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CMX60/80 BT Prime-Mover

Service Manuals 302825-000 1995_April 302825-000 1995_August 302825-000 1998_March

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

051401

SERVICE MANUAL Manual Part Number 302825-000 CMX-65/80 CENTER CONTROL RIDER PALLET TRUCK Effective Serial Number 245334

ISSUED APRIL 1995

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CMX

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TABLE OF CONTENTS

PAGE #

Section 0.0 Maintenance 0.1 0.2 0.3 0.4 0.5 0.6 0.7

Truck Identification System Operation Specifications Maintenance and Adjustments Troubleshooting Component Removal and Installation Component Repair

0-1 0-2 0-3 0-15 0-22 0-22 0-22

Section 1.0 Transmission 1.1 1.2 1.3 1.4 1.5 1.6 1.7

Component Identification System Operation Specifications Maintenance and Adjustments Troubleshooting Component Removal and Installation Component Repair

1-2 1-6 1-6 1-6 1-7 1-7 1-13

Section 2.0 Electrical 2.1 2.2 2.3 2.4 2.5 2.6 2.7

Component Identification System Operation Specifications Maintenance and Adjustments Troubleshooting Component Removal and Installation Component Repair

2-2 2-9 2-15 2-15 2-21 2-42 2-47

Section 3.0 Hydraulic 3.1 3.2 3.3 3.4 3.5 3.6 3.7

Component Identification System Operation Specifications Maintenance and Adjustments Troubleshooting Component Removal and Installation Component Repair

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3-1 3-11 3-12 3-12 3-13 3-16 3-20

Section 4.0 Frame 4.1 4.2 4.3 4.4 4.5 4.6

PAGE # Component Identification System Operation Specifications Maintenance and Adjustments Troubleshooting Component Removal and Installation

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0.0 MAINTENANCE

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0.1

Truck Identification This repair manual covers the following BT Prime-Mover products: CMX60 AND CMX80 CENTER CONTROL RIDER PALLET TRUCKS from serial number 245334 and above. These trucks are manufactured by The Prime-Mover Company in Muscatine, Iowa, USA. The Prime-Mover Company reserves the right to change the information and specifications contained within this manual at any time without incurring any obligation relating to such changes.

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0.2

System Operation Federal and State laws require that operators be completely trained in the safe operation of lift trucks. An Operator's Manual is attached to every BT 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 The Prime-Mover Company, 3000 North Highway 61, Muscatine, Iowa, 52761-5810, (319) 262-7700. This service manual is not a training manual. The information contained in this manual is intended as a guide to help the authorized technician safely service the truck.

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0.3

Specifications 0.3.1 Transmission

CMX65

CMX80

Gear ratio

14.8:1

Oil type

GL5 85W90

Oil capacity

Approx. 1 liter

Drive tire size

10.5 X 5 X 6.5 "

10.5 X 5 X 6.5"

0.3.2 Electrical Battery amp draw:

CMX65

At top speed empty

95 amps

Lifting - full load

95 amps

Drive Motor:

CMX65

CMX80

Min. brush length

.75"

New spring tension

56 oz.

Min. commutator diameter

2.625"

Hydraulic Motor:

CMX65

CMX80

Min. brush length

.25"

New spring tension

32 - 40 oz.

Min. commutator diameter

1.5"

"Prime-Trak" hydraulic motor Min. brush length

.25"

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CMX80

CMX65

CMX80 .25"

New spring tension

32 - 40 oz.

Min. commutator diameter

1.5"

0.3.3 Hydraulic

CMX65

CMX80

Type of Fluid: Standard usage

10W40 CD

10W40CD

Freezer service

Texaco 15

Fluid capacity

approx. 1 liter

Lift relief pressure

2800 psi

3100 psi

Prime-Trak relief pressure

250 psi

0.3.4 Frame

CMX65 Truck lifting capacity

6000 lbs

8000 lbs

Lifting height travel

OAL fork height

3.25"

Top travel speed empty

7.5 mph

Top travel speed loaded

6.0 mph

Load wheel size

3.25" X 6"

Lubricating grease

Texas Refineries C & C #880

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CMX80

I N CH ( S AE ) AN D ME T R I C F AS T E N E R S

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INTRODUCTION Threaded fasteners like bolts, nuts, capscrews 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 according to its specifications. The Prime-Mover Company buys parts from many countries. There are several standards used by these countries in the manufacture of threaded fasteners. Many of these fasteners are similar, but cannot be used as direct replacement. Service persons must use replacement fasteners that have the same specifications. Fasteners made to each specification have identification marks for that specification. This specification is commonly called "Grade" for SAE standards and "property" for metric standards. This section describes the identification of some common fasteners. The metric system used by BT Prime-Mover 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. NOMENCLATURE, THREADS The thread design is specified by a series of numbers and letters for inch and metric fasteners. (See Figure 1). The diameter of the shank of the fastener is shown first in the series [M12=12mm, M20=20mm (1/2=1/2 inch, 3/4=3/4 inch)]. The number of threads per inch is normally not shown for inch nomenclature and only the UNC (Unified National Coarse) or UNF (Unified National Fine) is shown. This number of threads per inch is not shown because a UNC or UNF fastener has a standard number of threads per inch for a specific diameter. The length of a shank is often indicated as part of the description of a fastener. This length is shown in inches for inch fasteners and in millimeters for metric fasteners. A capscrew will have the following description:

A= B= C= D=

INCH

METRIC

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

M12 x 1.75 x 50 A B C

SHANK DIAMETER NUMBER OF THREADS PER UNIT OF LENGTH TYPE OF THREAD SHANK LENGTH

A= B= C=

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THREAD SIZE PITCH LENGTH

FIGURE 1 - THREAD DESIGN

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 capscrew or on a nut. Property classes less then 8.8 are often not marked. Grades for inch bolts go from 2 to 8. Grade 2 fasteners normally do not have marks. The following tables show the marks that identify the grades and property classes for different fasteners. When fasteners must be replaced, the new fasteners must be of the same strength or greater then the original fasteners. The new fasteners must also be the correct size. NOTE: IDENTIFICATION MARKS ARE ACCORDING TO BOLT STRENGTH. THE HIGHER THE NUMBER OR THE INCREASE IN THE NUMBER OF MARKS INDICATES INCREASED BOLT STRENGTH.

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TABLE 1 - BOLTS AND SCREWS

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TABLE 2 - STUDS AND NUTS

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TABLE 3 - TORQUE NUTS

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TABLE 4 - TORQUE NUTS WITH NYLON INSERT

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TABLE 5 CONVERSION TABLE FOR METRIC AND ENGLISH UNITS AREA MULTIPLY BY

TO GET

MULTIPLY BY

TO GET

inches²

6.452

centimeters² (cm²)

centimeters²

0.155

inches² (in²)

feet²

0.093

meters² (m²)

meters²

10.764

feet² (ft²)

LINEAR MULTIPLY BY

TO GET

MULTIPLY BY

TO GET

inches

25.4

millimeters (mm)

millimeter

0.039

inches (in)

feet

0.305

meters (m)

meter

3.281

feet (ft)

yards

0.914

meters (m)

meter

1.094

yards (yd)

miles

1.609

kilometers (km)

kilometer

0.621

miles (mi)

MASS MULTIPLY BY

TO GET

MULTIPLY BY

TO GET

ounces (oz)

28.35

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 BY horsepower

TO GET

0.746

MULTIPLY BY

kilowatts (kW)

kilowatts

1.34

TO GET horsepower (hp)

PRESSURE MULTIPLY BY

TO GET

MULTIPLY BY

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)

TEMPERATURE MULTIPLY BY (°Fahrenheit-32)

0.56

TO GET

° Celsius (C)

MULTIPLY BY (°Celsius x 1.8)

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+32

TO GET

°Fahrenheit (F)

TORQUE MULTIPLY BY

TO GET

MULTIPLY BY

TO GET

pound inches

0.113

Newton meter (N.m)

Newton meter

8.851

pound inches (lbf in)

pound feet

1.356

Newton meter (N.m)

Newton meter

0.738

pound feet (lbf in)

VELOCITY MULTIPLY BY miles/hour

1.609

TO GET

MULTIPLY BY

kilometer/hour (km/h)

kilometer/hour

0.621

TO GET

miles/hour (mph)

VOLUME MULTIPLY BY

TO GET

MULTIPLY BY

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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TABLE 6 TORQUE VALUES FOR COARSE THREADED METRIC FASTENERS Property, Class

Size and Pitch

Property, Class

8.8*

10.9**

Property, Class

12.9***

N.m

lbs ft

N.m

lbs ft

N.m

lbs ft

M5 x 0.8 M6 x 1

5-6 8-10

lbs in. 44-53 71-88

7-8 12-14

lbs in 62-71 106-124

8-10 14-16

lbs in 71-88 124-142

M8 x 1.25

20-25

30-35

lbs ft 22-26

34-40

lbs ft 26-30

M10 x 1.5

40-45

177-221 lbs ft 30-33

60-65

44-48

70-75

52-55

M12 x 1.75 M14 x 2

70-80 110-125

30-33 52-59

100-110 155-180

74-81 114-133

115-130 180-210

85-96 133-155

M16 x 2 M20 x 2.5

170-190 340-380

125-140 251-280

240-270 450-500

177-199 332-369

280-320 550-600

207-236 406-443

M24 x 3

580-650

428-479

800-900

590-664

900-1050

664-774

M30 x 3.5

1150-1300

848-959

1600-1800

1180-1328

1850-2100

1364-1549

M36 x 4

2000-2250

1479-1660

2800-3150

2065-2323

3250-3700

2397-2729

* Property class 8.8, Protective Treatment CMHC Specification "H" (zinc phosphate), apply also to internally threaded fasteners made of property class 8 material. **Property class 10.9, Protective Treatment CMHC Specification "H" (zinc phosphate), apply also to internally threaded fasteners made of property class 10 material. *** Property class 12.9, Protective Treatment CMHC Specification "H" (zinc phosphate), apply also to internally threaded fasteners of property class 12 material.

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0.4

Maintenance and Adjustments

0.4.1 Maintenance Planned Maintenance is a critical part of safe pallet truck operation. By following a regular schedule of planned maintenance procedures the correct and safe functioning of the pallet truck can be better assured. A good planned maintenance program will alert you to the need for adjustments and minor repairs and will greatly reduce the potential for unexpected failures. An effective planned maintenance program will include a daily inspection to be made by the operator prior to each operating shift. This should include a visual inspection for damage, leaks, and fluid levels as well as testing for the correct operation of safety devices. In addition to the operator's daily inspection a regular scheduled planned maintenance service should be performed by a qualified BT Prime-Mover technician. This service should include a thorough visual inspection, lubrication of service points, operational checks and minor adjustments. The basic planned maintenance visit should be made every 200 operating hours or once every three months. Heavy truck usage is estimated at 200 hours per month, more detailed service should be performed once a year. A comprehensive schedule of planned maintenance operations and detailed planned maintenance procedures are in the sections that follow.

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0.4.3 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. SERVICES TO BE PERFORMED DAILY OR AT EACH 8 HOUR OPERATING SHIFT: The daily inspection is to be made by the operator prior to each operating shift. It is the operator's responsibility to report any defects to the proper authorities and the truck should not be operated until it has been inspected and repaired by a qualified technician. The operator is ultimately responsible for the safe operation of this pallet truck. Battery The battery should be charged when it reaches the 80% discharged level. This is indicated on the optional Battery Discharge Indicator when the single red LED bar on the far left is illuminated. A warning will be given at the 70% discharged level by means of the two red LED bars flashing alternately on and off. If the truck is equipped with the optional Lift Interrupt then lift lockout will occur at the 80% discharged level. If the optional Battery Discharge Indicator is not mounted then the battery should be charged after 6 to 8 operating hours. Hydraulic System Inspect the entire truck for leaks; especially around the hydraulic pump assembly and the 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 and do not operate the truck until it has been inspected and repaired by a qualified technician. 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 and do not operate the truck until it has been inspected and repaired by a qualified technician. Wheels/Tires Inspect wheels and tires for wear and damage. Trash wrapped around wheels and axles will cause premature tire wear and bearing damage. Any trash should be removed before operating the truck and the floors should be kept clear of trash to prevent damage to the wheels and tires. Functions/Operations Test the truck for the proper operation of all functions; including the travel controls, lift and lower functions, the brakes and the emergency reverser button. Safety devices must be operational. Report any problems to the proper 0-18

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authorities and do not operate the truck until it has been inspected and repaired by a qualified technician. SERVICES TO BE PERFORMED MONTHLY OR EVERY 200 OPERATING HOURS: The monthly planned maintenance service should be performed by a qualified technician. Daily Inspection All of the services and inspections listed above for the daily inspection should be performed at this time. The inspection procedure should be more thorough and minor deficiencies should be corrected. Transmission Check the transmission fluid level. The level check point is a plug on the side cover of the transmission about 100 mm (4") above the bottom of the transmission case. Remove the plug and inspect the level of the fluid inside the transmission case. The fluid level should come to about 10 mm (3/8") below the plug and should never be above the level of the plug. Brakes The brakes should stop a fully loaded truck at full speed in approximately one truck length and should hold the truck from rolling on a 10% incline. The brakes should fully release when the brake control handle is in the release position. Adjust the brake linkage as required. Battery At the 200 hour or monthly service interval the specific gravity of the battery should be measured with a battery hydrometer. The difference in the highest cell and lowest cell readings should not be greater then 20 (.020) points. An average battery will have a specific gravity of 1.170 at the 80% discharged level. However, there are many different batteries on the market and only the battery manufacturer can accurately determine the fully charged and 80% discharged levels. Contact the battery manufacturer for this information. Electrical Connections All electrical connections should be checked that they are clean and tight. Plug-in connectors should be unplugged and plugged back in to clean the terminals. If the truck is equipped with any of the cold-storage, freezer use, or corrosive environment application packages then the di-electric compound in the plug-in connectors should be renewed. This compound is available through the parts department of your authorized dealer. Contactor Tips -

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Inspect contactor tips for arcing, pitting, or burning. Minor pitting of the tips is not a problem, however, if the tips are pitted through the tip to the copper bar the tips should be replaced. DO NOT file tips and replace tips only in complete sets. Some contactors have concealed tips or are fully sealed so that tips cannot be replaced. Motor Brushes Inspect the drive, the lift pump motor and the "Prime-Trak" pump motor for brush wear and condition of the commutator. Minimum brush lengths are given in the specifications section of this manual. As a rule of thumb the brushes should be replaced if the brush spring is within 1mm of touching the brush holder. Drive Motor Blow out the drive motor fan and vents. Check for any signs of oil on the drive motor fan and air vents. Check for any damage to the fan or air vents. Compressed air used for cleaning MUST be reduced to less than 30 p.s.i., and then only with effective chip-guarding and personal protective equipment. Hydraulic Reservoir Check the fluid level in the hydraulic reservoir. The level check point is the breather cap on the reservoir. Remove the breather cap and check the level of the hydraulic fluid by looking down inside the elbow that the breather cap screws into. The fluid level should come up to the bottom of the elbow when the pallet forks are fully lowered. Frame Lube The pressure type grease fittings (zerk fittings) should be lubricated with Texas Refineries #880 Crown and Chassis lubricating grease. The total number of grease fittings depends on the truck options when built. A truck with a coldstorage, freezer use, or corrosive environment application package will have more grease fittings then a standard truck. Look for flush type grease fittings on the load wheel axles and wheel fork pins. Regular fittings may be found on the ends of the pull rods at the transmission mounting bearing, and the lift cylinder mounting shafts. Pivot Points There are some pivot points and other items that need to be lubricated but do not have grease fittings. These include, but are not limited to, the brake control linkage. Lubricate these non-greasable wear points with a drip oil can using 10 wt. machine oil. SERVICES TO BE PERFORMED ANNUALLY OR EVERY 2000 OPERATING HOURS. 0-20

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The annual planned maintenance service will take a longer period of time to complete then does the monthly service. This would be a good time to arrange other repairs that have been noted on the monthly service. Daily Inspection and Monthly Inspection All of the services and inspections listed above 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. Transmission The transmission fluid should be drained. The drain port is the lower left hand bolt holding the side cover in place. Remove the bolt to drain the transmission fluid. Flush the transmission case with safety solvent by pouring clean solution into the level check plug in the side cover and allowing it to run out of the drain port while the transmission is running with the drive tire off the ground. Stop the flushing when the solution is running clean. Allow the solvent to drain well before replacing the drain plug bolt. Replace the drain plug bolt. Refill the transmission with the proper oil before operating truck. Battery At the 2000 hour, or annual service interval it is recommended that the battery be removed from the truck for cleaning. Use fresh water to wash the battery and a soft, non-conductive brush to scrub the battery. Soda may be used to neutralize acid on the outside of the battery but care must be taken so that soda and water does not enter the battery cells. Also clean the battery compartment in the truck. About every three years the battery should be inspected and serviced by the battery manufacturer's authorized service center. Hydraulic System - (Lift and "Prime-Trak") At the 2000 hour, or annual service internal hydraulic system should be drained, flushed and refilled, and the pressure relief valve setting should be checked and adjusted. Disconnect and remove the hydraulic pump assembly. Remove hydraulic reservoir from assembly. Drain the oil and clean the inside of the reservoir. Drain oil from hydraulic hose and lift cylinder. Reassemble hydraulic pump assembly and re-install on truck. Fill reservoir with proper fluid. Operate raise and lower function several times to purge air from system. Re-check fluid level. Put rated truck capacity load on forks and adjust pressure relief valve, if necessary so that truck will lift rated load.

Brakes Remove brake drum and inspect brake shoe linings and brake drum for wear. 0-21

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If the brake drum is damaged or worn a new drum should be fitted. The brake shoes should be replaced if the linings have worn down so much that the brakes will not meet stopping and holding specifications. See the procedures for adjusting brakes before replacing the brake shoes. 0.5

Troubleshooting See individual sections on transmission, electrical, hydraulic and frame for troubleshooting.

0.6

Component Removal and Installation See individual sections on transmission, electrical, hydraulic and frame for component removan and installation.

0.7

Component Repair See individual sections on transmission, electrical, hydraulic and frame for component repair.

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1.0 TRANSMISSION

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FIGURE # 1.1 TRANSMISSION ASSEMBLY

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1-1

FIG ITEM # # 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1

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1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 19 19 19 19 19 20 21 21 21 21 21 21 22 23 24 25 26 27 28 29 30 31 32

# FOR ASSY.

NAME Seal, felt Bearing Seal, felt Bearing Case, gear Dowel Key Pinion, gear Nut (Torque 50 ft./lbs.) Cover Screw, socket head (Torque 14 ft./lbs.) Plug, drain/fill pipe Bearing Washer, sealing Set, gear Bearing Ring Seal Wheel, Flat rubber drive Wheel, Urethane drive Wheel, Non-marking XLC drive Wheel, Traction-lug drive Wheel, Grip rubber shell drive Wheel, Siped rubber Wheel, drive Tire, Flat rubber Tire, Urethane Tire, Non-marking XLC drive Tire, Traction-lug drive Tire, Grip rubber shell drive Tire, Siped rubber Nut, flanged (Torque 250 ft./lbs.) Bracket, brake cable Motor, drive Drum, brake Brake assembly Cam Plate Lever Ring, retainer Spring Shoe

1-2

1 1 1 1 1 2 2 1 2 1 18 2 2 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2

Flat rubber Urethane Non-marking Traction-lug Grip rubber Siped rubber Flat rubber Urethane Non-marking Traction-lug Grip rubber Siped rubber

FIGURE # 1.2 STEERING STEM ASSEMBLY

CONNECT TO BRAKE ON FIGURE # 1.4

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1-3

FIG ITEM # # 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2

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1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 30 31 32 33 34 35 36

# FOR ASSY.

NAME Stem, handle Screw, socket flat head Pin, yoke Cotter, internal Link, pivot Bushing, flanged Washer, shim (.030) Pin, groove Pin, spring Bracket, hand brake Control head assy. with Picking Knob Control head assy. without Picking Knob Cover Handle, brake (AS SHOWN) Grip Bushing, sleeve Pivot Screw, socket head Spring Clevis Nut, jam Bar, brake link Screw, socket head Joint, ball Nut Handle, park brake Nut, clip Screw, socket flat head Knob Cover, "Prime-Trak" brake Cover, STANDARD brake Spring Nut, jam Anchor, spring Cable, brake Pin with cotter pin Screw, socket head

1-4

1 6 1 1 1 2 4 2 2 1 1 1 1 1 2 2 2 2 2 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 6

AS SHOWN

"Prime-Trak" STANDARD

1.2

SYSTEM OPERATION

The CMX65 and CMX80 center control rider pallet trucks use the same transmission. This transmission is of the double reduction type. The gears are a combination of helical and straight cut gears for strength and low noise. The final drive gear is mounted on opposing tapered roller bearings and the intermediate gear is mounted on ball bearings. Gears and bearings are enclosed in an oil filled case. The drive motor is mounted externally with the drive motor pinion gear mounted on the armature shaft. The brakes are on the drive motor. 1.3

SPECIFICATIONS

Gear Ratio Oil Type Oil Capacity Drive Tire Size 1.4

14.8:1 GL5 85W90 Approximately 1 liter 10.5" x 5" x 6.5"

MAINTENANCE AND ADJUSTMENTS

Maintenance of the transmission is limited to the planned maintenance checks of the transmission fluid level and periodic changes of the transmission fluid. If the transmission fluid is discolored or has evidence of metal contamination then it is recommended that the transmission be inspected further to determine the cause. The brake mechanism is connected directly to the transmission and is covered in this section. BRAKE THEORY OF OPERATION The brake in the CMX center control pallet truck is a cable operated design. The brake has a drum that is mounted on the drive motor armature shaft. The brake shoes are mounted on a backing plate that is bolted directly to the drive motor. This design gives excellent braking and long life since the drum and shoes are protected from dirt and other abrasive materials. Braking is accomplished by operating either one of two levers on the control handle. The levers are connected via a cable to the brake arm on the brake backing plate. The brake arm operates a cam that forces the brake shoes against brake drum. This action clamps the brake shoes against drum and provides braking any time the handle lever is operated. When the lever is released a spring inside the brake drum returns the brake shoes and linkage to the "brake released" position. The control handle stem has a parking brake lever mounted on the side towards the operator compartment. The parking brake is applied by lifting the lever and latching it in the slot provided. It is released by lifting the lever out of the latching slot and allowing it to go back down.

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BRAKE ADJUSTMENT

1.5

Disconnect battery, block drive wheel off floor and open front access door.

Place the parking brake linkage in the "brake released" position.

Loosen the cable sheath mounting nuts at the bracket by the drive motor and adjust cable to increase or decrease braking action. To increase braking action move the cable sheath away from the bracket. (Move the mounting nuts toward the end of the cable.) To decrease the braking action move the cable sheath towards the bracket. (Move the mounting nuts to allow more of the threaded end of the cable to be exposed.)

After the proper cable adjustment is made tighten the mounting nuts to prevent the cable sheath from moving.

Adjust brake interlock switch so that it operates as brakes are released and applied. The switch should close when the brakes are released.

The brake drum may be removed and the operating lever moved one spline to compensate for brake shoe wear.

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

1.6

COMPONENT REMOVAL AND INSTALLATION 1.6.1 TRANSMISSION REMOVAL AND INSTALLATION (ref. Figure #1.1 and 1.2). OVERHEAD LIFTING DEVICE CAPABLE OF LIFTING 4000 LBS. IS REQUIRED. REMOVAL 1.

Disconnect the battery.

Open access door on front of truck and lift door off hinge.

Remove cover on front of truck. 1-6

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Disconnect power cables from drive motor, label and remove from transmission case and housing. Cables may be left attached to control panel on truck.

Remove the cotter pin and pin attaching the brake cable to the brake lever at the motor. Remove the wires to the brake interlock switch and detach the brake cable bracket.

