with handset. H. Replace A1.

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3. No rearward travel (forks first). Line contactor closes when control handle is pulled down to operating position. Forward travel and the lift, lower, and horn function. 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”. Control handle pulled down to operating position with brakes released and S10 closed. Travel controls operated to travel in the rearward direction (forks leading). 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. Repair power cable between F1 and K10. G. Power circuit negative side of K10. If battery voltage is NOT measured here, verify line contactor operation; and replace line contactor. 238

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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 to approximately 1 volt. K. A2 terminal on drive motor voltage should be battery voltage in neutral and decrease with throttle input down to approximately 1 volt. L. Test with handset. M. Replace A1. 4. No forward travel (forks trailing). Line contactor closes when control handle is pulled down to operating position. Rearward travel and the lift, lower, and horn function. 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”. Control handle pulled down to operating position with brakes released and S10 closed. Travel controls operated to travel in the rearward direction (forks first). 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 J1-12, wire number 2, A1.

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Repair open wire number 2 between S16 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. Repair power cable between F1 and K10. G. Power circuit negative side of K10. If battery voltage is NOT measured here, 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 to approximately 1 volt. K. A2 terminal on drive motor voltage should be battery voltage in neutral and decrease with throttle input down to 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”. 240

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Control handle pulled down to operating position with brakes released and S10 closed. Travel controls to be operated from neutral to full speed in both directions as tests are made. A. Test voltage at plug J1-6, wire number 9, on A1. This voltage should start out between 3 and 4 volts in neutral and decrease smoothly to zero 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, adjust or replace accelerator potentiometer. B. Transistor controller may be in thermal cutback. Allow controller to cool and retest. C. Test with handset. D. Replace A1. 6. Improper operation of emergency reverse circuit; truck will not move in fork direction when emergency reverse button is pressed. 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”. Control handle pulled down to operating position with brakes released and S10 closed. S20 button on end of control handle pressed. Test for voltage at: A. Plug J1-13 wire number 11A on A1. B. Plug J1-10 wire number 11B on A1. C. Test with handset. D. Replace A1. © BT Prime-Mover, Products Inc.

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7. Lift function does not operate. Conditions for testing: Truck blocked to prevent it from rolling. Battery fully charged and connected to truck. Emergency disconnect switch to the “RUN” position. Key switch turned “ON”. Lift switch bar pushed to close lift switch. Test for battery voltage at: A. Positive side of lift switch S34, wire number 6. Repair open wire number 6 between key switch S17 and lift switch S34. B. Negative side of lift switch S34, wire number 5. Adjust or replace lift switch S34 and bar assembly. C. Positive side of lift limit switch S36, wire number 5. Repair open wire number 5 between lift switch S34 and lift limit switch S36. D. Negative side of lift limit switch S36, wire number 17. NOTE!

If pallet forks are fully raised then the lift limit switch should be open to shut off the lift motor. Adjust or replace lift limit switch.

E. Positive side of lift solenoid coil, wire number 17. Repair open wire number 17 between lift limit switch S36 and lift solenoid coil. F. Negative side of lift solenoid coil, wire number 13 (Wire number 20 if truck is equipped with Lift Interrupt System).

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Special Instructions: If truck is NOT equipped with Lift Interrupt System follow step “a”. If truck IS equipped with Lift Interrupt System follow step “b”. a. For trucks WITHOUT Lift Interrupt System. If battery voltage is measured here, repair open wire number 13 between lift solenoid coil and battery negative. If battery voltage is NOT measured here, continue testing with test G. b. For trucks WITH Lift Interrupt System. Test for battery voltage at terminal 3 on back of BDI gauge, wire number 20. If battery voltage is NOT measured here, repair open wire number 20 between lift solenoid coil and BDI gauge. If battery voltage IS measured here, continue to test in step (c). c.

Test for battery voltage at negative terminal on back of BDI gauge, wire number 13. If battery voltage IS measured here, repair open wire number 13 between BDI gauge and battery negative. Also verify that battery voltage is sufficient for Lift Interrupt System to allow lift function to operate. If battery voltage is NOT measured here, replace BDI gauge which contains the Lift Interrupt System.

d. All testing to resume with test G. G. Positive side of lift solenoid tips. Repair open power cable between F1 and lift solenoid. H. Negative side of lift solenoid tips. Replace lift solenoid. I. A1 terminal on lift motor. Repair open power cable between lift solenoid and lift motor.