Remove six (6) socket head screws (#36) that secure handle stem to transmission pivot tube. Lift handle stem from transmission. Caution: Transmission assembly is secured to truck frame with bolts that mount control handle tube.

Use overhead lifting device to lift truck off of transmission. Bearing (Figure #1.1; item #2) may be tight on transmission tube. Transmission must be supported to keep it from falling over when tube clears truck frame.

Remove transmission from under truck.

INSTALLATION (Refer to Figure # 1.1) 1.

Place bearing cup (#4) into bore in bottom of truck frame (shown in dashed lines). Bearing cup is a slip fit and may be retained using a dab of heavy grease between cup and frame.

Place new felt seal material (#3) into groove formed by bearing cup and frame.

Press bearing cone (#4) onto transmission case. Seat bearing tight on case. Using an inductive bearing heater will facilitate this operation. Prelube bearing after installation.

Raise truck frame with overhead lifting device and position transmission under frame. Carefully lower frame onto transmission. Be careful to not dislodge bearing cup or felt seal.

Install upper bearing cup and cone assembly (#2) and felt seal material (#1) on top of transmission tube. Prelube bearing cone.

Route power cables and wires to the brake interlock switch through transmission housing tube (#5). Connect cables to drive motor. 1-7

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Install brake cable bracket, install brake interlock switch wires and attach cable to brake lever.

Install handle stem, using six (6) socket head screws (#36).

Adjust brakes and brake switch.

10.

Install floor plate.

11.

Install door.

1.6.2 DRIVE WHEEL REMOVAL AND INSTALLATION REMOVAL The drive wheel can be removed without removing the transmission by following these steps: 1.

Disconnect the battery, block truck with drive tire off floor (about 1 inch).

Open front door and remove floor plate on front of truck.

Remove axle hub and wheel retaining nut. Pull tire and wheel from axle.

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Press drive tire from wheel hub. This is usually done in the same process as pressing on a new tire. See INSTALLATION below.

INSTALLATION 1.

Press drive tire in wheel hub. This is usually done while pressing off old tire. Press hub to center of tire.

Install drive tire and hub on axle. The drive tire retaining nut should be torqued to 250 ft./lbs.

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1.6.3 AXLE SEAL REMOVAL AND INSTALLATION REMOVAL The drive axle seal can be replaced without removing the gear case cover by following these steps: Before starting disassembly of any parts thoroughly clean outside of assembly with safety solvent or other non-corrosive cleaning fluid. Air dry all parts. 1.

Drain transmission oil.

Disconnect the battery, block truck with drive tire off floor (about 1 inch).

Open front door and remove floor plate from front of truck for access.

Remove drive wheel. See Section 1.6.2.

Remove axle seal with seal puller or pry out with pry bar. Take care not to damage sealing surface or mounting bore.

INSTALLATION 1.

Check thread on hub and nut for damage.

Install new oil seal.

Install drive wheel and tire. The drive wheel retaining nut should be torqued to 250 ft./lbs.

Install side cover over drive tire. Torque to 35 ft./lbs.

Lower truck off blocks.

Refill transmission case with new oil.

Install floor plate and close front door.

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1.6.4 BRAKE SHOE REMOVAL AND INSTALLATION REMOVAL 1.

Disconnect battery and block truck with drive tire off floor (about 1 inch).

Open front door for access to drive motor and brake drum.

Engage parking brake and remove nut on brake drum.

Release parking brake.

Remove brake drum.

Lift brake shoes away from backing plate so that shoes come together in center and springs relax. Shoes can now be removed from backing plate together.

If the entire brake assembly with backing plate is to be replaced then disconnect brake cable and remove bolts holding backing plate to drive motor.

INSTALLATION 1.

If a new backing plate is to be fitted it comes with new brake shoes. Do not remove the brake shoes from the backing plate. Verify that the brake lever is mounted at the proper angle of 41° as shown below. A clip on the shaft retains the brake lever. Place backing plate with brake shoes attached into place on the drive motor. Raise each brake shoe individually and install mounting bolt into drive motor. Reconnect brake cable.

If only new shoes are to be fitted install springs to brake shoes before 1-11

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installing shoes on backing plate. Place brake shoes and springs over backing plate and press into position. Use caution to prevent springs from flying out of place.

1.7

Install brake drum and torque retaining nut to 25 ft. lbs.

Adjust brake linkage and brake interlock switch (see Section 1.4).

COMPONENT REPAIR 1.7.1 TRANSMISSION DISASSEMBLY AND ASSEMBLY DISASSEMBLY After draining gear case lubricant, thoroughly clean outside with safety solvent or other non-corrosive cleaning fluid. Air dry all parts and proceed with disassembly of transmission as follows: 1.

Remove transmission from truck. See section 1.6

Remove gear case cover.

Block transmission with gear case side down. Allow room for gears to drop between blocks.

Heat retaining collar with propane torch and press drive axle through collar and bearing. Drive axle and intermediate gear will come out together.

Remove old bearings and races from gears and case. Clean transmission case.

ASSEMBLY

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Heat bearing cone on bearing heater to facilitate installation. 1.

Install new bearings on intermediate gear.

Install new inner bearing cone on drive axle.

Install new bearing cups in transmission case.

Position transmission on work bench with gear case side up. Place drive axle and intermediate gear in case as a unit with gears meshed. Because of gear size and bearing interference these pieces cannot be installed separately.

Use Loctite #515 "gasket eliminator" on mating surface and install gear case side cover. Be sure that two dowel pins are in case to position cover. Torque cover bolts to 14 ft./lbs.

Reposition transmission case so that it rests on gear case cover.

Install drive motor in transmission case.

Install outer drive axle bearing cone and retaining collar:

Place bearing cone over shaft. Use a standard 1" x 14 nut, or reuse old nut, and bearing installation tool to push bearing on drive axle. At this time the bearing will not seat on shoulder of drive axle. Remove nut and pusher.

Install drive axle seal in transmission case.

Install collar on drive axle. Use bearing installation tool and nut to press collar on shaft. This should also press bearing down to seat on shoulder. Turn axle shaft while you torque nut to 250 ft./lbs. Control the drive axle turning by holding brake lever on drive motor.

Transmission assembly is now complete. Install transmission in truck and reinstall control handle. Route electric cables and control wiring through pivot tube. Liberally grease top and bottom bearing cones on pivot bearing. Bottom cup of pivot bearing is a slip fit in mounting frame, be certain that bearing cup has not fallen out of frame.

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2.0 ELECTRICAL

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THIS PAGE BLANK

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2.1

Component Identification The CMX65 and CMX80 electric center control rider pallet trucks use the Curtis PMC transistor controller for travel speed control. This system allows the operator infinite variable speed control. Electrical schematics and diagrams are shown on the following pages.

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FIGURE # 2.1 ELECTRICAL SCHEMATIC

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FIGURE # 2.2 ELECTRICAL SCHEMATIC SYMBOLS

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FIGURE # 2.3 ELECTRICAL ASSEMBLY

NOTE: USE HEAT CONDUCTING MATERIAL DOW #340 BETWEEN PANEL ASSEMBLY AND FRAME.

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FIG ITEM # # 1 2.3 2 2.3 3 2.3 4 2.3 5 2.3 6 2.3 7 2.3 8 2.3 9 2.3 9 2.3 10 2.3 11 2.3 12 2.3 13 2.3 14 2.3 15 2.3 16 2.3 17 2.3 18 2.3 19 2.3 20 2.3 21 2.3 22 2.3 23 2.3 24 2.3 25 2.3 26 2.3 27 2.3 28 2.3 29 2.3 30 2.3 31 2.3 32 2.3 33 2.3 34 2.3 35 2.3 36 2.3 37 2.3 38 2.3 39 2.3 40 2.3 41 2.3 42 2.3 43 2.3 44 2.3 45 2.3 46 2.3 47 2.3 48 2.3 49 2.3

NAME Panel assembly Screw, socket head Clamp Screw, cap Suppressor (used with "Prime-Trak") Harness, wire Switch, emergency disconnect Switch, key Display, gauge Display, BDI/Hourmeter lift interrupt Motor, drive Connector assembly Screw, flat head Nut Bracket, limit switch Screw machine Nut, twin Cable Cable Cable Cable Sleeve (4 feet) Cable Cable Breaker, circuit Cable Switch, "Prime-Trak" rocker Prime-Trak pump assy. Screw, thread form Jumper (NOT used on 8000 lbs. trucks) Harness, platform Plug, diode Resistor Suppressor Filter, horn Lift pump assembly Nut Clamp Lockwasher Extension, terminal Switch, overtravel Harness, backrest (optional) Clamp Switch, rocker (optional) Fitting, male wire tab Switch, sealed Nut, twin (with "Prime-Trak") Screw machine (with "Prime-Trak") Switch, sealed (with "Prime-Trak") Fitting, male wire tab (with "Prime-Trak")

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# FOR 1 4 2 2 2 1 1 1 1 1 1 1 2 2 1 8 4 1 1 1 1 As Req'd. 1 3 1 1 1 1 4 1 1 5 1 3 1 1 1 2 1 1 2 1 1 2 8 1 1 2 1 1

ASSY.

FIGURE # 2.4 ELECTRICAL PANEL ASSEMBLY

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FIG #

ITEM #

2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4

1 2 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41

# FOR ASSY.

NAME Panel Controller Controller, remanufactured Contactor Breaker, control Switch, sealed Screw, machine Nut, twin Horn Breaker, power Relay Contactor assembly, forward & rearward Nut Lockwasher Screw, cap Screw, thread form Screw Lockwasher Fitting, male wire tab Resistor assembly Spacer, horn Screw, cap Screw, cap Bracket, switch Bar, buss Bar, buss Bar, buss Bar, buss Screw, cap Suppressor Bar, buss Bar, buss Resistor, field weakening Contactor assembly, field weakening Contactor assembly, 1A Delay, time 1 sec. Cable Cable Screw, cap Decal, DO NOT STEAM CLEAN Suppressor, 15 OHM Screw, socket head

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1 1 1 1 1 1 2 1 1 2 3 1 4 8 7 2 6 6 8 1 1 17 2 1 1 1 1 1 10 2 2 1 1 1 1 2 1 1 1 1 1 1

2.2

System Operation The BT Prime-Mover CMX65 and CMX80 electric center control pallet trucks use a Curtis PMC transistor control to supply power to the series wound drive motor. This allows the operator infinite variable speed control. These trucks are equipped with the "Prime-Trak" traction control system that automatically adjusts the stabilizing caster height to regulate the load on the drive tire for easier steering and better traction depending upon the travel mode. The lift and lower functions are directly controlled by the operator with the lift controls having an automatic lift limit at 4" of lift. This can be over-ridden by the operator releasing the lift button and pressing it again to obtain the full 6" of lift. All circuits are protected against overload with automatic resetting circuit breakers. These trucks are equipped with key switches for security, emergency disconnects for safety, and brake interlock switches to prevent drive operation if the brakes are applied. During normal operation the following circuits are activated. Battery connected and emergency disconnect push button switch pulled out to "run" position. Battery positive voltage will be available via the battery positive cable, battery connector, and power cable to the positive side of the 110 amp hydraulic motor circuit breaker. A power cable is connected from the positive side of the hydraulic circuit breaker to the positive side of the 150 amp drive motor circuit breaker. A power cable connects the negative side of the hydraulic circuit breaker to the positive side of the hydraulic pump contactor and a buss bar connects the negative side of the drive motor circuit breaker to the positive side of the line contactor. Since neither contactor is energized no current is flowing, but voltage can be read across the resistor. Battery voltage is also available from the positive side of the 150 amp circuit breaker via wire #28, 12 amp circuit breaker, wire #26, emergency disconnect push button switch, and wire #27 to positive side of the key switch and battery discharge indicator input on optional BDI/HM. Because the BDI/HM display is connected directly to battery negative via wire #13 the battery discharge indicator will be illuminated to indicate the state of the battery charge.

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Key switch turned "on" With the key switch turned "on" positive battery voltage is available via the key switch and wire #6 to the brake interlock switch. Because the parking brake is not released the brake interlock switch will be open and no current will flow. Positive battery voltage is also available via the key switch and wire #6 to the lift, lower, and horn switches in the control handle, to the auxiliary lift and lower switches in the backrest handgrips. Positive battery voltage is also available via the key switch and wire #6 to the hour meter display and to the optional cold storage heater circuit. The hour meter will display the hours used but will not begin accumulating hours until the truck is operated. Parking brake released and brake interlock switch closed. With the brake interlock switch closed positive battery voltage will be available via wire #7 to the line contactor coil. Wire #13, battery negative, is connected to the other side of the line contactor coil therefore the line contactor coil is energized and the line contactor will close. When the line contactor closes positive battery voltage is available through the line contactor to the B+ terminal on the Curtis PMC controller and to the A1 terminal on the drive motor. Positive battery voltage is also available via wire #7 to the directional switch, "Prime-Trak" toggle switch and platform switch. When the "Prime-Trak" toggle switch is closed, voltage is available through the switch and wire #34 to the "Normally Closed" tips of the "Prime-Trak" relay to wire #41 to the "Prime-Trak" release solenoid (L2) which is connected to battery negative. The solenoid energizes and causes the "Normally Open" hydraulic valve to close. Voltage is also available through wire #41, a time delay, wire #40, a caster limit switch, and wire #47 to the "Prime-Trak" pump motor contactor coil (P2) which is connected to battery negative. This causes the contactor coil to energize, the contactor to close, and the "Prime-Trak" pump motor to turn on and pump oil into the stabilizing caster lift cylinders. The pump will continue to run until the stabilizing caster linkage opens the caster limit switch and power is cut off to the contactor coil. The stabilizing casters will remain in the raised position to reduce the load on the drive wheel to allow easier steering when the truck is used for order picking. When the "Prime-Trak" platform switch is closed, voltage is available through the switch and wire #35 to coil of the "Prime-Trak" relay since the relay is connected to battery negative on the other side of the coil the relay will energize. With the "Prime2-10

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Trak" toggle switch closed voltage is available through the switch and wire #34 to the "normally open" tips of the "Prime-Trak" relay to wire #18 to the "Prime-Trak" control switch located in the control handle. When the "Prime-Trak" control switch is closed voltage is available to wire #41 the time delay, to a caster limit switch wire #40, and wire #47 to the "Prime-Trak" pump motor contactor coil (P2) which is connected to battery negative. This causes the contactor coil to energize, the contactor to close, and the "Prime-Trak" pump motor to turn on and pump oil into the stabilizing caster lift cylinders. The pump will continue to run until the stabilizing caster linkage opens the caster limit switch and power is cut off to the contactor coil. The stabilizing casters will remain in the raised position to reduce the load on the drive wheel to allow easier steering until the travel controls are turned far enough to a higher travel speed to open the "Prime-Trak" control switch in the control handle or until the brakes are applied and the brake interlock switch opens. When the brake interlock switch or the "PrimeTrak" control switch opens current flow to the release solenoid is broken and the solenoid returns to its "Normally Open" state allowing the hydraulic oil to flow out of the stabilizer lift cylinders and more weight to be on the drive tire. Wire #7 also supplies voltage to the 1A bypass contactor coil, and to a terminal on the Curtis PMC controller to turn on the controller. On the CMX65 wire #7 is connected through a jumper to wire #23 and on to the time delay for the field weakening contactor coil. On the CMX80 wire #7 goes to a pressure switch, in place of the jumper, that is open when there is hydraulic pressure in the system so that the field weakening contactor coil can not energize. Although the truck is not moving the Curtis PMC controller has been turned on to recognize SRO signal inputs. Reverse travel (fork direction) switch is closed. When the reverse switch is closed to make the truck travel in the fork direction positive battery voltage is made available via wire #3 to the reverse contactor coil. Wire #3 also supplies battery positive voltage to the PMC controller to signal it that a direction has been selected. Wire #3 also supplies voltage through a diode to wire #37 and on to the hour meter run input on the hour meter/BDI. Battery negative for the reverse coil is supplied via wire #21 through the PMC controller. When the controller has satisfied its safety circuits the reverse contactor coil is energized and the reverse contactor will close. At this time the Curtis PMC controller will start "pulsing" power to the drive motor at a rate based on the accelerator potentiometer position. The PMC power circuit and the accelerator potentiometer circuit are described later. Forward travel (control handle direction) switch is closed. 2-11

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When the forward switch is closed to make the truck travel in the control handle direction positive battery voltage is made available via wire #2 to the forward contactor coil. Wire #2 also supplies battery positive voltage to the PMC controller to signal it that a direction has been selected. Wire #2 also supplies voltage through a diode to wire #37 and on to the hour meter run input on the hour meter/BDI. Battery negative for the forward coil is supplied via wire #21 through the PMC controller. When the controller has satisfied it safety circuits the forward contactor coil is energized and the forward contactor will close. At this time the Curtis PMC controller will start "pulsing" power to the drive motor at a rate based on the accelerator potentiometer position. The PMC power circuit and the accelerator potentiometer circuit are described later. Curtis PMC controller power circuits. When either the forward or reverse contactors are closed current will flow from the battery positive terminal through the battery cable, through the 150 amp circuit breaker, through the line contactor to the B+ terminal on the Curtis PMC controller. From the B+ terminal through the drive motor armature, A1 to A2, through the normally open (now closed) contacts of the chosen direction contactor; through the drive motor field coils (S1 to S2 or S2 to S1 depending on direction), through the normally closed contacts of the opposite direction contactor, to the M- terminal of the Curtis PMC controller. The current flowing into the M- terminal will be connected internally in the Curtis PMC controller to the B- terminal which is connected directly to the battery negative terminal. Inside the Curtis PMC controller a high power semi-conductor switch, consisting of an array of paralleled power MOSFET transistors, controls the current through the drive motor. The transistors are turned on and off at the rate of 15,000 times per second by the control circuitry, while the ratio of the on and off times is regulated by the input of the accelerator potentiometer. This is called Pulse Width Modulation. When the transistors are on, current flows through the drive motor and builds up energy in the motor's magnetic field. When the transistors turn off, this stored energy continues to flow in the drive motor through the freewheel, or flyback diode. Thus, the average motor current is greater then the average battery current and smooth, stepless control of the power delivered to the drive motor is achieved with very little power loss in the control components. Accelerator Potentiometer Circuits 2-12

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The accelerator potentiometer is used to signal the Curtis PMC controller of the desired motor speed. By controlling the position of the accelerator potentiometer the operator can control the travel speed of the truck. The accelerator potentiometer is connected between terminals 2 and 3 on the Curtis PMC controller. When in neutral the resistance through the accelerator potentiometer is high, approximately 5200 ohms. As the truck controls are operated to a higher travel speed the resistance through the accelerator potentiometer decreases. The resistance should decrease to below 50 ohms at full speed. The resistance of the accelerator potentiometer is used to regulate the voltage potential on terminals 2 and 3 of the Curtis PMC controller. In neutral with a high resistance through the accelerator potentiometer the voltage potential, with respect to battery negative will be 1.85 volts +/10% on terminal 3 and 5.20 volts +/- 10% on terminal 2. When the controls are operated to high speed and the resistance through the accelerator potentiometer is at a minimum the voltage potential, with respect to battery negative, will equalize at 4.3 volts +/- 10% on both terminals 2 and 3. Because the accelerator potentiometer is not polarity oriented it does not matter which lead of the potentiometer is connected to either terminal 2 or 3. A foot pedal switch is connected in the accelerator potentiometer circuit to allow limited travel speed with the "walk-along" controls when the operator is walking along side the truck. When the foot pedal is not depressed the accelerator circuit is forced to go through an additional resistor by the open foot pedal switch. This causes the accelerator circuit to not go to high speed. When the operator is standing on the foot pedal the switch is closed and full travel speed is available with the accelerator controls. Lift Pallet Forks As stated previously when the key switch is turned on battery voltage is available via wire #6 to the lift switches. When the lift switch bar or either lift switch on a handgrip is pushed the lift switch closes and positive battery voltage is supplied via wire #5 and lift limit switch to the lift contactor coil. The other side of the lift contactor coil is connected to battery negative via wire #13 or through the circuitry in the lift interrupt battery discharge indicator and so the lift contactor coil energizes and the lift pump contactor closes. If the truck is equipped with the optional lift interrupt system then the 2-13

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negative wire from the lift contactor coil is connected to the BDI/HM/Lift Interrupt gauge. If the battery voltage is above the lift interrupt threshold voltage then the lift contactor coil negative is connected to battery negative internally through the gauge/controller. If the battery voltage is below the lift interrupt threshold voltage then the lift contactor coil negative will not be connected to battery negative inside the gauge/controller. When the lift contactor closes positive battery voltage is supplied through the 150 amp circuit breaker and the lift contactor to the lift motor. The other side of the lift motor is connected to battery negative and the motor starts running and the lift pump rotates. When the pump motor runs the pallet forks will raise. When the pallet forks reach the set height of lift limit switch (full 6 inches of lift) the limit switch will open and voltage to the lift contactor coil (P1) will no longer be available causing the coil to de-energize and lifting stops. Lower pallet forks When any lowering switch bar is pushed the lowering switch closes and positive battery voltage is supplied to the lowering solenoid valve coil via wire #4. The other side of the coil is connected directly to battery negative via wire #13 and the solenoid valve energizes to release the oil in the lift cylinders, and the pallet forks lower.

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2.3

Specifications 2.3.1 Fuse and Circuit Breaker Ratings Control Circuit Breaker 12 amp Power circuit breaker (auto reset) 150 amp 2.3.2 Amp Draws (battery amps) Travel - full speed - empty Lifting - full load

CMX65

CMX80

95A 95A

2.3.3 Motor repair specifications Drive motor: Minimum brush length New brush spring tension Minimum commutator diameter

2.4

.75" 56oz 2.625"

Pump motor: Minimum brush length New brush spring tension Minimum commutator diameter

.25" 32-40oz 1.5"

"Prime-Trak" motor Minimum brush length New brush spring tension Minimum commutator diameter

.25" 32-40oz 1.5"

Maintenance and Adjustments 2.4.1 Maintenance The electrical system requires little maintenance. Connections must be kept clean and tight and electrical components should be protected from moisture. Motor brushes should be inspected for minimum length at each month planned maintenance service and the motors should be cleaned using an approved compressed air blower. If the truck is equipped with cold storage, freezer, or corrosive environment application package then the di-electric compound in the plug-in connectors should be renewed periodically. This compound is available through the parts department of your authorized dealer.

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2.4.2 Adjustments Lift Limit Switch

#1 (3") and #2 (6")

The lift limit switch is accessible by opening the door on the front of the truck. The switch operates off the lift linkage arms. To adjust switch: 1. Open door on front of truck. 2. Loosen mounting screws on limit switch and move lift limit switch away from lift linkage arm. 3. Raise pallet forks to maximum height (9 1/4"). Do not stall hydraulics against relief. 4. Adjust lift limit switch to open at this point and tighten mounting screws. 5. Close front door. Accelerator Potentiometer The accelerator potentiometer is accessible inside the control handle head by removing the switch plate. The accelerator potentiometer operates off a gear toothed shaft (rack) that is moved when the travel controls are twisted. To adjust the accelerator potentiometer: 1. Disconnect the battery. 2. Remove the six (6) outside screws securing the raise/lower/horn switch plate to the control handle head. Do not remove the center screw on the switch plate. Remove the switch plate and lay it over to one side. 3. The accelerator potentiometer leads must be disconnected from the controller before connecting an ohmmeter for adjusting. Remove the sheet metal console cover and disconnect wires #9 and #22 from the controller. 4. Connect ohmmeter leads to the accelerator potentiometer leads.

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5. In neutral the ohmmeter reading should be 5500 to 6000 ohms and will reduce to below 50 ohms as the travel controls are operated to high speed. 6. Loosen the mounting screws for the accelerator potentiometer mounting bracket and slide bracket up or down as necessary to make adjustments. Hold the bracket snug against the handle housing while taking measurements. If the slotted holes in the bracket do not allow enough adjustment then the bracket may be lifted slightly and the potentiometer drive gear can be rotated by one tooth. 7. Tighten bracket mounting screws and reassemble switch plate and covers. Brake Interlock Switch The brake interlock switch is located on the brake cable bracket at the drive motor. It is activated by the brake lever. Its purpose is to shut off electrical power to the control of the drive motor when the brake is applied by opening the control circuit. To adjust the interlock switch: 1. Turn steering fully to left for access to brake interlock switch. 2. Disconnect battery. 3. Apply parking brake. 4. Loosen the two (2) bolts holding switch to bracket. 5. Adjust switch so that it is just opened. 6. Test switch operation. Switch should close when brakes are released. Hourmeter with battery discharge indicator and lift interrupt The lift interrupt controller is built into the combination hour meter and BDI gauge. On the back of the gauge are two adjusting potentiometer labeled "discharge" and "reset". Adjustment is made by using a small screwdriver to rotate these potentiometer to the desired setting. The alphabetic settings and the linear markings are accurately calibrated and are precision repeatable from unit to unit. The RESET potentiometer on all units leaves the factory set at 2-17

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RESET "B", this means the gauge will reset to "Full" if the voltage of a newly installed battery is above 2.09 VPCl (volts per cell). Turning the potentiometer clockwise from "B" to "E" increases the voltage per cell required to reset the gauge. Turning it counterclockwise toward "A" decreases the voltage per cell required to reset the gauge. Example: With the new generation batteries, particularly those of the high acid type, open circuit voltage can be a bit higher then in lower acid batteries. In such cases, to properly align the unit to the particular battery characteristics, simply adjust the RESET potentiometer to a level above the "C" marking for reset to occur when the battery's voltage is above 2.12 VPC, the higher open circuit voltage. Example: In those circumstances when shutdowns cannot be tolerated because of the negative effect on productivity and it is necessary to use a partially charged battery, the gauge reset level can be decreased from 2.09 VPC to as low as 2.00 VPC. Though the gauge initially reads "Full" once it resets, as the equipment is used it will quickly catch up with the battery and provide a correct reading of the actual state-of-charge of the partially charged battery. Keep in mind that RESET adjustments must be made prior to connecting the battery to the equipment. RESET adjustments made after battery/equipment connection have no effect. The RESET action is instantaneous. The gauge will reset or not within seconds. If reset does not occur and it is necessary to readjust the potentiometer setting, first unplug the battery and equipment, wait at least 10 seconds, adjust potentiometer to new setting and reconnect the battery. The DISCHARGE potentiometer on all units leaves the factory set at DISCHARGE "N", this means the discharge profile is set for a final end point of 1.73 VPC, where lockout will occur. This profile has proven to be average. Turning the potentiometer clockwise from "N" to "P" decreases the depth of discharge and, in turn, the operating time of the equipment. Turning it counter-clockwise from "N" to "K" increases the depth of the discharge and, in turn, the operating time of the equipment. Example: On occasion, equipment is required for work beyond its normally assigned work cycle and time does not permit changing of battery. In these cases, lift lockout can be delayed by increasing the 2-18

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depth of discharge from the standard 1.73 VPC ("N" setting) to as low as 1.56 VPC (beyond "K" setting). Example: Equipment and battery are sized for the type of work they are used for. On occasion, equipment designated for heavy work might be used for light tasks. Lighter work means low-current drain which, in turn, means the recommended 80% depth of discharge lockout point will be at a higher voltage level. In these cases, to properly align the low-current work profile and the required higher lift lockout point, the DISCHARGE potentiometer can be adjusted to the "O" (1.78 VPC) or the "P" (1.82 VPC) settings. It is important to note that adjustments of the DISCHARGE potentiometer can be made at any time during a work cycle prior to lift lockout. However, DISCHARGE potentiometer adjustments made late in a work cycle have little or no effect in delaying lift lockout in that particular work cycle. Once lift lockout does occur, the gauge must be reset before DISCHARGE potentiometer adjustments can have an effect. TABLE OF POTENTIOMETER SETTINGS AND ASSOCIATED VOLTAGES PER CELL DISCHARGE

RESET

1.82 VPC*

2.18 VPC

1.78

2.15

N factory set

1.73

2.12

1.68

B factory set

2.09

1.63

2.06

1.57

Beyond A

2.00

Beyond K

1.56

*The DISCHARGE voltage of the unit is not an instantaneous voltage, nor a measure of the open circuit voltage at the time of lift lockout. 2-19

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Controller adjustments This figure shows the locations of the adjustment potentiometer on the PMC controller. To make the adjustments: 1. Remove the socket head screw (1/8" Allen) for the adjustment you want to make. 2. Adjust the small internal potentiometer with a small trim pot adjustment tool. This is a 270 degree turn potentiometer. NOTE: If the proper tool is NOT used to adjust these potentiometers, it is possible to damage the printed circuit board causing the controller to fail. 3. Replace the socket head screw and nylon seal washer. Tighten to 8 inch/pounds. 4. These adjustments can be made to suit the operator. Higher plugging current will mean a shorter stopping distance when plugging. This distance should not be shorter then 10 feet.

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2.5

Troubleshooting Troubleshooting can be broken down into individual circuits. By knowing the exact symptoms of the truck operation many hours of troubleshooting time can be saved. If the proper contactor operates for the chosen direction and speed then the problem can be found in the power circuit of that function. If a particular contactor does not operate when a function is chosen then the problem can generally be found in the control 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 on the following pages then go to the expanded outline and follow the testing procedures described. Voltage tests are made with the negative lead of the volt meter connected to battery negative. If the negative lead is connected to a negative terminal on the electrical panel you must first verify the negative connection to the battery by touching the positive meter lead to the positive battery post. The battery voltage must be at least 25.2 volts for a 24 volt system. If the battery voltage is below 22 volts (no load) then the controller may not operate properly. You will then have to charge the battery before starting the troubleshooting procedures. When testing voltage, the "POSITIVE SIDE" of any component refers to the terminal on that component that is closest electrically to the battery positive terminal. The "NEGATIVE SIDE" of any component refers to the terminal on that component that is farthest electrically from the battery positive terminal. It is possible, and in many cases desirable, to measure battery voltage on the negative side of a component. "Forward" direction refers to travel in the direction of the control handle with the forks trailing. "Reverse" direction refers to travel with the forks leading. After the final test is completed the truck should be repaired and operating properly. If it is not, then you must verify your test results and possibly reevaluate the failure symptoms. If you still have not repaired the truck then you should call your local BT Prime-Mover dealer for assistance. When you call, the following information is required: Truck model and serial number, service meter hours, actual battery voltage at open circuit and at hydraulic operation under full load, the precise operating symptoms, and the exact results of the testing you have done. Authorized BT Prime-Mover dealers may call the factory directly if necessary. The first steps of any troubleshooting procedure are to: 2-21

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

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.

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TROUBLESHOOTING CHART INDEX 2.5.1

Dead truck, nothing operates. No travel, no lift, "Prime-Trak" does not engage, no lower, no horn.

2.5.2

No travel, line contactor does not close. "Prime-Trak", lift, lower, and horn function okay.

2.5.3

No reverse travel (forks leading); reverse contactor will not close when travel controls are operated. The lift, lower, and horn functions work okay. "Prime-Trak" engages properly.

2.5.4

No forward travel (forks trailing); forward contactor will not close when travel controls are operated. The lift, lower, and horn functions work okay. "Prime-Trak" engages properly.

2.5.5

No reverse travel (forks leading); reverse contactor does close when travel controls are operated. The lift, lower, and horn functions work okay. "Prime-Trak" engages properly.

2.5.6

No forward travel (forks trailing); forward contactor does close when travel controls are operated. The lift, lower, and horn functions work okay. "Prime-Trak" engages properly.

2.5.7

Truck travel speed does not respond to controls properly. Contactors close for chosen direction but truck does not have full speed control.

2.5.8

"Prime-Trak" pump will not operate, when truck is not moving, and operator is off of the platform. Lift, lower and horn operate properly.

2.5.9

"Prime-Trak" pump runs, but cylinders do not extend.

2.5.10

"Prime-Trak" pump will not operate, platform switch closed, toggle switch closed and direction switch in neutral. Forward and reverse direction, lift, lower and horn operate properly.

2.5.11

"Prime-Trak" pump runs when high speed forward or reverse is selected. Forward and reverse direction, lift, lower and horn operate properly.

2.5.12 2.5.13

"Prime-Trak" pump will not operate. All other functions operate properly. Lift function does not operate.

2.5.14

Lowering function does not operate.

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TROUBLESHOOTING CHARTS 2.5.1

Dead truck, nothing operates. No travel, no lift, "Prime-Trak" does not engage, no lower, no horn. Conditions for testing: Truck raised and blocked with drive tire off ground. Battery fully charged and connected to truck. Emergency disconnect pushbutton switch pulled out to the "run" position. Key switch turned "on". Test for voltage at: A. Positive side of 150 amp power circuit breaker. Repair open power cable between battery positive terminal and 150 amp power circuit breaker. B. Positive side of 12 amp control circuit breaker, wire #28. Repair open wire #28 between 150 amp power circuit breaker and 12 amp control circuit breaker. C. Negative side of 12 amp control circuit breaker, wire #26. Replace 12 amp control circuit breaker. D. Positive side of emergency disconnect pushbutton switch, wire #26. Repair open wire #26 between 12 amp control circuit breaker and emergency disconnect pushbutton switch. E. Negative side of emergency disconnect pushbutton switch, wire #27. Replace emergency disconnect pushbutton switch. F. Positive side of key switch, wire #27. Repair broken wire #27 between emergency disconnect pushbutton switch and key switch. G. Negative side of key switch, wire #6. Replace key switch. H. If truck is not functioning re-evaluate symptoms and troubleshoot individual functions.

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2.5.2

No travel, line contactor does not close. Lift, lower, and horn function okay. Conditions for testing: Truck raised and blocked with drive tire off ground. Battery fully charged and connected to truck. Emergency disconnect pushbutton switch pulled out to the "run" position. Key switch turned "on". Test for battery voltage at: A. Positive side of brake interlock switch, wire #6. Repair wire #6 between key switch and brake interlock switch. B. Negative side of brake interlock switch, wire #7. Adjust or replace brake interlock switch. C. Positive side of line contactor coil, wire #7. Repair open wire #7 between brake interlock switch and line contactor coil. D. Negative side of line contactor coil, wire #13. Special instructions: If battery voltage is found here then repair open wire #13 to battery negative. If no battery voltage is found here then replace line contactor coil.

2.5.3

No reverse travel (forks leading); reverse contactor will not close when travel controls are operated. The lift, lower, and horn functions work okay. "Prime-Trak" engages properly. Conditions for testing: Truck raised and blocked with drive tire off ground. Battery fully charged and connected to truck. Emergency disconnect pushbutton switch pulled out to the "run" position. Key switch turned "on". Travel controls operated to travel in the reverse direction (forks leading). Test for battery voltage at: A. Wire #7 terminal on transistor controller. 2-25

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Repair open wire #7 between brake interlock switch and transistor controller. B. Positive side of reverse direction control switch, wire #7. Repair open wire #7 between brake interlock switch and reverse direction control switch. C. Negative side of reverse direction control switch, wire #3. Replace reverse direction control switch. D. Positive side of reverse contactor coil, wire #3. Repair open wire #3 between reverse direction control switch and reverse contactor coil. E. Negative side of reverse contactor coil, wire #21. Repair or replace contactor. F. Pin #3, wire #21, at seven-pin, plug-in connector on PMC controller. 0 volts - unplug seven-pin connector and retest pin #3, wire #21. If still 0 volts, repair open wire #21 between negative side of rearward contactor coil and pin #3 on seven-pin connector. Battery volts - PMC controller is failed. Verify operating sequence procedure. Verify testing procedure. Replace controller.

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2.5.4

No forward travel (forks trailing); forward contactor will not close when travel controls are operated. The lift, lower and horn functions work okay. "Prime-Trak" engages properly. Conditions for testing: Truck raised and blocked with drive tire off ground. Battery fully charged and connected to truck. Emergency disconnect pushbutton switch pulled out to the "run" position. Key switch turned "on". Travel controls operated to travel in the forward direction (forks trailing). Test for battery voltage at: A. Wire #7 terminal on transistor controller. Repair open wire #7 between brake interlock switch and transistor controller. B. Positive side of forward direction control switch, wire #7. Repair open wire #7 between brake interlock switch and forward direction control switch. C. Negative side of forward direction control switch, wire #2. Replace forward direction control switch. D. Positive side of forward contactor coil, wire #2. Repair open wire #2 between forward direction control switch and forward contactor coil. E. Negative side of forward contactor coil, wire #21. Repair or replace contactor. F. Pin #3, wire #21, at seven-pin, plug-in connector on PMC controller. 0 volts - unplug seven-pin connector and retest pin #3, wire #21. If still 0 volts, repair open wire #21 between negative side of rearward contactor coil and pin #3 on seven-pin connector. I Battery volts - PMC controller is failed. Verify operating sequence procedure. Verify testing procedure. Replace controller.

2.5.5

No reverse travel (forks leading); reverse contactor does close when travel controls are operated. The lift, lower, and horn 2-27

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functions work okay. "Prime-Trak" engages properly. Conditions for testing: Truck raised and blocked with drive tire off ground. Battery fully charged and connected to truck. Emergency disconnect pushbutton switch pulled out to the "run" position. Key switch turned "on". Travel controls operated to travel in the reverse (forks leading) direction with reverse contactor closed. Test for battery voltage at: A. Positive side of 150 amp circuit breaker. Repair open power cable between battery positive terminal and 150 amp circuit breaker. B. Negative side of 150 amp circuit breaker. Replace 150 amp circuit breaker. C. Positive side of line contactor tips. Repair open power cable between 150 amp circuit breaker and line contactor. D. Negative side of line contactor tips. Repair or replace line contactor. E. B+ terminal on transistor controller. Repair open power cable between line contactor and transistor controller. F. A1 terminal on drive motor. Repair open power cable between transistor controller B+ terminal and drive motor A1 terminal. G. A2 terminal on drive motor.

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Repair drive motor. H. S1 terminal on drive motor. Repair open power circuit between drive motor A2 terminal and drive motor S1 terminal. NOTE: This includes the normally open (N.O.) reverse contactor tips. I. S2 terminal on drive motor. Repair drive motor. J. M- terminal on transistor controller. Repair open power circuit between drive motor S2 terminal and Mterminal on transistor controller. NOTE: This includes the normally closed (N.C.) forward contactor tips. K. B- terminal on transistor controller. Special Instructions: If battery voltage is found here then repair open power cable to battery negative. If no battery voltage is found here then it is possible that the transistor controller has failed. Before replacing the transistor controller perform the tests for the accelerator potentiometer listed in chart 2.5.7. 2.5.6

No forward travel (forks trailing); forward contactor does close when travel controls are operated. The lift, lower, and horn functions work okay. "Prime-Trak" engages properly. Conditions for testing: Truck raised and blocked with drive tire off ground. Battery fully charged and connected to truck. Emergency disconnect pushbutton switch pulled out to the "run" position. Key switch turned "on". Travel controls operated to travel in the forward (forks trailing) direction with forward contactor closed. Test for battery voltage at: A. Positive side of 150 amp circuit breaker. 2-29

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Repair open power cable between battery positive terminal and 150 amp circuit breaker. B. Negative side of 150 amp circuit breaker. Replace 150 amp circuit breaker. C. Positive side of line contactor tips. Repair open power cable between 150 amp circuit breaker and line contactor. D. Negative side of line contactor tips. Repair or replace line contactor. E. B+ terminal on transistor controller. Repair open power cable between line contactor and transistor controller. F. A1 terminal on drive motor. Repair open power cable between transistor controller B+ terminal and drive motor A1 terminal. G. A2 terminal on drive motor. Repair drive motor. H. S2 terminal on drive motor. Repair open power circuit between drive motor A2 terminal and drive motor S2 terminal. NOTE: This includes the normally open (N.O.) forward contactor tips. I. S1 terminal on drive motor. Repair drive motor. J. M- terminal on transistor controller. Repair open power circuit between drive motor S2 terminal and Mterminal on transistor controller. NOTE: This includes the normally closed (N.C.) reverse contactor tips. 2-30

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K. B- terminal on transistor controller. Special Instructions: If battery voltage is found here then repair open power cable to battery negative. If no battery voltage is found here then it is possible that the transistor controller has failed. Before replacing the transistor controller perform the tests for the accelerator potentiometer listed in chart 2.5.7. 2.5.7

Truck travel speed does not respond to controls properly. Contactors close for chosen direction but truck does not have full speed control. NOTE: There are two series of tests for the accelerator potentiometer circuits. The first series will test the resistance through the potentiometer circuit and the second series will test the control voltages on the transistor controller. Resistance testing Conditions for testing: Battery disconnected from truck. Truck blocked to prevent it from rolling. Wires #9 and #22 removed from transistor controller. Access cover removed from control handle to allow access to accelerator potentiometer. Test Procedure A: Connect an ohmmeter with at least a 10K ohm scale to wires #9 and #10 that are connected to accelerator potentiometer. The purpose is to test the resistance through the accelerator potentiometer as the travel controls are operated through full range. Operate travel controls slowly and smoothly to full speed in both directions; read ohmmeter.

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Test Results: In neutral the resistance should be approximately 5000 ohms through the accelerator potentiometer. As the controls are operated to high speed the resistance through the accelerator potentiometer should drop smoothly to below fifty (50) ohms. Recommended Action: If the test indicates an open circuit between wires #9 and #10 then replace the accelerator potentiometer. If the test indicates zero (0) ohms resistance between wires #9 and #10 then replace the accelerator potentiometer. Test Procedure B: Connect one lead of the ohmmeter to wire #9 at the accelerator potentiometer and the other lead of the ohmmeter to wire #9 that was removed from the transistor controller. Test Results: The ohmmeter should indicate zero (0) ohms resistance in wire #9. Recommended Action: If the ohmmeter indicates significant resistance in this wire than repair or replace wire #9. Be sure to check wiring harness connectors for corrosion when repairing wire. Test Procedure C: Conditions for testing Same as for test A and C, except with battery plugged in, so high speed relay can be energized when platform switch is closed.

Connect one lead of the ohmmeter to wire #10 at the accelerator 2-32

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potentiometer and the other lead of the ohmmeter to wire #22 that was removed from the transistor controller. Read resistance indicated on meter and then press the high speed "platform" switch, read resistance measured on meter again. Test Results: The first resistance reading should be in the approximately of 1800 ohms and when the "platform" switch is pushed the resistance should drop to zero (0) ohms. Recommended Action: If the resistance readings are not correct then repair or replace wire #10 or #22, or repair or replace the high speed "rabbit" switch or 1800 ohm resistor in parallel with the switch. Voltage Testing Conditions for testing: Wires #9 and #22 reconnected to transistor controller. Truck raised and blocked with drive tire off ground. Battery fully charged and connected to truck. Emergency disconnect pushbutton switch pulled out to the "run" position. Key switch turned "on". Test Procedure: Connect a volt meter with at least a 20 volt DC scale to the terminals on the transistor controller with wires #9 and #22 connected. The purpose is to test the voltage differential between wires #9 and #22 as the travel controls are operated through their full range in both directions. Operate travel controls slowly and smoothly to full speed in both directions. Read volt meter. Test Results: In neutral the voltage difference should be 5 to 6 volts DC. As the controls are operated to high speed the voltage should drop to close to zero (0) volts difference. Recommended Action: 2-33

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If the test indicates proper accelerator voltage then replace the transistor controller. NOTE: Some mechanical problems, such as brake adjustment, could cause the same symptoms. Be sure that this is not the case before replacing the transistor controller. If the test indicates improper accelerator voltage then verify correct resistance tests before replacing transistor controller. 2.5.8

"Prime-Trak" pump will not operate. when truck is not moving, and operator off of the platform. Lift, lower, and horn operate properly. Conditions for test: Battery fully charged and connected to truck. Emergency disconnect pushbutton switch pulled out to the "run" position. Key switch closed. Prime-Trak toggle switch closed. Platform switch open. Directional control in neutral. Test for voltage at: A. Positive side of Prime-Trak toggle switch. Repair wire #7 between toggle switch and key switch. B. Negative side of Prime-Trak toggle switch. Replace toggle switch. C. Position 5- wire # 34 on relay. Repair wire #34 between toggle switch and position 5 on relay. D. Position 1 - wire #41 on relay. Replace relay. E. Positive side of one (1) second time delay module. Repair wire #41 between relay and one (1) second time delay module. F. Negative side of time delay module after one (1) second.

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Replace time delay module. G. Positive side of R.E.S.S. (Reduced Effort Steering System) limit switch. Repair wire #40 between time delay and limit switch. H. Negative side of limit switch. Adjust or replace limit switch. I. Positive side "Prime-Trak" pump contactor. Repair wire #47 between limit switch and pump contactor. J. Negative side of "Prime-Trak" pump contactor. 0 Volts - Replace contactor. If battery voltage IS measured here repair wire #13 between contactor and battery negative. 2.5.9 "Prime-Trak" pump runs, but cylinders do not extend. Conditions for test: Battery fully charged and connected to truck. Emergency disconnect pushbutton switch pulled out to the "run" position. Key switch closed. "Prime-Trak" toggle switch closed. Platform switch open. Directional control in neutral Test for voltage at: A. Positive side of "Prime-Trak" L2 lowering valve coil. Repair wire #41 from position 1 on relay. B. Negative side of L2 lowering valve coil. 0 volts - Replace the coil. If battery voltage IS measured here repair wire #13 between the coil and battery negative. 2-35

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2.5.10

"Prime-Trak" pump will not operate when operator is on the truck, with direction switch in neutral. Forward and reverse direction, lift, lower, and horn operate properly. Conditions for test: Battery fully charged and connected to truck. Emergency disconnect pushbutton switch pulled out to the "run" position. Key switch closed. "Prime-Trak" toggle switch closed. Platform switch closed. Directional control in neutral. Test for voltage at: A. Positive side of platform switch. Repair wire #7 between interlock switch and platform switch. B. Negative side of platform switch. Replace platform switch. C. Position 7 - wire #35 on relay. Repair wire #35 between platform switch and position 7 on relay. D. Position 8 - wire #13 on relay. 0 volts-Replace relay. If battery voltage IS measured here repair wire #13 between the relay and battery negative. E. Position 3 - wire #16 on relay. Replace relay. F. Positive side of "Prime-Trak" master switch. Repair wire #16 between relay and master switch. G. Negative side of "Prime-Trak" master switch.

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Replace master switch. H. Perform test 2.5.8 steps E thru J. 2.5.11

"Prime-Trak" pump runs when high speed forward or reverse is selected. Forward and reverse direction, lift, lower, and horn operate properly. Conditions for test: Battery fully charged and connected to truck. Emergency disconnect pushbutton switch pulled out to the "run" position. Key switch closed. "Prime-Trak" toggle switch closed. Platform switch closed. Forward or reverse direction selected. "Prime-Trak" master switch open. Test for voltage at: A. Position 3 - wire #16 on relay. 0 volts - Perform test 2.5.10 steps A thru E. B. Position 1 - wire #41 on relay. MUST be 0 volts - If battery voltage IS measured here replace relay. C. Negative side of "Prime-Trak" master switch. If battery voltage is measured here replace master switch.

"Prime-Trak" electrical power circuit 2.5.12

"Prime-Trak" pump motor will not operate. Forward and reverse, lift, lower and horn operate properly. Conditions for test: P2 contactor closed.