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J. S2 terminal on lift motor. Special Instructions: If battery voltage IS measured here, repair open power cable between lift motor and battery negative. If battery voltage is NOT measured here, repair lift motor. 8. Lift motor does not turn off at full lift height. Adjust or replace lift limit switch. 9. Lowering function does not operate. Conditions for testing: Truck blocked to prevent it from rolling. Battery fully charged and connected to truck. Emergency disconnect switch to the “RUN” position. Key switch turned “ON”. Lowering switch bar pushed to close lowering switch. Test for battery voltage at: A. Positive side of lowering switch, wire number 6. Repair open wire number 6 between key switch and lowering switch. B. Negative side of lowering switch, wire number 4. Adjust or replace lowering switch and bar assembly. C. Positive side of lowering valve coil. Repair open wire number 4 between lowering switch and lowering valve coil. D. Negative side of lowering valve coil, wire number 13.

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Special Instructions: If battery voltage IS measured here, repair open wire number 13 between lowering valve coil and battery negative. If battery voltage is NOT measured here, check operation of lowering valve coil by holding a screwdriver next to coil. If screwdriver is magnetically attracted to coil, the problem is likely hydraulic contamination preventing valve from operating. If screwdriver is not magnetically attracted to coil then problem is likely a failed lowering valve coil. Replace valve and/or coil as necessary.

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S6.0 6000 Hydraulic System

Version no

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390

C-code

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

1. General The hydraulic system consists of a compact hydraulic unit, including a electric solenoid valve, pressure relief valve and a cylinder for lifting the forks.

2. Troubleshooting NOTE!

Proper care and cleanliness should be observed in servicing to insure oil does not become contaminated with dirt or other foreign material. Contaminants can be drawn into pump so as to stick or score pump which will cause failure of pump assembly.

If the hydraulic pump assembly does not operate properly, the following preliminary checks should be made: 1. Proper oil level 2. All electrical connections tight 3. Battery fully charged When checking voltage at solenoids, make sure hydraulic lines and components are fully installed. When possible, keep the key switch OFF and battery connector disconnected.

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After the preliminary check is accomplished, install a 0-5000 psi (0-34473 kPa) pressure gauge in the 0.375 inch (9.525 mm) NPTF outlet port near the relief valve in the adaptor. The installation of a pressure gauge is required to insure proper observation of what is occurring in the unit during trouble shooting. Start pump and raise lift cylinder to its upper limit stops to develop maximum pressure of the unit, which will normally be passing all flow over a relief valve. Pressure gauge should be reading the set pressure of the relief valve. Remove pressure on hydraulic system by actuating the solenoid operated lowering valve. Normal trouble that may occur with pump assembly have been grouped under three headings: Failure to (A) Raise (B) Hold (C) Lower load. One or more of the listed trouble sources may be causing improper operation. Refer to the proper heading (relief valve) for detailed instructions for disassembly, check and adjustment of parts to remedy the trouble. A. If pump operates but will only develops low pressure or slow lift: (1) Relief valve seat scored, foreign particles under ball or relief valve out of adjustment (see page 262). (2) Dirt in solenoid-operated release (see page 262). (3) Pump worn, replace pump. B. If pump develops pressure but will not hold: (1) Dirt in solenoid-operated release. (2) Relief valve seat scored, foreign particles under ball or relief valve out of adjustment. C. If pump develops pressure but will not release load: (1) No electrical contact to solenoid operated release valve (see page 262). (2) Solenoid in solenoid-operated release valve burned out. (3) Relief valve bottomed causing pressure to go beyond the unloading limit of the solenoid release valve. 248

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3. Schematic

Lift Cylinder

Component Enclosure Hydraulic Lines Joining Motor (Electric) Hydraulic Pump Filter

Reservoir (Vented) Cylinder (Single Acting) Cylinder (Double Acting) Check Valve Hydraulic Lines Crossing

Hydraulic Pump

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4. Description 4.1. Lift When lift button is pushed, the lift pump solenoid is energized starting the pump and motor. Fluid is drawn from the reservoir, through a pick up screen to the inlet of the gear pump. As the gear pump rotates, oil is forced out the pressure port and is blocked from returning to the reservoir by a closed relief valve and lowering valve. Oil continues to flow to the top of the lift cylinder and pushes against the end of cylinder rod to extend the rod from the cylinder tube. When the lift pump motor is shut off and the gear pump is not turning, the cylinder is held extended by a closed check valve and normally closed lowering valve.