Test for voltage at: 2-37

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A. Power positive side of P2 contactor. Repair power wire between circuit breaker and P2 contactor. B. Power negative side of P2 contactor. 0 volts - replace P2 contactor tips If battery voltage IS measured here repair wire negative power wire between contactor and battery negative. 2.5.13 Lift function does not operate. Conditions for testing: Truck blocked to prevent it from rolling. Battery fully charged and connected to truck. Emergency disconnect pushbutton switch pulled out to the "run" position. Key switch turned "on". Lift switch bar pushed to close lift switch when stated in test. Pallet forks fully lowered with lift limit switch closed. Test for battery voltage at: A.

Positive side of lift limit switch , wire #5. Repair open wire #5 between key switch and lift limit switch.

Negative side of lift limit switch , wire #17. Adjust or replace lift limit switch.

Positive side of lift contactor coil, wire #17. Repair open wire #17 between lift limit switch and lift contactor coil.

Negative side of lift contactor coil, wire #13

Special Instructions: If truck is NOT equipped with Lift Interrupt System follow step "a". If 2-38

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truck IS equipped with Lift Interrupt System follow step "b". (a)

For trucks WITHOUT Lift Interrupt System. If battery voltage is measured here then repair open wire #13 between lift contactor coil and battery negative. If battery voltage is NOT measured here continue testing with test E.

(b)

For trucks WITH Lift Interrupt System. Test for battery voltage at terminal 6 on back of BDI gauge, wire #43. If battery voltage is NOT measured here then repair open wire #43 between lift contactor coil and BDI gauge. If battery voltage IS measured here then continue to test (c).

(c).

Test for battery voltage at negative terminal on back of BDI gauge, wire #13. If battery voltage IS measured here repair open wire #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) E.

ALL testing to resume with test O.

Positive side of 110 amp circuit breaker. Repair open power cable between battery positive terminal and 110 amp circuit breaker.

Negative side of 110 amp circuit breaker. Replace 110 amp circuit breaker.

Positive side of lift contactor.

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Repair open power cable between 110 amp circuit breaker and lift contactor. H.

Negative side of lift contactor. Replace lift contactor.

A1 terminal on lift motor. Repair open power cable between lift contactor and lift motor.

S2 terminal on lift motor. Special Instructions: If battery voltage IS measured here then repair open power cable between lift motor and battery negative. If battery voltage is NOT measured here then repair lift motor.

2.5.14

Lowering function does not operate. Conditions for testing: Truck blocked to prevent it from rolling. Battery fully charged and connected to truck. Emergency disconnect pushbutton switch pulled out 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 #6. (Test each lowering switch.) Repair open wire #6 between key switch and lowering switch. B. Negative side of lowering switch, wire #4. (Test each switch.) Adjust or replace lowering switch and bar assembly. C. Positive side of lowering valve coil. Repair open wire #4 between lowering switch and lowering valve coil. D. Negative side of lowering valve coil, wire #13. Special Instructions:

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If battery voltage IS measured here then repair open wire #13 between lowering valve coil and battery negative. If battery voltage is NOT measured here then 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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2.6

COMPONENT REMOVAL AND INSTALLATION 2.6.1 DRIVE MOTOR REMOVAL AND INSTALLATION REMOVAL 1. Disconnect the battery, block unit from moving and remove cover door. 2. Disconnect brake linkage at clevis and remove brake cable bracket from case. 3. Disconnect power cables and note their proper position. 4. Remove four (4) motor mounting bolts (motor will be loose when bolts are removed). 5. Place drive motor assembly on a bench to continue disassembly. 6. Remove locknut and pinion gear from motor armature shaft. 7. Remove locknut and brake drum from motor armature shaft. By lifting one brake shoe of the brake assembly at a time, the mounting bolts can be removed without disassembling the brake assembly. 8. Clean gasket eliminator from face of motor and transmission housing. Surfaces must be thoroughly cleaned. 9. To disassemble motor see the section in this manual covering the motor assembly. INSTALLATION The drive motor can be reinstalled without removing the gear case cover by following these steps: 1. Thoroughly clean all parts with safety solvent or other noncorrosive cleaning fluid. Air dry all parts.

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2. Install brake assembly by lifting one brake shoe at a time and installing mounting bolts.

NOTE: LOCATION OF ACTIVATING LEVER SHOULD BE AS SHOWN. 3.

Install brake drum on the armature shaft over the key.

Install pinion gear on drive motor over the key and tighten locknut. Placing a wrench on both locknuts tighten nut to 30 ft./lbs.

Apply gasket eliminator (Loctite 515) on mating faces of motor and transmission.

Slide drive motor in gear case and work it around until the pinon gear lines up with intermediate gear.

Install the four (4) motor mounting bolts and torque to 35 ft./lbs.

Connect the power cables to their proper terminal.

Install brake cable bracket and linkage.

10.

Reinstall cover door.

11.

Remove blocks, connect battery and test operation of unit.

2.6.2 DRIVE MOTOR BRUSH REMOVAL AND INSTALLATION REMOVAL 1.

Disconnect battery before beginning work.

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Remove the shields around motor end cover to expose brushes.

Remove screw holding brush lead.

Lift spring off brush, remove brush from holder.

INSTALLATION 1.

Place new brushes in holder in same orientation that old brushes were removed and tighten screws on brush leads.

2.6.3 PUMP AND MOTOR REMOVAL The hydraulic pump and motor assembly must be removed from the truck in order to separate the pump and motor. The lift frame must be fully lowered before removing pump. 1.

Lower lifting frame to release pressure in system.

Disconnect battery, remove access doors, and key switch mounting bracket.

Disconnect hydraulic hose and electrical cables. Disconnect solenoid control wiring.

Unbolt pump and motor mounting bracket and remove assembly.

Remove motor end cover for access to through bolts that hold motor to adapter.

Remove through mounting bolts and separate motor from pump adapter.

2.6.4 PUMP MOTOR BRUSH REMOVAL AND INSTALLATION The brushes are accessible under the pump motor end cover and can be replaced without separating the motor and pump. Lift the brush spring and pull brush from holder, unscrew lead and remove brush. Check that new brushes are properly seated during installation. 2.6.6 CONTACTOR TIPS 2-44

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CONTACTOR TIP REMOVAL AND INSTALLATION SHOCK HAZARD!!! Disconnect battery before doing any work on/or around contactor panel assembly. CONTACTOR TIP/BAR REPLACEMENT 1.

Contactor tips are the only serviceable part of contactors. The bars should be replaced when tips have worn through the silver contact in any area.

Disconnect buss bars from contactors.

Remove screws holding contactor cover in place.

Remove cover, being careful not to drop springs.

Install new bars and tips.

Install cover with springs in correct place.

2.6.7 DIRECTION CONTROL SWITCHES The direction control switches are mounted in the control handle head. It is not necessary to remove the head to change the switches. Refer to Figure 4.3 1.

Remove the screws around the outer edge of the switch cover plate on the control handle head. Do not remove the center screw. Lay cover to side.

Remove two screws holding forward/reverse switch bracket to housing.

Remove switch wires from wire harness plug and remove switches and bracket.

The switches may now be replaced by unbolting them from the bracket.

Reconnect switch wires and reinstall bracket in housing.

Test switch operation and adjust bracket before installing 2-45

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switch cover plate. 2.6.8 RAISE, LOWER AND HORN SWITCHES There are raise, lower, and horn switches mounted in the switch cover plate on the control handle head. There are also a set of raise and lower switches mounted in the hand grips on the operator compartment backrest. The switches in the control handle are molded into 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 the switches. To replace switches in the control handle: Refer to Figure 4.3 1.

Remove the screws around the outer edge of the switch cover plate on the control handle head. Do not remove the center screw at this time.

Remove the control handle head (See 4.6.1).

Remove center screw and nut holding switch bar retainer to cover plate. The switch bars and springs will now be free to come out.

Push wire terminals for the failed switch out of the wiring harness connector plug.

Install new switch wire terminals into plug.

Position switch bars and springs into switch cover plate and reinstall switch bar retainer with one screw and nut.

Reinstall control handle head.

Reinstall switch cover plate.

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2.7

COMPONENT REPAIR 2.7.1 DRIVE MOTOR DISASSEMBLY 1.

Remove motor brushes.

Remove four screws holding brush end bell to field housing.

Separate end bell from field housing. The armature will come out with end bell.

Troubleshooting When a motor has trouble in operation, a reasonable decision has to be made as to the proper corrective course action. We have reviewed many troubleshooting guides, and have reduced them to a few which seem to be the most effective Symptom/Cause relationships. Table 1 - Indications, causes and correction of unsatisfactory brush performance. Table 2 - Primary sources of unsatisfactory brush performance.

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TABLE #1 INDICATIONS, CAUSES AND CORRECTION OF UNSATISFACTORY BRUSH PERFORMANCE INDICATIONS IMMEDIATE CAUSES PRIMARY FAULTS Sparking

Commutator surface condition Over-commutation Under-commutation Too rapid reversal of current Faulty machine adjust 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

Etched or Burned Bands on Brush Face

Pitting of Brush Face

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

Glowing

See "Glowing at Brush Face" See "Copper in Brush Face"

Commutator surface condition

7-12-30-32

See specific surface fault in evidence. Also 50. See "Sparking" 11-14-15-16-51-52 54-58

Embedded copper

See "Copper in Brush Face"

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

7-12 38-39-41-42 46-47 57-61-62

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38-39-40-41-42

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

Severe sparking Imperfect contact with commutator Wrong brush grade Glowing at Brush Face

7-12-30-32 8-9-11 6-14-15-16-17-18-1920-21-28-29 25-27-28-29

Over-commutation Under-commutation Too rapid reversal of current

Embedded copper Rapid Brush Wear

1-2-3-43-44-45-46-4959-60 7-12-31-33 7-12-30-32

Copper in Brush Face

Commutator surface condition Bad service condition Wrong brush grade

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

Flashover at Brushes

Machine condition Bad load condition Lack of attention

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

Chattering or Noisy

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

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

INDICATIONS APPEARING AT COMMUTATOR SURFACE INDICATIONS Brush Chipping or Breakage

IMMEDIATE CAUSES Commutator surface condition Looseness in machine Vibration Chattering

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

Sluggish brush movement

Rough or Uneven Surface

1-2-3-4-17

Dull or Dirty Surface

5-44-60

Eccentric Surface

1-19-22-52

High Commutator Bar

Sparking

Low Commutator Bar Streaking or Threading of Surface

Sparking Copper or foreign material in brush face Glowing

2-25 43-44-45-46-49-59

Bar Etching or Burning

Sparking Flashover

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

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PRIMARY FAULTS

2-3-46-47-48-61 See "Glowing at Brush Face"

Bar Marking at Pole Pitch Spacing

Sparking

25-37

Bar Marking at Slot Pitch Spacing

Sparking

7-12-30-57-60

Flat Spot

Sparking Flashover Lack of attention

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

Discoloration of Surface

High temperature

See "Heating at Commutator" 44-46 60

Atmospheric condition Wrong brush grade Raw Copper Surface

Embedded copper Bad service condition Wrong brush grade

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

Rapid Commutator Wear with Blackened Surface

Burning Severe Sparking

2-3-11-14 See "Sparking"

Rapid Commutator Wear with Bright Surface Copper Dragging

Foreign material in brush face Wrong brush grade Brush vibration

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

INDICATIONS APPEARING AS HEATING INDICATIONS Heating in Windings

Heating at Commutator

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

38-41-42-53

Severe load condition Severe sparking High friction

38-41-42 7-8-9-12-20-33-45-57 10-11-36-43-45-49-5859 See specific surface fault in evidence 6-24

Poor commutator surface Depreciation High contact resistance

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PRIMARY FAULTS

18-19-20-21-27-28-29 8-19-22-25-27-28-29-37 7-13-23-34

Heating at Brushes

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

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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

TABLE 2 PRIMARY SOURCES OF UNSATISFACTORY BRUSH PERFORMANCE PREPARATION AND CARE OF MACHINE 1. 2. 3. 4. 5. 6.

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

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

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

MECHANICAL FAULT IN MACHINE 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.

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

ELECTRICAL FAULT IN MACHINE 25. 26. 27. 28. 29.

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

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MACHINE DESIGN 30. 31. 32. 33. 34. 35. 36. 37.

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

LOAD OR SERVICE CONDITION 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50.

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

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

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

2-53

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DISASSEMBLY 1. Remove the cover band from the commutator end of the motor (if equipped).

2. Use a brush hook to reach into the motor and lift the brush springs. Pull the brushes out of the brush holders. Either position the brushes outside the motor or remove the brush retaining screws and remove the brushes from the motor.

3. Scribe or center punch locating marks in the end head and the frame. Although locating marks are not always necessary because of locating pins in some motors, they can save a lot of time when the motor does not have locating pins. 4. Remove the commutator end head retaining screws. Almost all motors have a slip fit bearing at the commutator end, and the end head can be removed with very little trouble. On motors that have a shaft extension on both ends of the armature, the attachment on the commutator end of the shaft must be removed before the end head can be separated from the motor. 5. Remove the drive end head retaining screws, if necessary. Some of the 2-54

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smaller pump motors retain the drive end head with the motor through bolts. Separate the armature and drive end head as an assembly from the frame and field coil assembly.

Separate the armature from the drive end head. This operation is usually done by pressing the armature out of the drive end bearing. On some of the larger motors, the end head and bearing will have to be removed with a puller.

When a puller is used, protect the end of the armature shaft with a nut or a thick flat washer. If the shaft, coupling, or spline is damaged when removing the end head, the armature or the drive spline usually has to be replaced. Use caution and do not damage the armature.

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

PRESSING END HEAD BACK ON ARMATURE SHAFT

2-56

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8. The ventilation fans are cast aluminum. Once these fans have been pressed onto the armature, they must be heated to be removed without damage. A puller is installed and a slight pressure exerted against the fan. Use a small propane torch to heat the area of the fan around the shaft. When the fan becomes loose on the shaft, as evidenced by the puller becoming loose, it should be removed as quickly as possible.

10.

When the fan is reassembled on the shaft, make sure it is a tight fit. Use "Loctite Retaining Compound 40" or equivalent on the inside of the fan hub when reassembling fan.

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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2.7.2 CONTROLLERS No internal repairs can be made to the transistor controllers. Contact the parts department for exchange units.

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THIS PAGE BLANK

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3.0 HYDRAULICS

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FIGURE # 3.1 LIFT HYDRAULIC SCHEMATIC

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3-1

FIGURE # 3.2 LIFT HYDRAULIC SCHEMATIC SYMBOLS

COMPONENT ENCLOSURE

HYDRAULIC LINES JOINING

MOTOR (ELECTRIC)

HYDRAULIC PUMP

FILTER

RESERVOIR (VENTED) CYLINDER (SINGLE ACTING) CYLINDER (DOUBLE ACTING)

CHECK VALVE

HYDRAULIC LINES CROSSING

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3-2

FIGURE # 3.3 LIFT HYDRAULIC SYSTEM ASSEMBLY

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3-3

FIG ITEM # # 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3

1 2 3 4 5 6 7 8K 9 10K 11K K

3.3 3.3 3.3 3.3 3.3 3.3 3.3

12 13 14 15 16 17 18

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# FOR ASSY.

NAME Hydraulic pump and motor assembly Hose assembly Adapter O ring O ring Cylinder assembly Body, cylinder Ring, retainer Rod, cylinder Seal, rod Wiper, rod Kit, seal (CONTAINS ITEMS MARKED WITH "K") Screw, socket flat head Hose assembly Switch, pressure Clamp Screw, taplite Washer, flat Bolt, shoulder

3-4

1 1 1 2 1 1 1 1 1 1 1 1 3 1 1 1 1 1 1

UNIT

FIGURE # 3.4 "PRIME-TRAK" HYDRAULIC SCHEMATIC

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3-5

FIGURE # 3.5 "PRIME-TRAK" HYDRAULIC SCHEMATIC SYMBOLS

COMPONENT ENCLOSURE

HYDRAULIC LINES JOINING

MOTOR (ELECTRIC)

HYDRAULIC PUMP

FILTER

RESERVOIR (VENTED) CYLINDER (SINGLE ACTING) CYLINDER (DOUBLE ACTING)

CHECK VALVE

HYDRAULIC LINES CROSSING

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3-6

FIGURE # 3.6 PRIME-TRAK HYDRAULIC SYSTEM ASSEMBLY

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3-7

FIG ITEM # # 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6

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1 2 3 4 5 6 7 8 9 10K 11K 12 13K 14 15 16 17 18 19 20 21 22 23 24 K

# FOR ASSY.

NAME Hydraulic pump and motor assembly Elbow, 45° Adapter Hose (2 feet) Connector, wire Switch, sealed Nut, twin Cylinder assembly, with switch plate Cylinder assembly Wiper, rod Seal, rod Rod, cylinder Ring, retainer Tube, cylinder, with switch plate Tube, cylinder Screw, machine Hose Tee Adapter Screw, cap "Prime-Trak" pump & motor assembly Elbow, 90° Elbow, 90° Elbow, 90° Kit, cylinder seal (CONTAINS ITEMS MARKED WITH "K")

3-8

1 1 1 As Req'd. 2 1 1 1 1 1 1 1 1 1 1 2 2 1 1 2 1 1 1 1 1

UNIT

FIGURE # 3.7 "PRIME-TRAK" PUMP & MOTOR ASSEMBLY

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3-9

FIG ITEM # # 3.7 3.7 3.7 3.7 3.7 3.7 3.7 3.7 3.7 3.7 3.7 3.7 3.7 3.7 3.7 3.7 3.7 3.7 3.7 3.7 3.7 3.7 3.7 3.7 3.7 3.7 3.7 3.7

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1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 * 18 19 20 21 22 23 24 25 26 27

# FOR ASSY.

NAME Pump assembly Cap, relief valve O ring Screw, adjusting valve Spring Ball Seal, oil Ball Spring Plug Valve, NO solenoid Coil Screw, flat head Bracket, mounting Spacer Coupler Motor assembly Set, brush Boot Cable assembly Switch Assembly Solenoid Wire assembly Screw, socket head Lockwasher Pin, dowel Adapter, pump Screw, socket head

3-10

1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 2 1 1 1 1 2 2 1 1 2

UNIT

3.2 SYSTEM OPERATION 3.2.1 Raise pallet forks When the lift pump and motor are running, 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 reservoir by the closed relief valve and lowering valve. The oil continues to flow to the base of the cylinder and pushes against the end of the cylinder rod to extend the rod from the cylinder barrel. When the motor is shut off and the gear pump is not turning, the cylinder is held extended by the closed check valve and normally closed lowering valve. 3.2.2 Lower pallet forks Hydraulic fluid is retained in the hydraulic cylinder by the check valve and electrical solenoid lowering valve. When the solenoid is energized, an oil passage from the cylinder to the reservoir is opened. Due to the load on the lift cylinder, fluid is forced out of the cylinder and back to the reservoir while the cylinder is retracting. This process allows the machine to lower. 3.2.3 "Prime-Trak" The "Prime-Trak" traction control system is a hydraulic powered linkage that changes the pressure of the stabilizing casters depending on the travel speed of the truck. The system is contolled by a switch in the accelerator control linkage. When the truck is at rest with the brakes released power is supplied to close a normally open hydraulic solenoid (L2) and the "Prime-Trak" hydraulic motor is engaged after a short time delay. When the hydraulic motor runs, fluid is forced by the pump into the "Prime-Trak" caster cylinders causing the casters to carry more of the truck weight thus making the truck easier to steer as weight is taken off the steer wheel. The pump motor is turned off when the "Prime-Trak" linkage opens a limit switch at its full lift height. When the travel controls are operated to select a faster travel speed a switch in the control handle opens and removes electrical power from the "Prime-Trak" lift contactor and from the solenoid valve. The valve returns to its normally open state and allows fluid to leave the caster cylinders. 3-11

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This allows more weight on the drive tire to assure good traction for stopping. 3.3 SPECIFICATIONS Hydraulic fluid type Standard truck Freezer application

HYDO 32 Texaco 15

Hydraulic fluid capacity

1 quart

Lift system relief pressure

CMX65 - 2800 PSI CMX80 - 3100 PSI

"Prime-Trak" relief pressure. 3.4

250 PSI

MAINTENANCE AND ADJUSTMENTS 3.4.1 Maintenance The hydraulic fluid level must be checked periodically; see the Planned Maintenance Schedule. If the reservoir regularly requires the addition of oil to maintain the proper level then a leak is indicated and must be repaired. When scheduled, the reservoir should be removed and drained for cleaning. When the system is refilled, or if the truck seems to not lift a full load, then the pressure relief setting should be checked and adjusted. During normal operation the pressure relief setting will not change. As the pump wears with age some loss of pressure and volume will be experienced. When this loss becomes severe the pump should be replaced. 3.4.2 Adjustments The only adjustment is the pressure relief setting. This adjustment is made by removing the screw cap on the pressure relief valve and turning the screw to make the adjustment. Turning the screw in clockwise will increase the pressure relief setting.

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3.5

TROUBLESHOOTING (lift and "Prime-Trak") NOTE: Proper care and cleanliness should be observed in servicing so as to insure the oil does not become contaminated. Dirt or other foreign material can be drawn in the pump so as to stick or score pump which will cause failure of the pump assembly. IF HYDRAULIC PUMP ASSEMBLY DOES NOT OPERATE PROPERLY A FEW PRELIMINARY CHECKS SHOULD BE MADE: 1. 2. 3.

Proper oil level All electrical connections tight Battery fully charged

After the preliminary check is accomplished, install a 0-5000 PSI pressure gauge in the pressure line near the 1/8" NPTF outlet port in the adapter. The installation of the pressure gauge is required to insure proper observation of what is occurring in the unit during trouble shooting. Start the pump and raise the cylinder to its upper limit stops to develop maximum pressure of the unit, which will normally be passing all flow over the relief valve. The pressure gauge should be reading the set pressure of the relief valve. Remove pressure on the system by actuating the solenoid operated release valve. The normal troubles that may occur with the pump assembly have been grouped under three headings: Failure to (A) Raise (B) Hold (C) Lower the load. One or more of the listed trouble sources may be causing improper operation. Refer to the proper heading (i.e. relief valve) for detailed instructions for disassembly, check and adjustment of parts to remedy the trouble. A.

If pump operates but will only develop low pressure or slow lift: 1.

Relief valve seat scored, foreign particles under ball or relief valve out of adjustment (see relief valve).

Dirt in solenoid operated release (see solenoid operated release valve).

Pump worn - replace pump.

If pump develops pressure but will not hold:

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Dirt in solenoid operated release (see solenoid operated release valve).

Relief valve seat scored, foreign particles under ball or relief valve out of adjustment (see relief valve).

If pump develops pressure but will not release load: 1.

No electrical contact to solenoid operated release valve (see solenoid operated release valve).

Solenoid in solenoid operated release valve burned out.

Relief valve bottomed causing pressure to go beyond the unloading limit of the solenoid release valve (see relief valve).

RELIEF VALVE Remove hex cap on relief valve. 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 bottoming position. If the trouble is not remedied by the relief valve adjustment, remove adjustment screw and spring and ball. Valve seat should be clean and not scored. Replace spring and ball in cavity. Insert 1/4" drive pin punch down through spring coils and hold ball against valve seat. Tap gently on drive pin punch with ball peen hammer to seat the ball. Reassemble the relief valve parts. Adjust relief valve and recycle the pump per above. Do not operate motor/pump at relief valve setting any longer then is necessary (NO LONGER THEN 10 SECONDS AT ANY ONE PERIOD). REMOVING SOLENOID OPERATED RELEASE VALVE. Clean surface around valve before starting to avoid foreign matter from falling into cavity. Disconnect wires from terminals on coil, loosen and remove nut. Remove coil. Using wrench on flat surface, loosen and remove tube subassembly unit. Inspect and clean or replace strainer as required. INSTALL SOLENOID OPERATED RELEASE VALVE. Clean and inspect valve cavity to be sure it is free of all foreign matter. CAUTION: DO NOT BEND OR APPLY PRESSURE TO CENTER STUD OR HOLD CARTRIDGE BODY ANY PLACE BUT ON FLAT SIDES OF SUB3-14

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ASSEMBLY. Be sure o-ring and Teflon ring are in place. Apply a small amount of clean grease to all three rings. Be sure strainer is in place. Hand screw subassembly in place and tighten to a maximum of 35 ft./lbs. for die cast metal. Assemble coil on spool assembly and tighten nut to a maximum of 5 ft./lbs. Connect wires to terminals on coil.

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3.6

COMPONENT REMOVAL AND INSTALLATION 3.6.1 LIFT PUMP AND MOTOR REMOVAL AND INSTALLATION The hydraulic pump and motor assembly must be removed from the truck in order to separate the pump and motor. The lift frame must be fully lowered before removing pump. 1.

Lower the lifting frame to release pressure in system.

Disconnect battery, open front door, remove access covers.

Disconnect hydraulic hose and electrical cables. Disconnect solenoid control wiring.

Unbolt pump and motor mounting bracket and remove assembly.

3.6.2 REMOVING AND INSTALLING RESERVOIR AND LIFT PUMP It is necessary to remove the reservoir for access to the pump. REMOVING RESERVOIR Drain reservoir of oil. Set unit in vertical position with reservoir end up. Remove four 1/4" screws holding on reservoir. Tap reservoir lightly to loosen. Wiggle the reservoir sideways while pulling up at the same time. REMOVING THE LIFT PUMP Remove pump inlet tube. Remove screws holding pump to adapter. Lift pump off. INSTALLING THE LIFT PUMP Oil o-ring lightly and install on pump pilot. Align splines on motor drive and pump shaft. Gently push pump pilot in adapter. When pump is flush with adapter, pump and motor are connected. Replace screws, torque to 10-12 ft./lbs. Check strainer for clogging. Wash in suitable solvent, blow out with 30 P.S.I air hose from inside out. Insert inlet tube in pump. INSTALLING THE RESERVOIR 3-16

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Examine the inside leading edge of reservoir for any burrs or nicks that may cut o-ring during installation. Wipe the inside of the reservoir clean.

Oil the o-ring in the groove on adapter.

Start the reservoir over the flange on the adapter up to the o ring. Make sure it is aligned properly with the holes as well as not cocked.

Rest a block of wood on the back of the reservoir and strike it squarely with a sharp blow in the center of the reservoir end. The reservoir should move into position.

Install four (4) screws in position and tighten to snug condition.

REMOVING "PRIME-TRAK" PUMP ASSEMBLY 1. 2. 4. 5. 6. 7.

Open front door. Drain oil from lift hydraulic reservoir. Disconnect fitting (#24 figure 3.5) from the pump. Disconnect fitting (#23 figure 3.5) from the pump. Remove bolts (#20 figure 3.5) from under the truck. Remove pump from the truck.

REMOVING THE "PRIME-TRAK" PUMP Remove pump inlet tube. Remove screws holding pump to adapter. Lift pump off. INSTALLING THE "PRIME-TRAK" PUMP Oil o-ring lightly and install on pump pilot. Align splines on motor drive and pump shaft. Gently push pump pilot in adapter. When pump is flush with adapter, pump and motor are connected. Replace screws, torque to 10-12 ft./lbs. Check strainer for clogging. Wash in suitable solvent, blow out with 30 P.S.I air hose from inside out. Insert inlet tube in pump.

INSTALLING "PRIME-TRAK" PUMP ASSEMBLY

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1. 2. 3. 4. 5. 6.

Place pump in frame of truck. Install bolts (#20 Figure 3.5) from under side of truck. Connect fitting (#23 Figure 3.5) to the pump. Connect fitting (#24 Figure 3.5) to the pump. Fill hydraulic reservoir with proper oil. Test for proper operation and leakage at the fittings.

3.6.3 LIFT CYLINDER REMOVAL Reference Figures #3.3 and #4.1 1.

Raise and block lifting frame of truck. Release pressure in cylinder by activating lowering valve.

Block the carrier frame so it will not tip when the lift cylinder links are removed.

Disconnect and remove battery from unit to prevent accidental operation.

Remove front door and plastic cover. HOT OIL under pressure may be present. Be certain truck is safely blocked and pressure is released. Some spillage of hydraulic oil may occur.

Remove hydraulic line.

Remove bolt securing lift cylinder rod to the carrier frame.

Remove the set screws (#8 Figure 4.1) securing pins (#2 Figure 4.1).

Remove pins (#2 Figure 4.1) from the carrier frame and lift frame.

Remove lift cylinder and upper links from the truck.

10.

Thoroughly clean outside of cylinder before removing hydraulic hose.

The bushing in the upper links can be replaced at this time as well as resealing the lift cylinder.

3-18

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11.

Place on a clean bench for disassembly.

CYLINDER INSTALLATION 1.

In order to prevent air from filling the cylinder it is recommended to install the cylinder with rod retracted.

Install upper links on cylinder, install pins (#2 Figure 4.1) and new set screws (#8 Figure 4.1).

Connect hydraulic hose and use the pump to extend the cylinder.

Install bolt securing cylinder rod to the carrier frame.

Raise and unblock lifting frame of unit.

Install and connect battery to unit.

Test operation of cylinder and look for leakage around fitting and cylinder rod.

Install front door and plastic cover.

"PRIME-TRAK" CYLINDER REMOVAL Reference Figure 4.2 1. 2. 3. 4. 5. 6. 7.

Open front door. Disconnect battery. Jack up truck so casters are 2"-3" off of the floor. Disconnect hydraulic hoses from cylinders. Loosen jam nut (#13). Loosen cap screw (#14). Remove cylinder from truck.

"PRIME-TRAK" INSTALLATION 1. 2. 3. 4. 5. 6.

In order to prevent air from filling the cylinder it is recommended to install the cylinder with rod retracted. Place cylinder in caster spring. Connect hydraulic hoses to the cylinders. Lower truck to the floor. Adjust caster springs as per instructions on page 4.8. Test operation of cylinder and look for leakage around fitting and 3-19

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cylinder rod. 3.7

COMPONENT REPAIR 3.7.1 The pumps have no serviceable parts. If repair is necessary a new pump should be installed. 3.7.2 LIFT AND "PRIME-TRAK" CYLINDER DISASSEMBLY 1.

Thoroughly clean outside of cylinder assembly.

Position rod so end of rod and snap ring can be seen through inlet port.

Insert screwdriver in inlet port and slide snap ring into deep groove in rod assembly.

Remove rod assembly from barrel assembly.

Remove wiper seal and seal from inside diameter of barrel assembly.

It is not necessary to inspect wiper seal, seal or lock ring. These parts should be replaced as new items and are included in the seal repair kit available for this cylinder.

INSPECTION 1.

Thoroughly clean all parts and remove all nicks and burrs with emery cloth.

Inspect inside surface of barrel assembly for excessive wear or scoring.

Inspect outside surface of rod for nicks, scratches or scoring.

ASSEMBLY 1.

All parts should be cleaned and dried thoroughly. Metal parts should be lightly oiled prior to reassembly.

Install new seal in inside diameter of barrel. Install new wiper seal with lips facing inward to bottom of barrel.

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Install new lock ring in deep groove of rod end.

Oil outside of piston rod and carefully insert rod in barrel assembly.

Push rod in barrel assembly until snap ring area of rod can be seen through port.

By using screwdriver through port, move snap ring to lock position.

Extend rod to full out position to make sure snap ring is locked in place.

3-21

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4.0

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FRAME

FIGURE # 4.1 FRAME ASSEMBLY

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4-1

FIG ITEM # # 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1

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1 2 2 3 4 5 5 6 6 7 8 9 9 10 11 11 12 12 12 12 12 12 13 14 15 16 17 17 18 19 20 21 22 23 24 25 25 26 26 27 28 29 30 31

# FOR ASSY.

NAME Frame, lift Pin Pin (FREEZER/ CORROSION) Bushing, iron Bushing, iron Fork, load wheel Fork, load wheel 84"/94" Pin, load wheel Pin, load wheel (FREEZER/ CORROSION) Fitting, grease Screw, set Pin, concentric Pin, concentric (FREEZER/ CORROSION) Fitting, grease Pin Pin (FREEZER/ CORROSION) Rod, pull (for 36" long fork) Rod, pull (for 42" long fork) Rod, pull (for 48" long fork) Rod, pull (for 84",93" long fork) Rod, pull (for 96" long fork) Rod, pull (for 1150mm long forks) Link, lower Bearing Link, upper Link, upper Frame, carrier 27/28 Frame, carrier 22/23 Isolator Screw, socket lock Shim Bracket, harness Screw, cap Nut Clamp Pin, lower link Pin, lower link (FREEZER/ CORROSION) Pin, lower link Pin, lower link (FREEZER/ CORROSION) Bushing, iron Fitting, 90° grease Isolator Screw, thread form Bracket, limit switch

4-2

1 4 4 12 4 2 2 2 2 2 14 2 2 17 2 2 2 2 2 2 2 2 4 2 1 1 1 1 2 3 2 1 1 1 1 2 2 2 2 8 8 2 2 1

36" forks 42" forks 48" forks 84",93" forks 96" forks 1150mm

27" Wide 22" Wide

FIGURE # 4.2 CASTER TORSION ROD ASSEMBLY

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4-3

FIG ITEM # # 4.2 4.2 4.2 4.2 4.2 4.2 4.2 4.2 4.2 4.2 4.2 4.2 4.2 4.2

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

# FOR ASSY.

NAME Nut, hex Frame, carrier Pivot Screw, cap Bushing Bar, torsion Screw, cap Caster, solid Nut, hex Spring, suspension "Prime-Trak" hydraulic system assembly Retainer, spring (without "Prime-Trak") Nut, hex Screw, cap

4-4

4 1 2 4 2 1 8 2 8 2 1 2 2 2

FIGURE # 4.3 CONTROL HANDLE HEAD ASSEMBLY

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4-5

FIG ITEM # #

NAME

4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3

Cover Spring Bracket Screw, self tapping Pin, roll Cam Return Spring, return Housing, switch Bushing Shaft, cam Control, thumb Pin, threaded Block Coupler Pin, roll Grip, fixed Knob assembly Screw, flat head Screw, socket (not part of handle assy.) Guard Screw, shoulder Pin, roll Potentiometer and wires Gear Bracket, potentiometer Screw, machine Lockwasher Bracket Switch, "Prime-Trak" Nut Switch, forward Spacer Switch, rearward Heater, freezer pkg. Switch, lower Screw, flat head Cover Switch, lift Spring, return Switch, horn Bracket, switch Nut Clamp, cable Harness, head

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1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45

# FOR ASSY.

4-6

1 4 1 6 3 1 1 1 1 2 1 2 2 2 2 2 2 2 8 2 1 1 1 1 1 1 4 8 1 1 4 1 1 1 1 1 9 1 1 6 1 1 1 1 1

4.2

SYSTEM OPERATION The center control rider pallet trucks use a hydraulic cylinder coupled through a series of linkages to a lifting frame to lift the forks a maximum of six (6) inches. Support at the ends of the forks is provided by the 6 inch wide load wheels. The carrier frame is stabilized with casters that are load compensated by the "Prime-Trak" system.

4.3

SPECIFICATIONS Lowered height Lifting height Load wheel dimensions Drive tire dimensions

4.4

3.25 inches 6 inches 3.25 x 6 inches 10.5 x 5 x 6.5 inches

MAINTENANCE AND ADJUSTMENTS Normal maintenance of the truck frame consists of lubricating the bushings on the lift linkages periodically. See Planned Maintenance Schedule. If the optional lube or cold storage package has not been fitted on the truck during production then lubrication consists of dripping 10 wt. machine oil onto the pivot points so that it soaks into the bushings. In wet or corrosive environments it will be necessary to reduce the time between planned maintenance intervals. 4.4.1 Caster adjustment Reference Figure 4.2 1. Loosen lock nuts (#13) and cap screws (#14) until they are free of the cylinder rod (#11). 2. Tighten bolts (#14) until they contact the "Prime-Trak" cylinder rod (#11), then four (#4) full turns for proper caster adjustment.

4.5

TROUBLESHOOTING Very little troubleshooting is necessary on the frame assembly. Most faults can be found by visual inspection. These usually are evidenced by unequal fork height or improper raised or lowered height. The usual cause is wear in the bushings of the pull rod linkages connecting the rear of the fork frame to the load wheels. Other problems, such as slow raise and lower speeds and excessive noise during operation can also be caused by lack of lubrication which will lead to more serious problems if not quickly corrected. Occasionally a truck with unequal fork heights will be found to have been bent by overloading one fork. This condition may not be repairable.

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4.6

COMPONENT REMOVAL AND INSTALLATION 4.6.1 CONTROL HANDLE HEAD Remove the six screws around the outer edge of the front switch bar cover on the control handle head. Do not remove the center screw. Lift the cover off. Remove two socket head screws accessible from inside the head assembly that bolt the head to the handle. Lift the head assembly away from the handle and disconnect the wiring harness plug before removing head from handle. Reassemble in reverse order. 4.6.2 LOAD WHEELS The load wheel is a single wheel with a ball bearing at each end. Removal is accomplished by raising the forks to the maximum height. Block the forks in a safe manner and remove set screw out of the axle shaft and remove axle. When pressing bearings into the load wheel the sealed side of the bearing goes to the outside. Re-install wheel and axle. Screw in set screw to lock axle in place. 4.6.3 PULL ROD BUSHINGS PULL ROD BUSHINGS REMOVAL AND REPLACEMENT (Reference Figure #4.1) To replace pull rods and/or bushings it is easiest to work with machine upside down. Remove battery before turning truck over. Some hydraulic oil may leak from hydraulic reservoir. 1.

Remove set screws (#8) securing pins (#2,11, 26).

Remove pins (#9, 11, 25)

Remove the wheel fork (#5), load wheel , pull rod (#12) and lower links (#13) as an assembly.

Remove set screws (#8) securing pins (#9, 25).

Remove pins (#9, 25).

Install new bushings and set screws in pull rods, lower links, and wheel forks.

Re-assemble pull rods, lower links, wheels, and wheel forks.

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Re-connect assembly to lift frame.

Place truck upright and install the battery, connect battery, test operation of the lift frame.

4.6.4 CARRIER FRAME BUSHINGS The bushings on the upper links of the carrier frame can be replaced by removing the links and lift cylinder. See section 3.6.3 Lift Cylinder rremoval.

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4-10

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THE PRIME-MOVER CO. 3000 NORTH US HIGHWAY 61 MUSCATINE, IOWA 52761-5810

PROUDLY Made in AMERICA

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SERVICE MANUAL Manual Part Number 302825-000 CMX-65/80 CENTER CONTROL RIDER PALLET TRUCK Effective Serial Number 245334

ISSUED AUGUST 1995

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CMX

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TABLE OF CONTENTS

PAGE #

Section 0.0 Maintenance 0.1 0.2 0.3 0.4 0.5 0.6 0.7

Truck Identification System Operation Specifications Maintenance and Adjustments Troubleshooting Component Removal and Installation Component Repair

0-1 0-2 0-3 0-15 0-22 0-22 0-22

Section 1.0 Transmission 1.1 1.2 1.3 1.4 1.5 1.6 1.7

Component Identification System Operation Specifications Maintenance and Adjustments Troubleshooting Component Removal and Installation Component Repair

1-2 1-6 1-6 1-6 1-7 1-7 1-13

Section 2.0 Electrical 2.1 2.2 2.3 2.4 2.5 2.6 2.7

Component Identification System Operation Specifications Maintenance and Adjustments Troubleshooting Component Removal and Installation Component Repair

2-2 2-9 2-15 2-15 2-21 2-42 2-47

Section 3.0 Hydraulic 3.1 3.2 3.3 3.4 3.5 3.6 3.7

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Component Identification System Operation Specifications Maintenance and Adjustments Troubleshooting Component Removal and Installation Component Repair

3-1 3-11 3-12 3-12 3-13 3-16 3-20

Section 4.0 Frame 4.1 4.2 4.3 4.4 4.5 4.6

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PAGE # Component Identification System Operation Specifications Maintenance and Adjustments Troubleshooting Component Removal and Installation

4-1 4-7 4-7 4-7 4-7 4-8

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iii

0.0 MAINTENANCE

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0.1

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0-2

0.2

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0-3

0.3

Specifications 0.3.1 Transmission

CMX60

CMX80

Gear ratio

14.8:1

Oil type

GL5 85W90

Oil capacity

Approx. 1 liter

Drive tire size

10.5 X 5 X 6.5 "

10.5 X 5 X 6.5"

0.3.2 Electrical Battery amp draw:

CMX60

At top speed empty

95 amps

Lifting - full load

95 amps

Drive Motor:

CMX60

CMX80

Min. brush length

.75"

New spring tension

56 oz.

Min. commutator diameter

2.625"

Hydraulic Motor:

CMX60

CMX80

Min. brush length

.25"

New spring tension

32 - 40 oz.

Min. commutator diameter

1.5"

"Prime-Trak" hydraulic motor

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CMX80

CMX60

CMX80

Min. brush length

.25"

New spring tension

32 - 40 oz.

Min. commutator diameter

1.5"

0-4

0.3.3 Hydraulic

CMX60

CMX80

Type of Fluid: Standard usage

10W40 CD

10W40CD

Freezer service

Texaco 15

Fluid capacity

approx. 1 liter

Lift relief pressure

2800 psi

3100 psi

Prime-Trak relief pressure

250 psi

0.3.4 Frame

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CMX60

CMX80

Truck lifting capacity

6000 lbs

8000 lbs

Lifting height travel

OAL fork height

3.25"

Top travel speed empty

7.5 mph

Top travel speed loaded

6.0 mph

Load wheel size

3.25" X 6"

Lubricating grease

Texas Refineries C & C #880

0-5

INCH (SAE) AND METRIC FASTENERS

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0-6

A= B= C= D=

INCH

METRIC

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

M12 x 1.75 x 50 A B C

SHANK DIAMETER NUMBER OF THREADS PER UNIT OF LENGTH TYPE OF THREAD SHANK LENGTH

A= B= C=

THREAD SIZE PITCH LENGTH

FIGURE 1 - THREAD DESIGN

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0-7

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0-8

TABLE 1 - BOLTS AND SCREWS

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0-9

TABLE 2 - STUDS AND NUTS

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0-10

TABLE 3 - TORQUE NUTS

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0-11

TABLE 4 - TORQUE NUTS WITH NYLON INSERT

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0-12

TABLE 5 CONVERSION TABLE FOR METRIC AND ENGLISH UNITS AREA

MULTIPLY BY

TO GET

MULTIPLY BY

TO GET

inches²

6.452

centimeters² (cm²)

centimeters²

0.155

inches² (in²)

feet²

0.093

meters² (m²)

meters²

10.764

feet² (ft²)

LINEAR

MULTIPLY BY

TO GET

MULTIPLY BY

TO GET

inches

25.4

millimeters (mm)

millimeter

0.039

inches (in)

feet

0.305

meters (m)

meter

3.281

feet (ft)

yards

0.914

meters (m)

meter

1.094

yards (yd)

miles

1.609

kilometers (km)

kilometer

0.621

miles (mi)

MASS

MULTIPLY BY

TO GET

MULTIPLY BY

TO GET

ounces (oz)

28.35

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 BY horsepower

TO GET

0.746

MULTIPLY BY

kilowatts (kW)

kilowatts

1.34

TO GET horsepower (hp)

PRESSURE

MULTIPLY BY

TO GET

MULTIPLY BY

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)

TEMPERATURE

MULTIPLY BY (°Fahrenheit-32)

0.56

° Celsius (C)

MULTIPLY BY

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TO GET

MULTIPLY BY (°Celsius x 1.8) TORQUE

TO GET

+32

MULTIPLY BY

0-13

TO GET

°Fahrenheit (F)

TO GET

pound inches

0.113

Newton meter (N.m)

Newton meter

8.851

pound inches (lbf in)

pound feet

1.356

Newton meter (N.m)

Newton meter

0.738

pound feet (lbf in)

VELOCITY MULTIPLY BY miles/hour

1.609

TO GET

MULTIPLY BY

kilometer/hour (km/h)

kilometer/hour

0.621

TO GET

miles/hour (mph)

VOLUME MULTIPLY BY

TO GET

MULTIPLY BY

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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0-14

TABLE 6 TORQUE VALUES FOR COARSE THREADED METRIC FASTENERS Size and Pitch

Property, Class 8.8*

Property, Class 10.9**

Property, Class 12.9***

N.m

lbs ft

N.m

lbs ft

N.m

lbs ft

M5 x 0.8 M6 x 1

5-6 8-10

lbs in. 44-53 71-88

7-8 12-14

lbs in 62-71 106-124

8-10 14-16

lbs in 71-88 124-142

M8 x 1.25

20-25

30-35

lbs ft 22-26

34-40

lbs ft 26-30

M10 x 1.5

40-45

177-221 lbs ft 30-33

60-65

44-48

70-75

52-55

M12 x 1.75 M14 x 2

70-80 110-125

30-33 52-59

100-110 155-180

74-81 114-133

115-130 180-210

85-96 133-155

M16 x 2 M20 x 2.5

170-190 340-380

125-140 251-280

240-270 450-500

177-199 332-369

280-320 550-600

207-236 406-443

M24 x 3

580-650

428-479

800-900

590-664

900-1050

664-774

M30 x 3.5

1150-1300

848-959

1600-1800

1180-1328

1850-2100

1364-1549

M36 x 4

2000-2250

1479-1660

2800-3150

2065-2323

3250-3700

2397-2729

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0-15

0.4

Maintenance and Adjustments

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0-16

0-17

0-18

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0-20

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Brakes Remove brake drum and inspect brake shoe linings and brake drum for wear. 0-22

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Troubleshooting See individual sections on transmission, electrical, hydraulic and frame for troubleshooting.

0.6

Component Removal and Installation See individual sections on transmission, electrical, hydraulic and frame for component removan and installation.

0.7

Component Repair See individual sections on transmission, electrical, hydraulic and frame for component repair.

0-23

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0-24

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1.0 TRANSMISSION

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FIGURE # 1.1 TRANSMISSION ASSEMBLY

1-2

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FIG ITEM # # 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 19 19 19 19 19 20 21 21 21 21 21 21 22 23 24 25 26 27 28 29 30 31 32

# FOR ASSY.

1-3

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1 1 1 1 1 2 2 1 2 1 18 2 2 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2

Flat rubber Urethane Non-marking Traction-lug Grip rubber Siped rubber Flat rubber Urethane Non-marking Traction-lug Grip rubber Siped rubber

FIGURE # 1.2 STEERING STEM ASSEMBLY

CONNNECT TO BRAKE ON FIGURE # 1.4 1-4

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FIG ITEM # # 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 30 31 32 33 34 35 36

# FOR ASSY.

1-5

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1 6 1 1 1 2 4 2 2 1 1 1 1 1 2 2 2 2 2 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 6

AS SHOWN

"Prime-Trak" STANDARD

1.2

SYSTEM OPERATION

The CMX60 and CMX80 center control rider pallet trucks use the same transmission. This transmission is of the double reduction type. The gears are a combination of helical and straight cut gears for strength and low noise. The final drive gear is mounted on opposing tapered roller bearings and the intermediate gear is mounted on ball bearings. Gears and bearings are enclosed in an oil filled case. The drive motor is mounted externally with the drive motor pinion gear mounted on the armature shaft. The brakes are on the drive motor. 1.3

SPECIFICATIONS

Gear Ratio Oil Type Oil Capacity Drive Tire Size 1.4

14.8:1 GL5 85W90 Approximately 1 liter 10.5" x 5" x 6.5"

MAINTENANCE AND ADJUSTMENTS

1-6

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BRAKE ADJUSTMENT

1.5

Disconnect battery, block drive wheel off floor and open front access door.