4.2. Lower Hydraulic fluid is retained in the hydraulic cylinder by a check valve and electrical solenoid lowering valve. When the solenoid is energized, oil passage from the cylinder to reservoir is opened. Due to the load on the lift cylinder, fluid is forced out of the lift cylinder and back to the reservoir while the lift cylinder is retracting. Lowering speed is regulated by a flow regulator. This process allows the truck to lower.

4.3. Relief Pressure The relief pressure is set at 3200 psi (22063 kPa).

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5. Maintenance Hydraulic fluid level must be checked periodically (see “Planned Maintenance Schedule” on page 59). If the reservoir regularly requires additional oil to maintain proper level, a leak is indicated and must be repaired. When scheduled, the reservoir should be removed and drained for cleaning and replaced with new oil. After refilling, check lift, lower and other hydraulic functions for proper operation. If the truck will not lift a full load, the pressure relief setting should be checked and adjusted. During normal operation, pressure relief setting will not change. As the lift pump wears with age, some loss of performance will be experienced. When this loss becomes severe, the lift pump should be replaced.

6. Lift Limit Switch Lift limit switch is accessible by removing the outer cover. It is located on the lower right side of the lift carrier frame. The lift limit switch is actuated by a peg cast into the lift carrier frame. To adjust switch: WARNING Block all wheels to prevent truck from rolling. 1. Park truck on level surface and block truck from moving. 2. Disconnect battery connector from truck. 3. Remove cover. Turn truck to the down position. 4. Loosen mounting screws and move lift limit switch away from operating peg so that it will not operate. 5. Connect battery connector to truck. Raise pallet forks to maximum height. Do not stall hydraulics against relief for longer than necessary. 6. Lower pallet forks until the tops of the forks are 9.25 inches (234 mm) above the floor.

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WARNING Before adjustments are made, disconnect battery from truck to prevent accidental operation. 7. Disconnect battery connector from truck. 8. Adjust lift limit switch to operate at this point and tighten mounting screws. 9. Connect battery connector to truck. Test lift limit switch operation. Lift limit switch must close and stop the hydraulic pump when 9 inches (228 mm) is reached. 10. Replace cover.

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Hydraulic Pump 1 2

16 5 2

3 13

8 Part of 12 Part of 12

12 10

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PT S6.1 Hydraulic Pump

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Item No.

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Description

Item No.

Description

Pump assembly

Kit, pump assembly

Kit, solenoid

Breather

Valve check

Elbow, 90o

Pump motor

Kit, reservoir

Coupler

Coil, 24 volt

Adaptor

Valve, release

Kit, relief valve

Kit, orifice

O ring

Fitting, male tap 45o

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1. Removal The hydraulic pump and motor assembly must be removed from the truck in order to separate the pump and motor. The lifting frame must be fully lowered before removing pump. DANGER HOT OIL under pressure may be present. Be certain truck is safely blocked and pressure is released. Some spillage of hydraulic oil may occur. WARNING Block all wheels to prevent truck from rolling. 1. Park truck on a level surface, make sure parking brake is applied, and wheels are blocked to prevent accidental movement. 2. Lower lifting frame to release pressure in hydraulic system. 3. Disconnect battery connector from truck. Remove battery from unit to prevent accidental operation. 4. Remove outer cover to obtain access to the hydraulic pump and motor assembly. 5. Remove hydraulic line(s) from hydraulic pump assembly and cap ends to prevent contaminants from entering the hydraulic system. 6. Disconnect electrical power cables and mark their positions. Disconnect solenoid control wiring noting their position. 7. Remove three socket head screws located inside the battery compartment securing hydraulic pump and motor assembly to battery side of frame.

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2. Disassembly WARNING Compressed air used for cleaning MUST be reduced to less than 30 psi (206 kPa) and then only with effective chip-guarding and personal protective equipment. NOTE!

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

1. Before disassembly, clean exterior of the hydraulic pump and motor assembly in a cleaning solution to remove all contaminations. 2. Drain reservoir (12) of oil. 3. Set unit in vertical position with reservoir (12) end up. 4. Remove screw holding on reservoir (12). 5. Tap reservoir (12) lightly to loosen. Wiggle reservoir (12) sideways while pulling up at the same time. 6. Remove four screws holding pump to adaptor (6) and lift pump (9). 7. Disconnect wires from terminals on coil (13). Disconnect power cables from pump motor to pump main solenoid (2). 8. Remove coupler (5) from motor drive shaft. 9. Remove nut securing coil (13) and remove coil (13) from valve assembly (14). Remove valve assembly (14) from adaptor (6). 10. Remove relief vale assembly (7). 11. Remove check valve (3). 12. Scribe a line on both adaptor (6) and base of pump motor (4) to aid when reassembling. Pump motor (4) can be removed at this time by removing two screws that secure motor to adaptor (6) on top of the motor (4).

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3. Inspection WARNING Compressed air used for cleaning MUST be reduced to less than 30 psi (206 kPa) and then only with effective chip-guarding and personal protective equipment. NOTE!

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

1. Thoroughly clean all parts and remove all nicks and burrs with emery cloth. 2. Inspect all parts for excessive wear or scoring. If heavy scoring is found replace part. 3. Inspect breather (10) for clogging or excessive wear. Wash in a cleaning solution and air dry from inside out. 4. Inspect inside edges of reservoir (12) for any burrs or nicks that may cut the O ring during installation. Wipe inside of reservoir (12) clean. 5. Clean and inspect valve cavity to be sure it is free of all foreign matter. Inspect solenoid operated valve (14) strainer. CAUTION DO NOT bend or apply pressure to center stud or hold cartridge body any place but on flat sides of sub-assembly. 6. Inspect hydraulic hose and replace if worn.

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4. Reassembly WARNING Compressed air used for cleaning MUST be reduced to less than 30 psi (206 kPa) and then only with effective chip-guarding and personal protective equipment. NOTE!

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

1. All parts should be cleaned and dried thoroughly. Metal parts should be lightly oiled prior to reassembly. 2. If pump motor was removed from adaptor (6), install pump motor (4) by aligning scribe marks that were made earlier and secure with screws. 3. Connect power cables from pump motor to pump main solenoid (2), if solenoid (2) was replaced. 4. Install coupler (5) on motor drive shaft. 5. Align splines on pump (9) shaft to splines on motor coupler (5). Gently push pump (9) shaft in coupler (8) and align pump (9) mounting holes in adaptor (6). When pump (9) is flush with adaptor (6), pump and motor are connected. 6. Install two screws securing pump (9) to adaptor (6) and tighten cap screws to 10-12 ft-lb (13-16 N•m). 7. Oil O ring (8) lightly and install on adaptor (6). 8. Start reservoir (12) over flange on adaptor (6) up to O ring (8). Make sure it is aligned properly with holes as well as not cocked. 9. Gently push on the outer edge of the reservoir (12). The reservoir (12) should move into position. 10. Install screws in position and tighten to snug condition. 11. Install breather (10) and elbow into reservoir.

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CAUTION DO NOT bend or apply pressure to center stud or hold cartridge body any place but on flat sides of sub-assembly. 12. Apply a small amount of clean hydraulic oil to the O ring and backup ring and install on spool valve cartridge (14). 13. Install strainer in place on spool valve cartridge (14). 14. Hand screw spool valve assembly (14) in adaptor (6) cavity and tighten to a maximum of 35 ft-lb (47 N•m) for die cast metal. 15. Install solenoid coil (2) on spool valve (14) assembly, and tighten nut to a maximum of 5 ft-lb (6 N•m). Connect wires to terminals on coil (13). 16. Install check valve (3) and relief valve assembly (7), if removed.

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5. Installation WARNING Compressed air used for cleaning MUST be reduced to less than 30 psi (206 kPa) and then only with effective chip-guarding and personal protective equipment. NOTE!