Place the parking brake linkage in the "brake released" position.

After the proper cable adjustment is made tighten the mounting nuts to prevent the cable sheath from moving.

Adjust brake interlock switch so that it operates as brakes are released and applied. The switch should close when the brakes are released.

The brake drum may be removed and the operating lever moved one spline to compensate for brake shoe wear.

1.6

COMPONENT REMOVAL AND INSTALLATION 1.6.1 TRANSMISSION REMOVAL AND INSTALLATION (ref. Figure #1.1 and 1.2). OVERHEAD LIFTING DEVICE CAPABLE OF LIFTING 4000 LBS. IS REQUIRED. REMOVAL 1.

Disconnect the battery.

Open access door on front of truck and lift door off hinge.

Remove cover on front of truck. 1-7

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Disconnect power cables from drive motor, label and remove from transmission case and housing. Cables may be left attached to control panel on truck.

Remove the cotter pin and pin attaching the brake cable to the brake lever at the motor. Remove the wires to the brake interlock switch and detach the brake cable bracket.

Remove transmission from under truck.

INSTALLATION (Refer to Figure # 1.1) 1.

Place bearing cup (#4) into bore in bottom of truck frame (shown in dashed lines). Bearing cup is a slip fit and may be retained using a dab of heavy grease between cup and frame.

Place new felt seal material (#3) into groove formed by bearing cup and frame.

Press bearing cone (#4) onto transmission case. Seat bearing tight on case. Using an inductive bearing heater will facilitate this operation. Prelube bearing after installation.

Raise truck frame with overhead lifting device and position transmission under frame. Carefully lower frame onto transmission. Be careful to not dislodge bearing cup or felt seal.

Install upper bearing cup and cone assembly (#2) and felt seal material (#1) on top of transmission tube. Prelube bearing cone.

Route power cables and wires to the brake interlock switch through transmission housing tube (#5). Connect cables to drive motor. 1-8

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Install brake cable bracket, install brake interlock switch wires and attach cable to brake lever.

Install handle stem, using six (6) socket head screws (#36).

Adjust brakes and brake switch.

10.

Install floor plate.

11.

Install door.

1.6.2 DRIVE WHEEL REMOVAL AND INSTALLATION REMOVAL The drive wheel can be removed without removing the transmission by following these steps: 1.

Disconnect the battery, block truck with drive tire off floor (about 1 inch).

Open front door and remove floor plate on front of truck.

Remove axle hub and wheel retaining nut. Pull tire and wheel from axle.

Press drive tire from wheel hub. This is usually done in the same process as pressing on a new tire. See INSTALLATION below.

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INSTALLATION 1.

Press drive tire in wheel hub. This is usually done while pressing off old tire. Press hub to center of tire.

Install drive tire and hub on axle. The drive tire retaining nut should be torqued to 250 ft./lbs.

Drain transmission oil.

Disconnect the battery, block truck with drive tire off floor (about 1 inch).

Open front door and remove floor plate from front of truck for access.

Remove drive wheel. See Section 1.6.2.

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Remove axle seal with seal puller or pry out with pry bar. Take care not to damage sealing surface or mounting bore.

INSTALLATION 1.

Check thread on hub and nut for damage.

Install new oil seal.

Install drive wheel and tire. The drive wheel retaining nut should be torqued to 250 ft./lbs.

Install side cover over drive tire. Torque to 35 ft./lbs.

Lower truck off blocks.

Refill transmission case with new oil.

Install floor plate and close front door.

1.6.4 BRAKE SHOE REMOVAL AND INSTALLATION REMOVAL 1.

Disconnect battery and block truck with drive tire off floor (about 1 inch).

Open front door for access to drive motor and brake drum.

Engage parking brake and remove nut on brake drum.

Release parking brake.

Remove brake drum.

Lift brake shoes away from backing plate so that shoes come together in center and springs relax. Shoes can now be removed from backing plate together.

If the entire brake assembly with backing plate is to be replaced then disconnect brake cable and remove bolts holding backing plate to drive motor.

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INSTALLATION 1.

If only new shoes are to be fitted install springs to brake shoes before installing shoes on backing plate. Place brake shoes and springs over backing plate and press into position. Use caution to prevent springs from flying out of place.

Install brake drum and torque retaining nut to 25 ft. lbs.

Adjust brake linkage and brake interlock switch (see Section 1.4).

1.6.5 REMOVAL OF HAND BRAKE ASSEMBLY (Figure #1.2) 1.

Remove knob from parking brake handle (item #29).

Remove two (2) socket flat head screws (item #28) on hand brake cover (item #30) and remove.

Remove cotter pin (item #4) and yoke pin (item #3).

Remove brake assembly cover (item #13).

Remove the two (2) flat head screws (item #2) on each side of the handle stem that hold hand brake assembly and remove assembly.

TO INSTALL HAND BRAKE ASSEMBLY, REVERSE ABOVE PROCEDURE. 1.6.6 DISASSEMBLY OF BRAKE LEVER ASSEMBLY (Figure #1.2) 1-12

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Place assembly on bench with pivot link (item #5) up and brake lever toward rear.

Remove spring (item #19).

Remove spring pins (item #9) from hand brake bracket plate.

Using a punch, remove groove pins (item #8) from pivots.

Remove brake levers (item #14) from assembly. Washer shims (item #7), pivots (item #17), and pivot link (item #5), will come out at this time.

1.6.7 ASSEMBLY OF BRAKE LEVER

1.7

Place hand brake bracket on bench with top of plate up and to the rear.

Place brake handle lever (item #14) in hand brake bracket.

Install washer shim (item #7) on lever.

Install pivot (item #17) with spring pin up and pivot pointing toward rear. Install groove pin (item #8) in pivot and lever, make sure lever is pointing up away from table.

Install second washer shim (item #7) on lever.

Install remaining lever (item #14) in hand brake bracket with one washer shim (item #7), pivot (item #17), and pivot link (item #5).

Install remaining washer shims (item #7) between pivot and pivot link. Place shim between pivot and pivot link, pull lever out until washer lines up with lever.

Push lever in and install groove pin in pivot and lever.

Replace spring pins (item #9) in hand brake bracket plate and install springs.

COMPONENT REPAIR

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1.7.1 TRANSMISSION DISASSEMBLY AND ASSEMBLY DISASSEMBLY After draining gear case lubricant, thoroughly clean outside with safety solvent or other non-corrosive cleaning fluid. Air dry all parts and proceed with disassembly of transmission as follows: 1.

Remove transmission from truck. See section 1.6

Remove gear case cover.

Block transmission with gear case side down. Allow room for gears to drop between blocks.

Heat retaining collar with propane torch and press drive axle through collar and bearing. Drive axle and intermediate gear will come out together.

Remove old bearings and races from gears and case. Clean transmission case.

ASSEMBLY Heat bearing cone on bearing heater to facilitate installation. 1.

Install new bearings on intermediate gear.

Install new inner bearing cone on drive axle.

Install new bearing cups in transmission case.

Use Loctite #515 "gasket eliminator" on mating surface and install gear case side cover. Be sure that two dowel pins are in case to position cover. Torque cover bolts to 14 ft./lbs. 1-14

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Reposition transmission case so that it rests on gear case cover.

Install drive motor in transmission case.

Install outer drive axle bearing cone and retaining collar:

Install drive axle seal in transmission case.

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2.0 ELECTRICAL

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2-2

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2.1

Component Identification The CMX60 and CMX80 electric center control rider pallet trucks use the Curtis PMC transistor controller for travel speed control. This system allows the operator infinite variable speed control. Electrical schematics and diagrams are shown on the following pages.

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FIGURE # 2.1 ELECTRICAL SCHEMATIC

2-4

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FIGURE # 2.2 ELECTRICAL SCHEMATIC SYMBOLS

2-5

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FIGURE # 2.3 ELECTRICAL ASSEMBLY

NOTE: USE HEAT CONDUCTING MATERIAL DOW #340 BETWEEN PANEL ASSEMBLY AND FRAME.

2-6

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FIG ITEM # # 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3

1 2 3 4 5 6 7 8 9 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49

# FOR NAME

ASSY.

Panel assembly Screw, socket head Clamp Screw, cap Suppressor (used with "Prime-Trak") Harness, wire Switch, emergency disconnect Switch, key Display, gauge Display, BDI/Hourmeter lift interrupt Motor, drive Connector assembly Screw, flat head Nut Bracket, limit switch Screw machine Nut, twin Cable Cable Cable Cable Sleeve (4 feet) Cable Cable Breaker, circuit Cable Switch, "Prime-Trak" rocker Prime-Trak pump assy. Screw, thread form Jumper (NOT used on 8000 lbs. trucks) Harness, platform Plug, diode Resistor Suppressor Filter, horn Lift pump assembly Nut Clamp Lockwasher Extension, terminal Switch, overtravel Harness, backrest (optional) Clamp Switch, rocker (optional) Fitting, male wire tab Switch, sealed Nut, twin (with "Prime-Trak") Screw machine (with "Prime-Trak") Switch, sealed (with "Prime-Trak") Fitting, male wire tab (with "Prime-Trak")

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1 4 2 2 2 1 1 1 1 1 1 1 2 2 1 8 4 1 1 1 1 As Req'd. 1 3 1 1 1 1 4 1 1 5 1 3 1 1 1 2 1 1 2 1 1 2 8 1 1 2 1 1

FIGURE # 2.4 ELECTRICAL PANEL ASSEMBLY

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FIG #

ITEM #

2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4

1 2 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41

# FOR ASSY.

2-9

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1 1 1 1 1 1 2 1 1 2 3 1 4 8 7 2 6 6 8 1 1 17 2 1 1 1 1 1 10 2 2 1 1 1 1 2 1 1 1 1 1 1

2.2

System Operation The BT Prime-Mover CMX60 and CMX80 electric center control pallet trucks use a Curtis PMC transistor control to supply power to the series wound drive motor. This allows the operator infinite variable speed control. These trucks are equipped with the "Prime-Trak" traction control system that automatically adjusts the stabilizing caster height to regulate the load on the drive tire for easier steering and better traction depending upon the travel mode. The lift and lower functions are directly controlled by the operator with the lift controls having an automatic lift limit at 4" of lift. This can be over-ridden by the operator releasing the lift button and pressing it again to obtain the full 6" of lift. All circuits are protected against overload with automatic resetting circuit breakers. These trucks are equipped with key switches for security, emergency disconnects for safety, and brake interlock switches to prevent drive operation if the brakes are applied. During normal operation the following circuits are activated. Battery connected and emergency disconnect push button switch pulled out to "run" position. Battery positive voltage will be available via the battery positive cable, battery connector, and power cable to the positive side of the 110 amp hydraulic motor circuit breaker. A power cable is connected from the positive side of the hydraulic circuit breaker to the positive side of the 150 amp drive motor circuit breaker. A power cable connects the negative side of the hydraulic circuit breaker to the positive side of the hydraulic pump contactor and a buss bar connects the negative side of the drive motor circuit breaker to the positive side of the line contactor. Since neither contactor is energized no current is flowing, but voltage can be read across the resistor. Battery voltage is also available from the positive side of the 150 amp circuit breaker via wire #28, 12 amp circuit breaker, wire #26, emergency disconnect push button switch, and wire #27 to positive side of the key switch and battery discharge indicator input on optional BDI/HM. Because the BDI/HM display is connected directly to battery negative via wire #13 the battery discharge indicator will be illuminated to indicate the state of the battery charge.

2-10

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Trak" toggle switch closed voltage is available through the switch and wire #34 to the "normally open" tips of the "Prime-Trak" relay to wire #18 to the "Prime-Trak" control switch located in the control handle. When the "Prime-Trak" control switch is closed voltage is available to wire #41 the time delay, to a caster limit switch wire #40, and wire #47 to the "Prime-Trak" pump motor contactor coil (P2) which is connected to battery negative. This causes the contactor coil to energize, the contactor to close, and the "Prime-Trak" pump motor to turn on and pump oil into the stabilizing caster lift cylinders. The pump will continue to run until the stabilizing caster linkage opens the caster limit switch and power is cut off to the contactor coil. The stabilizing casters will remain in the raised position to reduce the load on the drive wheel to allow easier steering until the travel controls are turned far enough to a higher travel speed to open the "Prime-Trak" control switch in the control handle or until the brakes are applied and the brake interlock switch opens. When the brake interlock switch or the "PrimeTrak" control switch opens current flow to the release solenoid is broken and the solenoid returns to its "Normally Open" state allowing the hydraulic oil to flow out of the stabilizer lift cylinders and more weight to be on the drive tire. Wire #7 also supplies voltage to the 1A bypass contactor coil, and to a terminal on the Curtis PMC controller to turn on the controller. On the CMX60 wire #7 is connected through a jumper to wire #23 and on to the time delay for the field weakening contactor coil. On the CMX80 wire #7 goes to a pressure switch, in place of the jumper, that is open when there is hydraulic pressure in the system so that the field weakening contactor coil can not energize. Although the truck is not moving the Curtis PMC controller has been turned on to recognize SRO signal inputs. Reverse travel (fork direction) switch is closed. When the reverse switch is closed to make the truck travel in the fork direction positive battery voltage is made available via wire #3 to the reverse contactor coil. Wire #3 also supplies battery positive voltage to the PMC controller to signal it that a direction has been selected. Wire #3 also supplies voltage through a diode to wire #37 and on to the hour meter run input on the hour meter/BDI. Battery negative for the reverse coil is supplied via wire #21 through the PMC controller. When the controller has satisfied its safety circuits the reverse contactor coil is energized and the reverse contactor will close. At this time the Curtis PMC controller will start "pulsing" power to the drive motor at a rate based on the accelerator potentiometer position. The PMC power circuit and the accelerator potentiometer circuit are described later. Forward travel (control handle direction) switch is closed. 2-12

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2-15

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2.3

CMX60

CMX80

95A 95A

2.3.3 Motor repair specifications Drive motor: Minimum brush length New brush spring tension Minimum commutator diameter

2.4

.75" 56oz 2.625"

Pump motor: Minimum brush length New brush spring tension Minimum commutator diameter

.25" 32-40oz 1.5"

"Prime-Trak" motor Minimum brush length New brush spring tension Minimum commutator diameter

.25" 32-40oz 1.5"

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2.4.2 Adjustments Lift Limit Switch

#1 (3") and #2 (6")

2-17

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RESET

1.82 VPC*

2.18 VPC

1.78

2.15

N factory set

1.73

2.12

1.68

B factory set

2.09

1.63

2.06

1.57

Beyond A

2.00

Beyond K

1.56

*The DISCHARGE voltage of the unit is not an instantaneous voltage, nor a measure of the open circuit voltage at the time of lift lockout. 2-20

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2-21

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2.5

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2-23

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TROUBLESHOOTING CHART INDEX 2.5.1

Dead truck, nothing operates. No travel, no lift, "Prime-Trak" does not engage, no lower, no horn.

2.5.2

No travel, line contactor does not close. "Prime-Trak", lift, lower, and horn function okay.

2.5.3

No reverse travel (forks leading); reverse contactor will not close when travel controls are operated. The lift, lower, and horn functions work okay. "Prime-Trak" engages properly.

2.5.4

No forward travel (forks trailing); forward contactor will not close when travel controls are operated. The lift, lower, and horn functions work okay. "Prime-Trak" engages properly.

2.5.5

No reverse travel (forks leading); reverse contactor does close when travel controls are operated. The lift, lower, and horn functions work okay. "Prime-Trak" engages properly.

2.5.6

No forward travel (forks trailing); forward contactor does close when travel controls are operated. The lift, lower, and horn functions work okay. "Prime-Trak" engages properly.

2.5.7

Truck travel speed does not respond to controls properly. Contactors close for chosen direction but truck does not have full speed control.

2.5.8

"Prime-Trak" pump will not operate, when truck is not moving, and operator is off of the platform. Lift, lower and horn operate properly.

2.5.9

"Prime-Trak" pump runs, but cylinders do not extend.

2.5.10

"Prime-Trak" pump will not operate, platform switch closed, toggle switch closed and direction switch in neutral. Forward and reverse direction, lift, lower and horn operate properly.

2.5.11

"Prime-Trak" pump runs when high speed forward or reverse is selected. Forward and reverse direction, lift, lower and horn operate properly.

2.5.12 2.5.13

"Prime-Trak" pump will not operate. All other functions operate properly. Lift function does not operate.

2.5.14

Lowering function does not operate.

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TROUBLESHOOTING CHARTS 2.5.1

2-25

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2.5.2

2.5.3

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2-27

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2.5.4

2.5.5

No reverse travel (forks leading); reverse contactor does close when travel controls are operated. The lift, lower, and horn 2-28

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2-29

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2-32

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Connect one lead of the ohmmeter to wire #10 at the accelerator 2-33

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2-35

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2.5.10

2-37

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Replace master switch. H. Perform test 2.5.8 steps E thru J. 2.5.11

"Prime-Trak" electrical power circuit 2.5.12

"Prime-Trak" pump motor will not operate. Forward and reverse, lift, lower and horn operate properly. Conditions for test: P2 contactor closed.

Test for voltage at: 2-38

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Positive side of lift limit switch , wire #5. Repair open wire #5 between key switch and lift limit switch.

Negative side of lift limit switch , wire #17. Adjust or replace lift limit switch.

Positive side of lift contactor coil, wire #17. Repair open wire #17 between lift limit switch and lift contactor coil.

Negative side of lift contactor coil, wire #13

Special Instructions: If truck is NOT equipped with Lift Interrupt System follow step "a". If 2-39

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truck IS equipped with Lift Interrupt System follow step "b". (a)

(b)

(c).

(d) E.

ALL testing to resume with test O.

Positive side of 110 amp circuit breaker. Repair open power cable between battery positive terminal and 110 amp circuit breaker.

Negative side of 110 amp circuit breaker. Replace 110 amp circuit breaker.

Positive side of lift contactor.

2-40

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Repair open power cable between 110 amp circuit breaker and lift contactor. H.

Negative side of lift contactor. Replace lift contactor.

A1 terminal on lift motor. Repair open power cable between lift contactor and lift motor.

2.5.14 Lowering function does not operate. Conditions for testing: Truck blocked to prevent it from rolling. Battery fully charged and connected to truck. Emergency disconnect pushbutton switch pulled out 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 #6. (Test each lowering switch.) Repair open wire #6 between key switch and lowering switch. B. Negative side of lowering switch, wire #4. (Test each switch.) Adjust or replace lowering switch and bar assembly. C. Positive side of lowering valve coil. Repair open wire #4 between lowering switch and lowering valve coil. D. Negative side of lowering valve coil, wire #13. Special Instructions:

2-41

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2-42

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2.6

2-43

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2. Install brake assembly by lifting one brake shoe at a time and installing mounting bolts.

NOTE: LOCATION OF ACTIVATING LEVER SHOULD BE AS SHOWN. 3.

Install brake drum on the armature shaft over the key.

Install pinion gear on drive motor over the key and tighten locknut. Placing a wrench on both locknuts tighten nut to 30 ft./lbs.

Apply gasket eliminator (Loctite 515) on mating faces of motor and transmission.

Slide drive motor in gear case and work it around until the pinon gear lines up with intermediate gear.

Install the four (4) motor mounting bolts and torque to 35 ft./lbs.

Connect the power cables to their proper terminal.

Install brake cable bracket and linkage.

10.

Reinstall cover door.

11.

Remove blocks, connect battery and test operation of unit.

2.6.2 DRIVE MOTOR BRUSH REMOVAL AND INSTALLATION REMOVAL 1.

Disconnect battery before beginning work.

2-44

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Remove the shields around motor end cover to expose brushes.

Remove screw holding brush lead.

Lift spring off brush, remove brush from holder.

INSTALLATION 1.

Place new brushes in holder in same orientation that old brushes were removed and tighten screws on brush leads.

Lower lifting frame to release pressure in system.

Disconnect battery, remove access doors, and key switch mounting bracket.

Disconnect hydraulic hose and electrical cables. Disconnect solenoid control wiring.

Unbolt pump and motor mounting bracket and remove assembly.

Remove motor end cover for access to through bolts that hold motor to adapter.

Remove through mounting bolts and separate motor from pump adapter.

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CONTACTOR TIP REMOVAL AND INSTALLATION SHOCK HAZARD!!! Disconnect battery before doing any work on/or around contactor panel assembly. CONTACTOR TIP/BAR REPLACEMENT 1.

Contactor tips are the only serviceable part of contactors. The bars should be replaced when tips have worn through the silver contact in any area.

Disconnect buss bars from contactors.

Remove screws holding contactor cover in place.

Remove cover, being careful not to drop springs.

Install new bars and tips.

Install cover with springs in correct place.

2.6.7 DIRECTION CONTROL SWITCHES The direction control switches are mounted in the control handle head. It is not necessary to remove the head to change the switches. Refer to Figure 4.3 1.

Remove the screws around the outer edge of the switch cover plate on the control handle head. Do not remove the center screw. Lay cover to side.

Remove two screws holding forward/reverse switch bracket to housing.

Remove switch wires from wire harness plug and remove switches and bracket.

The switches may now be replaced by unbolting them from the bracket.

Reconnect switch wires and reinstall bracket in housing.

Test switch operation and adjust bracket before installing 2-46

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Remove the screws around the outer edge of the switch cover plate on the control handle head. Do not remove the center screw at this time.

Remove the control handle head (See 4.6.1).

Remove center screw and nut holding switch bar retainer to cover plate. The switch bars and springs will now be free to come out.

Push wire terminals for the failed switch out of the wiring harness connector plug.

Install new switch wire terminals into plug.

Position switch bars and springs into switch cover plate and reinstall switch bar retainer with one screw and nut.

Reinstall control handle head.

Reinstall switch cover plate.

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2.6.9 POTENTIOMETER The accelerator potentiometer is accessible inside the control handle head by removing the switch plate. The accelerator potentiometer operates off a gear toothed shaft (rack) that is moved when the travel controls are twisted. 1.

Disconnect the battery.

Remove the six (6) outside screws securing the raise/lower/horn switch plate to the control handle head. Do not remove the center screw on the switch plate. Remove the switch plate and lay it over to one side.

Remove the control handle head.

Push wire terminals for the potentiometer out of the wiring harness connector plug.

Remove the two (2) screws that secure the potentiometer bracket to the switch housing and remove the potentiometer, bracket, and gear as an assembly.

Support the potentiometer side of the gear and using a small punch, tap the potentiometer from the gear.

Remove the nut and washer securing the potentiometer to the bracket.

Mount the new potentiometer into the bracket aligning the pin on the potentiometer with the hole in the bracket. Secure the potentiometer to the bracket with the star washer and nut.

Push the gear onto the potentiometer until the gear is flush with the end of the potentiometer shaft.

10.

Install the new wire terminals in same position of wiring harness connector plug as the wires removed in step #4.

11.

Adjust the potentiometer per the instructions in section

2-48

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2.7

COMPONENT REPAIR 2.7.1 DRIVE MOTOR DISASSEMBLY 1.

Remove motor brushes.

Remove four screws holding brush end bell to field housing.

Separate end bell from field housing. The armature will come out with end bell.