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

1. All parts should be cleaned and dried thoroughly. 2. Install pump and motor assembly back in truck and secure with three socket head screws from the battery side of the frame. 3. Properly connect electrical power cables, noting their positions recorded earlier. 4. Properly connect solenoid control wiring, noting their positions recorded earlier. 5. Uncap and connect hydraulic hose to cylinder assembly and lift pump. 6. Fill hydraulic reservoir with new clean oil. 7. Install battery. Connect battery connector to truck. 8. Operate the lift/lower button to remove air from hydraulic hose and check operation of the whole hydraulic system. WARNING DO NOT use your hands to check for hydraulic leakage. Use a piece of cardboard or paper to search for leaks. Escaping fluid under pressure can penetrate the skin causing injury. Relieve pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Keep hands and body away from pinholes and nozzles which eject fluids under high pressure.

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9. After running the hydraulic system, check and fill the hydraulic reservoir (12) with clean oil. 10. Install outer cover.

6. Adjustments 5

2 4

Item No.

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Description

Item No.

Description

Fitting

Pump/motor assembly

Hose assembly

Cylinder assembly

Screw

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6.1. Relief valve (See “Hydraulic Pump” on page 253.) 1. Remove hex cap on relief valve. 2. If relief valve is causing the low pressure condition, the pressure can be increased by screwing in the adjusting screw, recycling the pump and noting pressure gauge reading. Be sure the final adjustment on the screw is at least 1/2 turn from bottom position. 3. If the trouble is not remedied by the relief valve adjustment, replace relief valve. 4. Adjust relief valve and recycle the pump per above. 5. Do not operate motor/pump at relief valve setting longer than 10 seconds at any one period.

6.2. Solenoid Operated Valve CAUTION DO NOT bend or apply pressure to center stud or hold cartridge body any place but on flat sides of sub-assembly. 1. Clean and inspect valve cavity to be sure it is free of all foreign matter. 2. Be sure O ring and backup ring are in place. 3. Apply a small amount of clean hydraulic oil to all three rings. Be sure strainer is in place. 4. Hand screw subassembly in place and tighten to a maximum of 35 ft-lb (47 N•m) for die cast metal. 5. Assemble coil on spool assembly, and tighten nut to a maximum of 5 ft-lb (6 N•m). 6. Connect wires to terminals on coil.

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S6.2

6420 Lift Cylinder

Version no

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390

Lift Cylinder 1 6 5 4

3 2

Item No.

Description

Item No.

1 2 3

Cylinder assembly Rod Ring

4 5 6

Description Wiper Seal Tube

WARNING DO NOT use your hands to check for hydraulic leakage. Use a piece of cardboard or paper to search for leaks. Escaping fluid under pressure can penetrate the skin causing injury. Relieve pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Keep hands and body away from pinholes and nozzles which eject fluids under high pressure. The lift cylinders are the positive displacement type (NO seals on the lower end of the cylinder rod).

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PT S6.2 Lift Cylinder

6420

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000

390

1. Cylinder Repair 1.1. Removal DANGER HOT OIL under pressure may be present. Be certain truck is safely blocked and pressure is released. Some spillage of hydraulic oil may occur. 1. Raise and block lifting frame of truck. Release pressure in cylinder by activating lowering valve. 2. Disconnect battery connector from truck. Remove battery from unit to prevent accidental operation. 3. Remove electrical outer cover and inner cover. 4. Remove hydraulic line and pivot cylinder out of pocket. 5. Thoroughly clean outside of cylinder before removing hydraulic hose. 6. Place on a clean bench for disassembly. 7. Clean the exterior of the lift cylinder. WARNING Compressed air used for cleaning MUST be reduced to less than 30 psi (206 kPa), and then only with effective chip-guarding and personal protective equipment. NOTE!

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

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S6.2

6420 Lift Cylinder

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000

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1.2. Disassembly 1. Thoroughly clean outside of cylinder assembly. 2. Push cylinder rod (2) in until end of rod and lock ring (3) can be seen through inlet port. 3. Insert screwdriver in inlet port and slide lock ring (3) in deep groove in cylinder rod (2. 4. Remove cylinder rod (2) from cylinder tube (6). 5. Remove wiper seal (4) and seal (5) from inside diameter of cylinder tube (6). 6. It is not necessary to inspect wiper seal (4), seal (5) or lock ring (3). These parts should be replaced as new items and are included in the seal repair kit available for the cylinder.

1.3. Inspection 1. Thoroughly clean all parts and remove all nicks and burrs with emery cloth. 2. Inspect inside surface of cylinder tube (6) for excessive wear or scoring. 3. Inspect outside surface of cylinder rod (2) for nicks, scratches or scoring.

1.4. Assembly 1. All parts should be cleaned and dried thoroughly. Metal parts should be lightly oiled prior to reassembly. 2. Install new seal (5) on the inside diameter of cylinder tube (6). Install new wiper seal (5) with lips facing inward to bottom of cylinder tube. 3. Install new lock ring (3) in deep groove of cylinder rod end. 4. Oil outside of piston rod and carefully insert rod in tube assembly.

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5. Push cylinder rod (2) in cylinder tube (6) until lock ring (3) area of cylinder rod can be seen through port. 6. By using screwdriver through port, move lock ring (3) to lock position. 7. Extend cylinder rod (2) to full out position to make sure lock ring (3) is locked in place.

1.5. Installation 1. In order to prevent air from filling the cylinder, it is recommended to install the cylinder with rod retracted. 2. Install upper mount first and hold in place with shoulder bolt. 3. Connect hydraulic hose and use the pump to extend the cylinder. 4. Place bottom of cylinder in line with lower pocket. 5. Raise and unblock lifting frame of unit. 6. Install battery. Connect battery connector to truck. 7. Test operation of cylinder and look for leakage around fitting and cylinder rod. 8. Install inner cover and electrical outer cover.

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PT S8.0 8340 Battery Charger, Optima Pack Version no

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000

390

Battery Charger, Optima Pack For a copy of the user’s manual and guide on the Optima pack battery charger, contact the battery manufacturer.

Battery Charger Wiring Diagram - Optima Pack AC Plug

AC Junction Box

Charger

Battery

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Connector

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S10.0 10010 Handset Operation

Version no

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000

390

Handset Operation The PMC handset allows the transistor controller to be programed, tested, and diagnosed. 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.

2 Item No.

Description

PMC handset

Cable, handset

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 the three keys.

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

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

Key identifies additional information about selected items. Use this key in combination with other keys to put the programmer in special modes.

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10010

CHANGE VALVE

The handset is operated via an 8-key keypad. Three keys select operating modes (Program, Test, Diagnostics), two keys scroll the display up and down and two keys 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 that is visible even in bright sunlight. The display contrast can be adjusted 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 the Program mode, selected item is highlighted by a flashing arrow.) To modify a parameter or obtain more information about it, scroll 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. 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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M1 ACCEL RATE M1 ACCEL RATE M1 DECEL M1 DECEL

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S10.0 10010 Handset Operation

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. A LED on each CHANGE VALUE arrow key indicates whether the key is active and change is permissible. When the value of a parameter is being increased, the LED on the “up” CHANGE VALUE key is on until the maximum value for that parameter is reached. The value cannot increase when the LED goes off. The MORE INFO key has three functions: 1. Display more information about the selected item. 2. Access the Special Program and Diagnostics mode (when used together).

Special

3. 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.

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1. Operating Modes

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 and 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 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 parameter Bar graph

Set value MODE 1 ACCELERATION RATE, SECS

1.3 MIN 0.2

MAX 3.0

Maximum value

Minimum value Some controllers parameters are dependent on other parameters, available settings for one parameter may be dependent on the limits of another parameter. For example, controller may not allow the reverse speed to be set below the Mode 1 minimum speed. In this example, if there is an 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 (see “Special Program Menu” on page 230). NOTE!

Some items may not be available on all models.

In the Test mode, accessed by pressing the TEST key, realtime information is displayed about the status of the inputs, TEST 272

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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. 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) (see “Test Menu” on page 230.) 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

* MORE INFO

PROGRAM

The MORE INFO key, when used in the Diagnostics mode, causes additional information to be displayed about the selected item. For a list of the abbreviations used in the Diagnostics display see “Diagnostics and Troubleshooting” on page 225. The Special Program mode allows a variety of tasks, most of which are self-explanatory. Through the Special Program Menu, 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, when the handset is in Program mode. To distinguish between the Program and Special Program modes, look at the menu items in the display.