2-49

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TABLE #1 INDICATIONS, CAUSES AND CORRECTION OF UNSATISFACTORY BRUSH PERFORMANCE INDICATIONS Sparking

IMMEDIATE CAUSES Commutator surface condition Over-commutation Under-commutation 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

Etched or burned bands on brush face

Pitting of Brush Face

Rapid Brush Wear

Glowing at Brush Face

7-12-30-32 8-9-11 6-14-15-16-17-18-19-2021-28-29 25-27-28-29 38-39-40-41-42 7-13-23-34 51-52 See "Chattering or Noisy Brushes" 55-57-59 50 7-12-31-33 7-12-30-32

Glowing Embedded copper

See "Glowing at brush face" See "Copper in brush face"

Commutator surface condition

See specific surface fault in evidence. Also see 50. See "Sparking"

Severe sparking Imperfect contact with commutator Wrong brush grade

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

Embedded copper

See "Copper in brush face"

Commutator surface condition Bad service condition Wrong brush grade 2-50

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1-2-3-43-44-45-46-49-5960 7-12-31-33 7-12-30-32

Over commutation Under commutation Too rapid reversal of current

Faulty machine adjustment Severe load condition Bad service condition Wrong brush grade Copper in Brush Face

PRIMARY FAULTS

7-12-30-32

7-12 38-39-41-42 46-47 57-61-62 2-3 43-46-47-48-49 59-61

TABLE #1 (cont.) INDICATIONS, CAUSES AND CORRECTION OF UNSATISFACTORY BRUSH PERFORMANCE INDICATIONS

IMMEDIATE CAUSES

PRIMARY FAULTS

Flashover at Brushes

Machine condition Bad load condition Lack of attention

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

Chattering or Noisy

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

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

INDICATIONS APPEARING AT COMMUTATOR SURFACE INDICATIONS Brush Chipping or Breakage

IMMEDIATE CAUSES Commutator surface condition Looseness in machine Vibration Chattering Sluggish brush movement

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

Rough or Uneven Surface

1-2-3-4-17

Dull or Dirty Surface

5-44-60

Eccentric Surface

1-19-22-52

High Commutator Bar

Sparking

Low Commutator Bar Streaking or Threading of Surface

Sparking Copper or foreign material in brush face Glowing

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

Bar Etching or Burning

Sparking Flashover

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

Bar Marking at Pole Pitch Spacing

Sparking

25-37

Bar Marking at Slot Pitch Spacing

Sparking

7-12-30-57-60

2-51

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PRIMARY FAULTS

TABLE #1 (cont.) INDICATIONS APPEARING AT COMMUTATOR SURFACE INDICATIONS

IMMEDIATE CAUSES

PRIMARY FAULTS

Flat Spot

Sparking Flashover Lack of attention

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

Discoloration of Surface

High temperature

See "Heating at Commutator" 44-46 60

Atmospheric condition Wrong brush grade Raw Copper Surface

Embedded copper Bad service condition Wrong brush grade

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

Rapid Commutator Wear with Blackened Surface

Burning Severe Sparking

2-3-11-14 See "Sparking"

Rapid Commutator Wear with Bright Surface Copper Dragging

Foreign material in brush face Wrong brush grade Brush vibration

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

INDICATIONS APPEARING AS HEATING INDICATIONS Heating in Windings

Heating at Commutator

IMMEDIATE CAUSES

PRIMARY FAULTS

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

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

Severe load condition Severe sparking High friction

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

Poor commutator surface Depreciation High contact resistance

2-52

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

TABLE #1 (cont.) INDICATIONS APPEARING AS HEATING INDICATIONS Heating at Brushes

IMMEDIATE CAUSES Severe load conditioin Faulty machine adjustment Severe sparking Raw streaks on commutator surface Embedded copper Wrong brush grade

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PRIMARY FAULTS 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

TABLE 2 PRIMARY SOURCES OF UNSATISFACTORY BRUSH PERFORMANCE PREPARATION AND CARE OF MACHINE 1. 2. 3. 4. 5. 6.

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

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

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

MECHANICAL FAULT IN MACHINE 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.

ELECTRICAL FAULT IN MACHINE 25. 26. 27. 28. 29.

MACHINE DESIGN 30. 31. 32. 33. 34. 35. 36. 37.

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LOAD OR SERVICE CONDITION 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50.

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

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DISASSEMBLY 1.

Remove the cover band from the commutator end of the motor (if equipped).

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.

Scribe or center punch locating marks in the end head and the frame. Although locating marks are not always necessary because of locating pins in some motors, they can save a lot of time when the motor does not have locating pins.

Remove the commutator end head retaining screws. Almost all 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.

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Remove the drive end head retaining screws, if necessary. Some of the smaller pump motors retain the drive end head with the motor through bolts. Separate the armature and drive end head as an assembly from the frame and field coil assembly.

2-57

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

PRESSING END HEAD BACK ON ARMATURE SHAFT

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The ventilation fans are cast aluminum. Once these fans have been pressed onto the armature, they must be heated to be removed without damage. A puller is installed and a slight pressure exerted against the fan. Use a small propane torch to heat the area of the fan around the shaft. When the fan becomes loose on the shaft, as evidenced by the puller becoming loose, it should be removed as quickly as possible.

When the fan is reassembled on the shaft, make sure it is a tight fit. Use "Loctite Retaining Compound 40" or equivalent on the inside of the fan hub when reassembling fan.

10.

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

2.7.2

CONTROLLERS No internal repairs can be made to the transistor controllers. Contact the parts department for exchange units.

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THIS PAGE BLANK

2-60

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3.0 HYDRAULICS

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FIGURE # 3.1 LIFT HYDRAULIC SCHEMATIC

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3-2

FIGURE # 3.2 LIFT HYDRAULIC SCHEMATIC SYMBOLS

COMPONENT ENCLOSURE

HYDRAULIC LINES JOINING

MOTOR (ELECTRIC)

HYDRAULIC PUMP

FILTER

RESERVOIR (VENTED) CYLINDER (SINGLE ACTING) CYLINDER (DOUBLE ACTING)

CHECK VALVE

HYDRAULIC LINES CROSSING

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3-3

FIGURE # 3.3 LIFT HYDRAULIC SYSTEM ASSEMBLY

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3-4

FIG ITEM # # 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3

1 2 3 4 5 6 7 8K 9 10K 11K K

3.3 3.3 3.3 3.3 3.3 3.3 3.3

12 13 14 15 16 17 18

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# FOR ASSY.

3-5

1 1 1 2 1 1 1 1 1 1 1 1 3 1 1 1 1 1 1

UNIT

FIGURE # 3.4 "PRIME-TRAK" HYDRAULIC SCHEMATIC

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3-6

FIGURE # 3.5 "PRIME-TRAK" HYDRAULIC SCHEMATIC SYMBOLS

COMPONENT ENCLOSURE

HYDRAULIC LINES JOINING

MOTOR (ELECTRIC)

HYDRAULIC PUMP

FILTER

RESERVOIR (VENTED) CYLINDER (SINGLE ACTING) CYLINDER (DOUBLE ACTING)

CHECK VALVE

HYDRAULIC LINES CROSSING

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3-7

FIGURE # 3.6 PRIME-TRAK HYDRAULIC SYSTEM ASSEMBLY

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3-8

FIG ITEM # # 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6

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1 2 3 4 5 6 7 8 9 10K 11K 12 13K 14 15 16 17 18 19 20 21 22 23 24 K

# FOR ASSY.

3-9

1 1 1 As Req'd. 2 1 1 1 1 1 1 1 1 1 1 2 2 1 1 2 1 1 1 1 1

UNIT

FIGURE # 3.7 "PRIME-TRAK" PUMP & MOTOR ASSEMBLY

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3-10

FIG ITEM # # 3.7 3.7 3.7 3.7 3.7 3.7 3.7 3.7 3.7 3.7 3.7 3.7 3.7 3.7 3.7 3.7 3.7 3.7 3.7 3.7 3.7 3.7 3.7 3.7 3.7 3.7 3.7 3.7

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1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 * 18 19 20 21 22 23 24 25 26 27

# FOR ASSY.

3-11

1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 2 1 1 1 1 2 2 1 1 2

UNIT

HYDO 32 Texaco 15

Hydraulic fluid capacity

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1 quart 3-12

Lift system relief pressure

CMX60 - 2800 PSI CMX80 - 3100 PSI 250 PSI

"Prime-Trak" relief pressure. 3.4

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3-13

3.5

Proper oil level All electrical connections tight Battery fully charged

If pump operates but will only develop low pressure or slow lift: 1.

Relief valve seat scored, foreign particles under ball or relief valve out of adjustment (see relief valve).

Dirt in solenoid operated release (see solenoid operated release valve).

Pump worn - replace pump.

If pump develops pressure but will not hold: 1.

Dirt in solenoid operated release (see solenoid operated release valve).

Relief valve seat scored, foreign particles under ball or relief valve out of adjustment (see relief valve).

If pump develops pressure but will not release load: 1.

Return

No electrical contact to solenoid operated release valve (see solenoid operated release valve). 3-14

Solenoid in solenoid operated release valve burned out.

Relief valve bottomed causing pressure to go beyond the unloading limit of the solenoid release valve (see relief valve).

RELIEF VALVE Remove hex cap on relief valve. 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 bottoming position. If the trouble is not remedied by the relief valve adjustment, remove adjustment screw and spring and ball. Valve seat should be clean and not scored. Replace spring and ball in cavity. Insert 1/4" drive pin punch down through spring coils and hold ball against valve seat. Tap gently on drive pin punch with ball peen hammer to seat the ball. Reassemble the relief valve parts. Adjust relief valve and recycle the pump per above. Do not operate motor/pump at relief valve setting any longer then is necessary (NO LONGER THEN 10 SECONDS AT ANY ONE PERIOD). REMOVING SOLENOID OPERATED RELEASE VALVE. Clean surface around valve before starting to avoid foreign matter from falling into cavity. Disconnect wires from terminals on coil, loosen and remove nut. Remove coil. Using wrench on flat surface, loosen and remove tube sub-assembly unit. Inspect and clean or replace strainer as required. INSTALL SOLENOID OPERATED RELEASE VALVE. Clean and inspect valve cavity to be sure it is free of all foreign matter. CAUTION: DO NOT BEND OR APPLY PRESSURE TO CENTER STUD OR HOLD CARTRIDGE BODY ANY PLACE BUT ON FLAT SIDES OF SUB-ASSEMBLY. Be sure o-ring and Teflon ring are in place. Apply a small amount of clean grease to all three rings. Be sure strainer is in place. Hand screw sub-assembly in place and tighten to a maximum of 35 ft./lbs. for die cast metal. Assemble coil on spool assembly and tighten nut to a maximum of 5 ft./lbs. Connect wires to terminals on coil.

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3-15

3.6

Lower the lifting frame to release pressure in system.

Disconnect battery, open front door, remove access covers.

Disconnect hydraulic hose and electrical cables. Disconnect solenoid control wiring.

Unbolt pump and motor mounting bracket and remove assembly.

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Examine the inside leading edge of reservoir for any burrs or nicks that may cut o-ring during installation. Wipe the inside of the reservoir clean.

Oil the o-ring in the groove on adapter.

Start the reservoir over the flange on the adapter up to the o ring. Make sure it is aligned properly with the holes as well as not cocked.

3-16

Rest a block of wood on the back of the reservoir and strike it squarely with a sharp blow in the center of the reservoir end. The reservoir should move into position.

Install four (4) screws in position and tighten to snug condition.

REMOVING "PRIME-TRAK" PUMP ASSEMBLY 1. 2. 4. 5. 6. 7.

INSTALLING "PRIME-TRAK" PUMP ASSEMBLY 1. 2. 3. 4. 5. 6.

3.6.3 LIFT CYLINDER REMOVAL Reference Figures #3.3 and #4.1

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Raise and block lifting frame of truck. Release pressure in cylinder by activating lowering valve.

Block the carrier frame so it will not tip when the lift cylinder links are removed.

Disconnect and remove battery from unit to prevent accidental operation. 3-17

Remove front door and plastic cover. HOT OIL under pressure may be present. Be certain truck is safely blocked and pressure is released. Some spillage of hydraulic oil may occur.

Remove hydraulic line.

Remove bolt securing lift cylinder rod to the carrier frame.

Remove the set screws (#8 Figure 4.1) securing pins (#2 Figure 4.1).

Remove pins (#2 Figure 4.1) from the carrier frame and lift frame.

Remove lift cylinder and upper links from the truck.

10.

Thoroughly clean outside of cylinder before removing hydraulic hose.

The bushing in the upper links can be replaced at this time as well as resealing the lift cylinder. 11.

Place on a clean bench for disassembly.

CYLINDER INSTALLATION 1.

In order to prevent air from filling the cylinder it is recommended to install the cylinder with rod retracted.

Install upper links on cylinder, install pins (#2 Figure 4.1) and new set screws (#8 Figure 4.1).

Connect hydraulic hose and use the pump to extend the cylinder.

Install bolt securing cylinder rod to the carrier frame.

Raise and unblock lifting frame of unit.

Install and connect battery to unit.

Test operation of cylinder and look for leakage around fitting and cylinder rod.

Install front door and plastic cover.

"PRIME-TRAK" CYLINDER REMOVAL Reference Figure 4.2 1.

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Open front door. 3-18

2. 3. 4. 5. 6. 7.

Disconnect battery. Jack up truck so casters are 2"-3" off of the floor. Disconnect hydraulic hoses from cylinders. Loosen jam nut (#13). Loosen cap screw (#14). Remove cylinder from truck.

"PRIME-TRAK" INSTALLATION 1. 2. 3. 4. 5. 6.

3.7

COMPONENT REPAIR 3.7.1 The pumps have no serviceable parts. If repair is necessary a new pump should be installed. 3.7.2 LIFT AND "PRIME-TRAK" CYLINDER DISASSEMBLY 1.

Thoroughly clean outside of cylinder assembly.

Position rod so end of rod and snap ring can be seen through inlet port.

Insert screwdriver in inlet port and slide snap ring into deep groove in rod assembly.

Remove rod assembly from barrel assembly.

Remove wiper seal and seal from inside diameter of barrel assembly.

It is not necessary to inspect wiper seal, seal or lock ring. These parts should be replaced as new items and are included in the seal repair kit available for this cylinder.

INSPECTION 1.

Thoroughly clean all parts and remove all nicks and burrs with emery cloth.

Inspect inside surface of barrel assembly for excessive wear or scoring.

Inspect outside surface of rod for nicks, scratches or scoring.

ASSEMBLY

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3-19

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All parts should be cleaned and dried thoroughly. Metal parts should be lightly oiled prior to reassembly.

Install new seal in inside diameter of barrel. Install new wiper seal with lips facing inward to bottom of barrel.

Install new lock ring in deep groove of rod end.

Oil outside of piston rod and carefully insert rod in barrel assembly.

Push rod in barrel assembly until snap ring area of rod can be seen through port.

By using screwdriver through port, move snap ring to lock position.

Extend rod to full out position to make sure snap ring is locked in place.

3-20

4.0 FRAME

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FIGURE # 4.1 FRAME ASSEMBLY

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4-2

FIG ITEM # # 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1

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1 2 2 3 4 5 5 6 6 7 8 9 9 10 11 11 12 12 12 12 12 12 13 14 15 16 17 17 18 19 20 21 22 23 24 25 25 26 26 27 28 29 30 31

# FOR ASSY.

4-3

1 4 4 12 4 2 2 2 2 2 14 2 2 17 2 2 2 2 2 2 2 2 4 2 1 1 1 1 2 3 2 1 1 1 1 2 2 2 2 8 8 2 2 1

36" forks 42" forks 48" forks 84",93" forks 96" forks 1150mm

27" Wide 22" Wide

FIGURE # 4.2 CASTER TORSION ROD ASSEMBLY

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4-4

FIG ITEM # # 4.2 4.2 4.2 4.2 4.2 4.2 4.2 4.2 4.2 4.2 4.2 4.2 4.2 4.2

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

# FOR ASSY.

4-5

4 1 2 4 2 1 8 2 8 2 1 2 2 2

FIGURE # 4.3 CONTROL HANDLE HEAD ASSEMBLY

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4-6

FIG ITEM # #

NAME

4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3

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1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45

# FOR ASSY.

4-7

1 4 1 6 3 1 1 1 1 2 1 2 2 2 2 2 2 2 8 2 1 1 1 1 1 1 4 8 1 1 4 1 1 1 1 1 9 1 1 6 1 1 1 1 1

4.2

4.3

SPECIFICATIONS Lowered height Lifting height Load wheel dimensions Drive tire dimensions

4.4

3.25 inches 6 inches 3.25 x 6 inches 10.5 x 5 x 6.5 inches

4.5

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4-8

4.6

Remove set screws (#8) securing pins (#2,11, 26).

Remove pins (#9, 11, 25)

Remove the wheel fork (#5), load wheel , pull rod (#12) and lower links (#13) as an assembly.

Remove set screws (#8) securing pins (#9, 25).

Remove pins (#9, 25).

Install new bushings and set screws in pull rods, lower links, and wheel forks.

Re-assemble pull rods, lower links, wheels, and wheel forks.

Re-connect assembly to lift frame.

Place truck upright and install the battery, connect battery, test operation of the lift frame.

4.6.4 CARRIER FRAME BUSHINGS The bushings on the upper links of the carrier frame can be replaced by removing

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4-9

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the links and lift cylinder. See section 3.6.3 Lift Cylinder rremoval.

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4-10

THE PRIME-MOVER CO. 3000 NORTH US HIGHWAY 61 MUSCATINE, IOWA 52761-5810

PROUDLY Made in AMERICA

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Service Manual CMX60/80

Electric Center Riding Pallet Truck Effective Serial Number CMX__26288001

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: 302825-000

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Date: March 20, 1998

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BT Standard Codes Version no

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000

BT Standard Codes B-Code

= Business area

F-Code

= Product family

T-Code

= Product type

C-Code

= Component function

Worksheet standard W-Code = Working code R-Code

= Reason code

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

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Chassis

0000

Drive Motor

1000

Drive Gear / Transmission

2000

Brake / Wheel System

3000

Steering System

4000

Electrical System

5000

Hydraulic / Pneumatic System

6000

Operating Function-lifting Mast / Cylinders

7000

Peripheral / Installation Equipment

8000

Optionals / Attachments

9000

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Table of Contents BT Standard Codes ....................................................................................... 1 Warning Symbols ......................................................................................... 11 Warning Levels ......................................................................................... 11 Prohibitory Symbols .................................................................................... 12 Ordinance Symbols .................................................................................. 12 Introduction, Service Manual ...................................................................... 13 Contents, Section M ..................................................................................... 15 Machine Information ................................................................................. 15 General Product Information ...................................................................... 17 Presentation of the Rider Trucks CMX60 and CMX80. ............................ 17 Intended Application of the Trucks ................................................... 17 Forbidden Application of the Trucks ................................................. 18 Truck Data ........................................................................................ 18 CMX Dimensions .............................................................................. 19 Data Plate ......................................................................................... 20 Main Components ..................................................................................... 21 Inch (SAE) and Metric Fasteners ............................................................... 23 Introduction ............................................................................................... 23 Nomenclature, Threads ............................................................................ 24 Strength Identification ............................................................................... 25 Conversion of Metric and English Units .................................................... 31 Technical Service Data ................................................................................ 33 Ordering Spare Parts ................................................................................... 37 Contents, Section P ..................................................................................... 39 Planned Maintenance ............................................................................... 39 Introduction, Maintenance .......................................................................... 41 Safe Jacking Procedure ............................................................................ 41 Service Schedule ......................................................................................... 43 Planned Maintenance Schedule ............................................................... 43 Planned Maintenance Procedures ............................................................ 47 Services to be Performed Daily ........................................................ 47 Services to be Performed Monthly .................................................... 49 Services to be Performed Annually .................................................. 52 Lubrication Chart ......................................................................................... 55 © BT Products

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Table of Contents Oil and Grease Specifications .................................................................... 57 Approved Oils and Grease ....................................................................... 57 Contents, Section S ..................................................................................... 59 Service Instructions .................................................................................. 59 Chassis ......................................................................................................... 61 General Information .................................................................................. 61 Door .......................................................................................................... 62 Removal ............................................................................................ 62 Lift Frame ...................................................................................................... 63 Pull rod ...................................................................................................... 64 Removal ............................................................................................ 64 Inspection ......................................................................................... 66 Installation ......................................................................................... 67 Drive Motor Mounting Points ...................................................................... 69 Drive Motor Brush ..................................................................................... 70 Removal and Installation .................................................................. 70 Drive Motor Assembly ............................................................................... 70 Remove ............................................................................................ 70 Installation ......................................................................................... 71 Drive Motor ................................................................................................... 73 General Information .................................................................................. 73 Operating Conditions ................................................................................ 73 Troubleshooting ........................................................................................ 73 Drive Motor Service ..................................................................................... 79 Motor Repair ............................................................................................. 80 Disassembly ..................................................................................... 80 Inspection and Troubleshooting ................................................................ 83 Drive End Head ................................................................................ 83 Commutator End Head ..................................................................... 83 Bearings ............................................................................................ 83 Brush and Commutator ..................................................................... 84 Armature ........................................................................................... 84 Frame and Field Assembly ............................................................... 85 Assembly .......................................................................................... 87 Changing Brushes .................................................................................... 88 Transmission ................................................................................................ 89 System Description ................................................................................... 89 Troubleshooting ........................................................................................ 89 Removal .................................................................................................... 90 © BT Products

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Table of Contents Installation ................................................................................................. 91 Transmission Axle Seal ............................................................................... 93 General Information .................................................................................. 93 Removal ............................................................................................ 93 Installation ......................................................................................... 93 Transmission Disassembly / Assembly ..................................................... 95 Disassembly ............................................................................................. 96 Assembly .................................................................................................. 96 Parking Brake System ................................................................................. 99 Brake Theory of Operation ...................................................................... 100 Brake Adjustment .................................................................................... 101 Brake Shoe Removal / Installation ........................................................... 102 Brake Interlock Switch ............................................................................. 103 Drive Wheel .................................................................................................. 105 Removal ........................................................................................... 105 Installation ........................................................................................ 106 Load Wheels ................................................................................................ 107 Support / Swivel Wheel ............................................................................... 109 Stabilizing Caster ..................................................................................... 109 Removal ........................................................................................... 110 Inspection ........................................................................................ 112 Installation ........................................................................................ 113 Maintenance .................................................................................... 114 Stabilizing Caster ........................................................................................ 115 Stabilizing Caster ..................................................................................... 115 Disassembly .................................................................................... 116 Inspection ........................................................................................ 117 Assembly ......................................................................................... 118 Steering Control Arm .................................................................................. 119 Control Handle Stem ............................................................................... 120 Removal ........................................................................................... 120 Installation ........................................................................................ 121 Hand Brake Levers .................................................................................. 122 Removal ........................................................................................... 122 Disassembly .................................................................................... 122 Assembly ......................................................................................... 122 Installation ........................................................................................ 123

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Table of Contents Steering Handle Head ................................................................................. 125 Control Handle Head ............................................................................... 127 Removal ........................................................................................... 127 Installation ........................................................................................ 127 Direction Control Switches ....................................................................... 128 Horn, Raise, and Lower Switches ............................................................ 129 Potentiometer .......................................................................................... 131 300/400 Amp Contactor .............................................................................. 133 Maintenance ............................................................................................ 134 Removal/Replacement of Contact Tips ........................................... 134 “EE” Contactor ............................................................................................ 137 Maintenance ............................................................................................ 138 Removal/Replacement of Contact Tips ........................................... 138 Battery Controller / Hourmeter / Lift Interrupt .......................................... 141 General Information ................................................................................. 141 Electrical .................................................................................................. 141 Voltage ............................................................................................. 141 Battery Controller (BC) ............................................................................ 142 General Information ......................................................................... 142 Reset ............................................................................................... 144 Key Switch ....................................................................................... 144 Hourmeter ........................................................................................ 144 Troubleshooting ....................................................................................... 145 Battery Discharge Indicator (BDI) .................................................... 145 Hourmeter ........................................................................................ 147 Battery Discharge Indicator / Hourmeter .................................................. 149 General Information ................................................................................. 149 Electrical .................................................................................................. 149 Voltage ............................................................................................. 149 Battery Discharge Indicator (BDI) ............................................................ 150 General Information ......................................................................... 150 Key Switch ....................................................................................... 150 Hourmeter ........................................................................................ 150 Troubleshooting ....................................................................................... 151 Battery Discharge Indicator (BDI) .................................................... 151 Hourmeter ........................................................................................ 152 24 Volt 400 Amp Electrical System ............................................................ 155 Electrical Panel Components ................................................................... 155 List of Symbols ........................................................................................ 156 Circuit Diagram 1(5) ......................................................................... 158 Circuit Diagram 2(5) ......................................................................... 159 © BT Products