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CONTROLLER CLONING Two of the Special Program Menu items, Save Controller Settings in Handset and Load Handset Settings into Controller, allows “clone” controllers. To complete this function, program one controller to the desired settings. Save these settings in the handset and load 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 within the Special Program mode, it performs 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. 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. 274

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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. 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 the previous settings are not remembered, as long as the handset has not been unplugged and power has not been removed from the controller.

3. Handset Self Test

SCROLL DISPLAY

Test the handset by displaying two special test screens. Press the MORE INFO key while the handset is powering up. During the Self Test, 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 the Self Test, 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.

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

…

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Index

Drive Wheel Tire Pressing

. . . . . . . . . . . . . . . . . 137

Application Intended . . . . . . . . . . . . . . . . . . . . . 30 Prohibited . . . . . . . . . . . . . . . . . . . . . 30

B Battery Discharge Indicator . . . . . . . . . . . . . 202 Electrical . . . . . . . . . . . . . . . . . . . . 202 History Record . . . . . . . . . . . . . . . . 176 Installation . . . . . . . . . . . . . . . . . . . 173 Maintenance . . . . . . . . . . . . . . . . . . 174 Removal . . . . . . . . . . . . . . . . . . . . 173 Safety . . . . . . . . . . . . . . . . . . . . . . . 17 Storage . . . . . . . . . . . . . . . . . . . . . 176 Battery Charger . . . . . . . . . . . . . . . . . . 267 Wiring Diagram . . . . . . . . . . . . . . . . 267 Battery Connector . . . . . . . . . . . . . . . . . 189 Inspection . . . . . . . . . . . . . . . . . . . 189 Installation . . . . . . . . . . . . . . . . . . . 190 Location . . . . . . . . . . . . . . . . . . . . . 189 Battery Controller General Information . . . . . . . . . . . . . 193 Battery Pack Swing Out . . . . . . . . . . . . . . . . . . . 177 Cable Routing Diagram . . . . . . . . 179 Charger Diagram . . . . . . . . . . . . 181 Troubleshooting . . . . . . . . . . . . . 182 Brake Adjustment . . . . . . . . . . . . . . . . . . . 133

C Conversion Formulas . . . . . . . . . . . . . . . . 44 Cylinder, Lift Repair . . . . . . . . . . . . . . . . . . . . . . 264

D Data Plate . . . . . . . . . . . . . . . . . . . . . . . 32 Decals . . . . . . . . . . . . . . . . . . . . . . 85, 87 Definition Caution . . . . . . . . . . . . . . . . . . . . . . 11 Danger . . . . . . . . . . . . . . . . . . . . . . 11 Note . . . . . . . . . . . . . . . . . . . . . . . . 11 Warning . . . . . . . . . . . . . . . . . . . . . . 11 Definitions . . . . . . . . . . . . . . . . . . . . . . 224 Drive Motor Maintenance Schedule . . . . . . . . . . . . 89

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Master Service Manual

E Electrical Battery Controller . . . . . . . . . . . . . . 192 Electrical Functions . . . . . . . . . . . . . . . . 159 Adjustable Settings . . . . . . . . . . . . . 159 Electrical Schematics . . . . . . . . . . . . . . . 169 Electrical Symbols . . . . . . . . . . . . . . . . . 165

F Fasteners Designations . . . . . . . . . . . . . . . . . . 38 Strength Identification . . . . . . . . . . . . . 37 Torque Specifications . . . . . . . . . . . . . 43 Torque Values . . . . . . . . . . . . . . . . . 42 Frame/Chassis . . . . . . . . . . . . . . . . . . . . 75 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . 48

G Grease Location Points

. . . . . . . . . . . . . . 72

H Handset Operation . . . . . . . . . . . . . . . . . . . 269 Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . 253 Hydraulic System Description . . . . . . . . . . . . . . . . . . . 250 General Information . . . . . . . . . . . . . 247 Lift Limit Switch . . . . . . . . . . . . . . . . 251 Maintenance . . . . . . . . . . . . . . . . . 251 Schematic . . . . . . . . . . . . . . . . . . . 249 Troubleshooting . . . . . . . . . . . . . . . 247

I Inspection Covers . . . . . . . . . . . . . . . . . . 81

L Lubricants Cold Storage . . . . . . . . . . . . . . . . . . 56 Corrosion . . . . . . . . . . . . . . . . . . . . . 55

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Index Standard . . . . . . . . . . . . . . . . . . . . . 55 Lubrication Chart . . . . . . . . . . . . . . . . . . . 71

M Motor Drive "E" . . . . . . . . . . . . . . . . . . . . 105 Primary Sources . . . . . . . . . . . . . . . . 94 Pump . . . . . . . . . . . . . . . . . . . . . . . 97

O Oils and Grease . . . . . . . . . . . . . . . . . . . 72 Operator Protection Reverser . . . . . . . . . . . . . . . . . . . . 147

P Parking Brake System . . . . . . . . . . . . . . 131 Planned Maintenance Schedule . . . . . . . . . 59 Pump Hydraulic . . . . . . . . . . . . . . . . . . . . 253

S Safety Battery . . . . . . . . . . . . . . . . . . . . . . . 17 Static . . . . . . . . . . . . . . . . . . . . . . . . 22 Welding . . . . . . . . . . . . . . . . . . . . . . 23 Spare Parts, Ordering . . . . . . . . . . . . . . . 49 Steering Control Handle Head . . . . . . . . . . . . 146 Direction Control Switches . . . . . . . . . 149 Horn, Raise, and Lower Switches . . . . 151 Potentiometer . . . . . . . . . . . . . 153, 158 Support/Swivel Wheel Maintenance and Adjustments . . . . . . 141 Switches Master Control On/Off . . . . . . . . . . . . 209 Start/Stop . . . . . . . . . . . . . . . . . . . . 207 Symbols Caution . . . . . . . . . . . . . . . . . . . . . . 11 Danger . . . . . . . . . . . . . . . . . . . . . . 11 Ordinance . . . . . . . . . . . . . . . . . . . . 12 Prohibitory . . . . . . . . . . . . . . . . . . . . 12 Warning . . . . . . . . . . . . . . . . . . . . . . 11

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Master Service Manual

T Technical Service Data . . . . . . . . . . . . . . 47 Theory of Operation Parking Brake . . . . . . . . . . . . . . . . . 132 Torque Specifications . . . . . . . . . . . . . . . 43 Transistor Controller Basics of Circuit Operation . . . . . . . . 211 Control Circuit . . . . . . . . . . . . . . . . . 216 Maintenance . . . . . . . . . . . . . . . . . 214 Motor Circuit . . . . . . . . . . . . . . . . . . 215 Parameter Settings . . . . . . . . . . . . . 231 Technical Specification . . . . . . . . . . . 232 Troubleshooting Chart . . . . . . . . . . . 227 Troubleshooting Chart Index . . . . . . . 235 Troubleshooting Chart Using Handset . 233 Transmission Axle Seal . . . . . . . . . . . . . . . . . . . . 129 Bearing Installation Tool . . . . . . . . . . 128 Guards . . . . . . . . . . . . . . . . . . . . . 122 Repair . . . . . . . . . . . . . . . . . . . . . . 120 System Description . . . . . . . . . . . . . 119 Troubleshooting . . . . . . . . . . . . . . . 119 Wrap Around Bumper . . . . . . . . . . . . 121 Troubleshooting Battery Discharge Indicator . . . . 196, 203 Battery Pack Swing Out . . . . . . . . . . 182 Drive Motor . . . . . . . . . . . . . . . . . . . 91 Guidelines . . . . . . . . . . . . . . . . . . . 217 Hourmeter . . . . . . . . . . . . . . . . . . . 199 Hydraulic System . . . . . . . . . . . . . . 247 Support/Swivel Wheel . . . . . . . . . . . 141 Transistor Controller . . . . . . . . . . . . 235 Transmission . . . . . . . . . . . . . . . . . 119 Truck Data . . . . . . . . . . . . . . . . . . . . . . . . 30 Dimensions . . . . . . . . . . . . . . . . . . . 31 Main Components . . . . . . . . . . . . . . . 33 Truck Side Views . . . . . . . . . . . . . . . . . . 29

W Wheels Drive . . . . . . . . . . . . . . . . . . . . . . . 135 Fork . . . . . . . . . . . . . . . . . . . . . . . 143

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Back Cover

BT Prime-Mover, Inc., 3305 N. Highway 38, Muscatine, Iowa 52761-8800 U.S.A. Tel (563) 262-7700 • Fax (563) 262-7600

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