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Table of Contents Circuit Diagram 3(5) ......................................................................... 160 Circuit Diagram 4(5) ......................................................................... 161 Circuit Diagram 5(5) ......................................................................... 162 Description of Function ............................................................................ 163 General Information ......................................................................... 163 References Information ................................................................... 163 Key Switch S17 in the ON Position .................................................. 163 Brake released, S10 Brake Switch Closed ...................................... 163 Driving, Fork Direction ..................................................................... 163 Driving, Steer Wheel Direction ......................................................... 164 Reversing/Motor Brake Fork Direction to Steer Wheel Direction ..... 164 Reversing/Motor Brake Steer Wheel Direction to Fork Direction ..... 164 Lifting the Forks ............................................................................... 164 Lowering the Forks .......................................................................... 164 Horn ................................................................................................. 165 Prime-Trak; operator off of the truck ................................................ 165 Prime-Trak; operator on the truck .................................................... 165 Lift Interrupt ...................................................................................... 166 24 Volt, 400 Amp Transistor Controller ..................................................... 167 Maintenance ............................................................................................ 167 Safety ............................................................................................... 167 Cleaning ........................................................................................... 167 Diagnostics and Troubleshooting .................................................... 168 Basics Of Circuit Operation ..................................................................... 170 Control Features .............................................................................. 171 Motor Circuit ............................................................................................ 174 Control Circuit .......................................................................................... 174 Diagnostics and Troubleshooting ............................................................ 177 1307 Programmer Diagnostics ........................................................ 177 Troubleshooting Chart ..................................................................... 178 Technical Specification .................................................................... 182 Troubleshooting Chart Using the Handset ....................................... 183 24 Volt, 400 Amp Transistor Controller Troubleshooting ....................... 185 Troubleshooting Chart Index ................................................................... 185 Troubleshooting Charts ........................................................................... 186 ...................................................................................................................... 203 Handset Operation ...................................................................................... 204 Operating Modes ..................................................................................... 206 Revert to Previous Settings ..................................................................... 210 Handset Self Test .................................................................................... 210 Pump Motor ................................................................................................ 211 © BT Products

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Table of Contents Component Repair ................................................................................... 212 Motor Disassembly .......................................................................... 212 Inspection and Troubleshooting ............................................................... 214 Drive End Head ............................................................................... 214 Commutator End Head .................................................................... 214 Bearings ........................................................................................... 214 Brush and Commutator .................................................................... 215 Armature .......................................................................................... 215 Frame and Field Assembly .............................................................. 216 Assembly ......................................................................................... 218 Changing Brushes ................................................................................... 219 Hydraulic System ........................................................................................ 221 Hydraulic Schematic ................................................................................ 221 General Information ................................................................................. 221 Description ............................................................................................... 222 Lift .................................................................................................... 222 Lower ............................................................................................... 222 Relief Pressure ................................................................................ 222 Maintenance ............................................................................................ 223 Adjustments ............................................................................................. 223 Lift Limit Switch ........................................................................................ 223 Troubleshooting ....................................................................................... 225 Prime-Trak Hydraulic System .................................................................... 227 Prime-Trak Hydraulic Schematic ............................................................. 227 General Information ................................................................................. 228 Maintenance ............................................................................................ 229 Adjustments ............................................................................................. 229 Prime-Trak Lift Limit Switch ..................................................................... 230 Troubleshooting ....................................................................................... 231 Lift Pump Assembly .................................................................................... 233 Removal ................................................................................................... 235 Disassembly ............................................................................................ 236 Inspection ................................................................................................ 237 Assembly ................................................................................................. 238 Installation ................................................................................................ 240 Adjustments ............................................................................................. 242 Relief valve ...................................................................................... 242 Solenoid Operated Valve ................................................................. 243 Prime-Trak Hydraulic Pump ....................................................................... 245 Removal ................................................................................................... 246 Disassembly ............................................................................................ 247 Inspection ................................................................................................ 248 © BT Products

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Table of Contents Assembly ................................................................................................. 249 Installation ................................................................................................ 251 Lift Cylinder ................................................................................................ 253 Removal ................................................................................................... 254 Disassembly ............................................................................................ 255 Inspection ................................................................................................ 256 Assembly ................................................................................................. 257 Installation ................................................................................................ 258 Prime-Trak Cylinders ................................................................................. 259 Removal ................................................................................................... 260 Disassembly ............................................................................................ 261 Inspection ................................................................................................ 262 Assembly ................................................................................................. 263 Installation ................................................................................................ 264

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PS Warning Symbols Version no

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000

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

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

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

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

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

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

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PS Prohibitory Symbols Version no

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000

Prohibitory Symbols

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

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

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

1. Ordinance Symbols

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

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

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Section

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M Introduction, Service Manual Version no

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000

CMX

Introduction, Service Manual The information in this Service Manual covers models CMX60 and CMX80. Federal and State laws require that operators be completely trained in the safe operation of lift trucks. An Operator’s Manual is attached to every BT lift truck when it is manufactured. If the Operator’s Manual is missing from the truck, a new manual may be obtained by contacting: BT Prime-Mover, Inc. 3305 N Highway 38 Muscatine, Iowa

52761-8800

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

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SUBJECT

MACHINE INFORMATION

PLANNED MAINTENANCE

SERVICE INSTRUCTIONS

OPTIONS

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M Introduction, Service Manual Version no

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000

CMX

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M Contents, Section M Version no

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001

Contents, Section M 1. Machine Information

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M1.0

GENERAL PRODUCT INFORMATION

M2.0

TECHNICAL SERVICE DATA

M3.0

ORDERING SPARE PARTS

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M Contents, Section M Version no

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PS M1.0 General Product Information Version no

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000

CMX

General Product Information 1. Presentation of the Rider Trucks CMX60 and CMX80. The CMX60 and CMX80 are battery powered center riding pallet trucks. These trucks are intended solely to be operated handling pallets or similar load carriers indoors. In their standard design, the trucks are equipped with a steering arm with all the controls for operating within easy access. The trucks have maximum lifting capacities of 6000/8000 lb (Review data plate on the truck to note the maximum lifting capacity). These trucks are equipped with a 24 volt electrical system, and the speed is regulated by means of a transistor controller to provide infinite control of acceleration and speed while driving. The forks are 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 specially equipped to work in cold conditions.

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

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CMX

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

As a towing tractor for trailers.

To tow other trucks.

To transport/lift passengers.

To drive on gravel or grass.

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

Truck data

CMX60

CMX80

Lifting capacity rated load, lb

6000 lb

8000 lb

Lift height, inches

9¼ in.

Operating speed without load, mph

8.0 mph

Operating speed with load, mph

6.0 mph

5.0 mph

Service weight without battery, lb

1350 lb

1450 lb

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

Above + battery weight

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

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CMX

1.4. CMX Dimensions The following diagram shows external dimensions for the CMX truck in its standard design. 9.1”

33.3”

37.4”

Extended tip fork

27.0”

10.1”

28.0”

102.6” Area of ride platform (541 in.2) Battery compartment 13.3”

30°

17.2” 51.5”

48.0”

47.6”

Battery roller height 6.1”

31.8”

3.25”

19° 6.0”

11.9” 4.2”

55.0” 79.1”

All dimensions shown for 48” long pallet Important Use only batteries that meet the following specifications: Compartment Size: Deep Wide Battery Weight

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

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

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CMX

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

Legend 1. Truck model number 2. Truck type 3. Truck serial number 4. Truck weight (less battery) 5. Truck voltage DC 6. Battery type UL class 7. Battery maximum AMP hours 8. Truck lifting capacity 9. Maximum battery weight 10. Minimum battery weight for Rubber Drive Tire 11. Minimum battery weight for Polyurethane drive tire

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CMX

2. Main Components 13 12

11 15 18

1 17 2 5

3 4 8, 9

1. Steering control handle: The truck is to be controlled by the operator with 180 degree steering angle. 2. Hydraulic unit: Pump motor and pump are an integrated unit. 3. Battery: 24 volt with different capacities and weights. 4. Drive unit with brake: Drive motor, gears, drive wheel, and brake combined in the drive unit. © BT Products

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CMX

5. Data plate: Contains data designation, manufacturing number, year of manufacture, service weight, battery weight, classified lifting capacity, battery voltage, and manufacturer. 6. Cover: Removable to provide good access for servicing. 7. Gauge: This provides information on the truck’s running hours and battery status. 8. Electronics: All electronics are collected in a protected compartment. 9. Circuit breaker: 12A, BT Control circuit breaker part number 301889-000 105A, BT Pump circuit breaker part number 307601-001 150A, BT Drive circuit breaker part number 307601-000 10. Key Switch (toggle switch): Shuts off electrical power to the control system. 11. Emergency stop switch The emergency stop switch will stop all control functions. 12. Prime-Trak Shuts on/off electrical power to the Prime-Trak control system. 13. Fork lower switch The forks will lower when the switch is pressed or until lower stops are reached. 14. Fork raise switch The forks will raise when switch is pressed or until lift stops are reached. 15. Horn switch The horn sounds to warn others of your position. 16. Handle brake lever Hand controlled lever that is squeezed to apply brake. 17. Parking brake lever Parking brake lever must be placed in the engaged position when truck is not in use (parked) or hand brake lever is not squeezed. 18. Travel speed / direction selection To select direction rotate in the direction you wish to move. The further in that direction you rotate the faster you move. 22

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

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001

Inch (SAE) and Metric Fasteners

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

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

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

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

METRIC

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

M12 x 1.75 x 50 A B C

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

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A = THREAD SIZE B = PITCH C = LENGTH

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

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3. Strength Identification The most common property classes for metric fasteners are 8.8 and 10.9. The property class is marked with a number on the head of the cap screw or on a nut. Property classes less then 8.8 are often not marked. Grades for inch bolts go from 2 to 8. Grade 2 fasteners normally do not have marks. The following tables show the marks that identify the grades and property classes for different fasteners. WARNING When fasteners must be replaced the new fasteners must be of the same strength or greater than the original fasteners. The new fasteners must also be the correct size. NOTE! Identification marks are according to bolt strength. The higher the number, or the increase in the number of marks, indicates increased bolt strength.

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

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001

Table 1. Bolt and Screw Designations

Types of Fasteners

Metric Fasteners

Inch Fasteners

Strength Levels: SAE Grades

5.2

Hex Head Bolts & Cap Screws 5

Strength Levels: Property Classes

* Markings Not Required 4.6*

4.8*

5.8*

8.8

4.6

4.8

5.8

8.8

9.8

10.9

12.9

9.8

10.9

12.9

Markings for size M5 and Larger

Hex Hea Flange Screws

Same As Above 5

12 Point Flange Screws

Hex Socket Head Cap Screws

Markings Not Required

5.1

8.8

12.9

8.8

12.9

4.8*

9.8

4.8

9.8

SEMS

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

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001

Table 2. Stud and Nut Designations

Types of Fasteners

Inch Fasteners

Metric Fasteners

* Markings Not Required

Strength Levels: SAE Grades

Strength Levels: Property Classes

5.2*

4.6*

4.8* 5.8*

8.8

4.6

4.8

8.8

9.8 9.8

5.8

10.9 12.9 Markings for size M5 and Larger

12.9

10.9

8.1 or

Studs

Optional Geometric Symbols for Size M5 through M11 ONLY.

Hex Nuts

Hex Slotted Nuts

Hex Flange Nuts

Return

8 or

Markings Not Required

Service Manual

1997-09-24

F-code

Section

C-code

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

T-code

001

Table 3. Torque Nut Designations

Types of Fasteners

Inch Fasteners

Strength Levels: SAE Grades

A or

Metric Fasteners

Strength Levels: Property Classes

All Metal Prevailing Torque Nuts

G 9

or All Metal Prevailing Torque Flange Nuts or

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Service Manual

1997-09-24

F-code

Section

C-code

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

T-code

001

Table 4. Torque Nut with Nylon Insert Designations

Types of Fasteners

Metric Fasteners

Inch Fasteners

Strength Levels: Property Classes

Strength Levels: SAE Grades

or Nylon Insert Prevailing Torque Nuts

Markings Not Require

or or

Markings Not Required

Nylon Insert Prevailing Torque Flange Nuts

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Service Manual

1997-09-24

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Section

C-code

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

T-code

001

Table 5. Fastener Torque Values

Size and Pitch

Property, Class 8.8*

Property, Class 10.9**

Property, Class 12.9***

N•m

in.-lb

N•m

in.-lb

N•m

in.-lb

5-6 8-10 20-25

44-53 71-88 177-221

7-8 12-14 30-35

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

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

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

N•m

ft-lb

N•m

ft-lb

N•m

ft-lb

M8 x 1.25 M10 x 1.5

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

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

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

22-26 44-48

34-40 70-75

26-30 52-55

M12 x 1.75 M14 x 2

70-80 110-125

30-33 52-59

100-110 155-180

74-81 114-133

115-130 180-210

85-96 133-155

M16 x 2 M20 x 2.5

170-190 340-380

125-140 251-280

240-270 450-500

177-199 332-369

280-320 550-600

207-236 406-443

M24 x 3

580-650

428-479

800-900

590-664

900-1050

664-774

M30 x 3.5

1150-1300

848-959

1600-1800

1180-1328

1850-2100

1364-1549

M36 x 4

2000-2250

1479-1660

2800-3150

2065-2323

3250-3700

2397-2729

M5 x 0.8 M6 x 1 M8 x 1.25

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

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

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Service Manual

1997-09-24

F-code

Section

C-code

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

T-code

001

4. Conversion of Metric and English Units AREA Multiply

To Get

Multiply

To Get

inches²

6.451

centimeters² (cm²)

centimeters²

0.155

inches² (in²)

feet²

0.093

meters² (m²)

meters²

10.764

feet² (ft²)

LINEAR Multiply

To Get

Multiply

To Get

inches

25.4

millimeters(mm)

millimeter

0.039

inches (in)

feet

0.305

meters (m)

meter

3.280

feet (ft)

yards

0.914

meters (m)

meter

1.094

yards (yd)

miles

1.609

kilometers (km)

kilometer

0.621

miles (mi)

MASS Multiply

To Get

Multiply

To Get

ounces (oz)

28.49

grams (g)

grams

0.035

ounces (oz)

pounds (lb)

0.454

kilograms (kg)

kilograms

2.205

pounds (lb)

tons (2000 lb)

907.18

kilograms (kg)

kilograms

0.001

tons (2000 lb)

0.907

metric ton (t)

metric ton

1.102

tons (2000 lb)

POWER Multiply

To Get

Multiply

To Get

horsepower

0.746

kilowatts (kW)

kilowatts

1.34

horsepower(hp)

PRESSURE Multiply

To Get

Multiply

To Get

pounds/in²

6.895

kilopascal (kPa)

kilopascals

0.145

pounds/in² (psi)

pounds/in²

0.007

megapascal (MPa)

megapascals

145.04

pounds/in² (psi)

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Service Manual

1997-09-24

F-code

Section

C-code

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

T-code

001

TEMPERATURE Multiply

To Get

Multiply

To Get

(Fahrenheit -32)

0.56

Celsius (C)

(Celsius x 1.8)

+32

Fahrenheit (F)

To Get

TORQUE Multiply

To Get

Multiply

inch pound

0.113

Newton meter (N•m) Newton meter

8.851

inch pounds in.-lb

feet pound

1.356

Newton meter (N•m) Newton meter

0.738

foot pounds ft-lb

VELOCITY Multiply

To Get

Multiply

To Get

miles/hour

1.609

kilometer/hour (km/h)

kilometer/hour

0.621

miles/hour (mph)

VOLUME

Multiply

To Get

Multiply

To Get

inches³

16.387

centimeters³ (cm³)

centimeters³

0.061

inches³ (in³)

inches³

0.016

liters

61.024

inches³ (in³)

quarts, U.S.

0.946

liters

1.057

quarts, U.S. (qt)

quarts, U.S.

0.83

quarts, Imp. (qt)

quarts, Imp.

1.205

quarts, U.S. (qt)

gallons, U.S.

3.785

liters

0.264

gallons, U.S. (gal)

gallons, U.S.

0.83

gallons, Imp. (gal)

gallons, Imp.

1.205

gallons, U.S. (gal)

ounces

29.57

milliliters (ml)

milliliters

0.034

ounces (oz)

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Service Manual

1997-09-24

F-code

Section

C-code

M2.0 Technical Service Data

Version no

T-code

000

CMX

Technical Service Data MODEL CMX60

CMX80

Type

Shunt wound

Power

1.8 hp.

Duty factor

60 min.

Min carbon brush length

0.62 in.

Min commutator diameter

2.80 in.

Min brush spring tension

40 oz.

305880-000

DRIVE MOTOR

Part no TRANSMISSION/GEAR Type

Vertical motor spiral-bevel output

Gear ratio

14.8:1

Oil volume

About 1 quart

Normal temperature

SAE 80W90

ATF

10.5 in. x 5 in. x 6.5 in.

250 ft-lb

3 1/4 in. x 6 in.

< +5oF-15°C WHEELS Drive wheel Drive wheel weight without load with battery, lb Drive wheel weight with rated load and battery, lb Torque axle nut Load wheel Load wheel weight with rated load, lb

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1997-09-24

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Section

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PS M2.0 Technical Service Data Version no

T-code

000

CMX

MODEL CMX60

CMX80

Power

24 Volts

Revolutions/min at work pressure

2200 rpm.

20% on 5 min. cycles

Minimum brush length

0.25 in.

Minimum commutator diameter

1.5 in.

Minimum brush spring tension

32-40 oz.

Part number

301822-000

Relief pressure

4000 psi

Prime-Trak relief pressure

250 psi

Pump flow

0.8 cc

Tank volume

About 1 quart

Normal temperature

Sunoco TH

< -10°F - 23°C

Texaco 15

0.5 in.

300947-055

301822-000

Pump circuit breaker

105 Amp

Drive circuit breaker

150 Amp

Control circuit

12 Amp

31¾ in. x 13e in. x 32 in

31¾ in. x 13e in. x 32 in.

Capacity (Min./Max. Amp-hrs.)

400/750

Weight (Minimum)

900 lb

HYDRAULIC UNIT

Duty factor

PRIME-TRAK HYDRAULIC MOTOR Min brush length Part number FUSES

BATTERIES Dimension W x L x H

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Service Manual

1997-09-24

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Section

C-code

M2.0 Technical Service Data

Version no

T-code

000

CMX

MODEL CMX60

CMX80

Without load

8.0 mph

With rated load

6.0 mph

5.0 mph

Lift without load

fpm

Lift with rated load

fpm

Lower without load

fpm

Lower with rated load

fpm

Driving without load

95 Amp

Driving with rated load

Amp

Lifting without load

Amp

Lifting with rated load

95 Amp

DRIVING SPEEDS

LIFTING/LOWERING TIME

CURRENT CONSUMPTION

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

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Service Manual

1997-09-24

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Section

C-code

PS M2.0 Technical Service Data Version no

T-code

000

CMX

Return

Service Manual

1997-09-24

F-code

PS Version no

Section

C-code

M3.0 Ordering Spare Parts T-code

000

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

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Service Manual

1997-07-15

F-code

Section

C-code

PS M3.0 Ordering Spare Parts Version no

T-code

000

Return

Service Manual

1997-07-15

F-code

PS Version no

Section

C-code

P Contents, Section P T-code

000

Contents, Section P 1. Planned Maintenance

Return

P1.0

INTRODUCTION, MAINTENANCE

P2.0

SERVICE SCHEDULE

P3.0

LUBRICATION CHART

P4.0

OIL AND GREASE SPECIFICATIONS

Service Manual

1997-07-15

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Section

C-code

PS P Contents, Section P Version no

T-code

000

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Service Manual

1997-07-15

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Section

C-code

P1.0 Introduction, Maintenance

Version no

T-code

000

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

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

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Service Manual

1997-07-15

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Section

C-code

PS P1.0 Introduction, Maintenance Version no

T-code

000

Return

Service Manual

1997-07-15

F-code

Section

P2.0 Service Schedule

Version no

T-code

000

CMX

C-code

Service Schedule

5200 6000

3100 4100

5300 3100 0840

5400 3500

7400 6125

5300 5400 5710

5110

7310 3500

1700 3100

0000

2550 3500

1. Planned Maintenance Schedule ITEM

0000 0000.1

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WORK REQUIRED Interval in Hours Interval in Days/Weeks/Months Chassis Check that the truck’s data plate is legible Service Manual

5 1d

25 1w

100 1m

300 3m

600 6m

1200 12 m

3600 36 m

1997-09-23

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Section

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PS P2.0 Service Schedule Version no

T-code

000

CMX

ITEM

0000.2 0000.3 0000.4 0640 0640.1 0640.2 0640.3 0840 0840.1 0840.2 1700 1700.1 1700.2 1700.3 1700.4 1700.5 2550 2550.1 2550.2 2550.3 3100 3100.1 3100.2 3100.3 3500 3500.1 3500.2 3500.3 3500.4 44

Return

WORK REQUIRED Interval in Hours Interval in Days/Weeks/Months Check for damage and cracks Retighten the truck body bolts Check the cover screws Operator Controls Check that the travel direction/ speed selectors are operational Check that the horn button is operational Check that the hydraulic buttons are operational Driver’s Protection Check that the emergency stop button is operational Check that all shields and guards are secure and installed correctly Drive Motor Check for arcing due to poor connections All connections tight Clean motor of dirt and dust Check torque of motor bolts Check for abnormal noise in motor bearings Drive Gear Check for oil leakage Clean motor of dirt and dust Check torque of motor bolts Brake Clean dust and debris Check wear on brake disc and brake shoes Check brake operation Wheels Remove all string, wrapping, and debris Check all wheels for wear Grease load wheel bearings Grease caster and caster wheels

5 1d

25 1w

100 1m

300 3m

600 6m X X X

1200 12 m

3600 36 m

X X X

X X

X X X X X

X X X X X X X X

Service Manual

X X 1997-09-23

ITEM

4100 4100.1 4100.2 5110 5110.1 5110.2 5110.3 5110.4 5200 5200.1 5300 5300.1 5300.2 5300.3 5400 5400.1 5400.2 5400.3 5400.4 5400.5 5710 5710.1 6000 6000.1 6000.2 6000.3 6000.4 6000.5

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WORK REQUIRED Interval in Hours Interval in Days/Weeks/Months Steering Control Arm Check fasteners Check ease of steering Battery Electrolyte level, 1/2 - 5/8 inch above cell plates All connections: battery, battery and charger plugs All cell and link covers intact Check battery specific gravity Instrument Panel Check battery indicator and hourmeter for correct operation Electrical Control System Check key switch Check brake switch Check power cables and control wiring harness for proper routing Electrical Panel Cleaning and mounting to chassis Tightening of connections Check contactor tips Check contactor tips for free movements Check all cable insulation for damage Electronic Card Check for connections in harness connectors Hydraulic System Check hose and connections for leakage Check hose for wear and damage Check hydraulic tank for cracks, leaks, and mounting Check correct oil level Change the hydraulic oil

Service Manual

5 1d

25 1w

F-code

Section

P2.0 Service Schedule

Version no

T-code

000

CMX

100 1m

300 3m

600 6m

C-code

1200 12 m

3600 36 m

X X X X X X X

X X X

X X X X X

1997-09-23

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Section

C-code

PS P2.0 Service Schedule Version no

T-code

000

CMX

ITEM

6125 6125.1 6125.2 6125.3 6125.4 6125.5 6125.6 6125.7 7310 7310.1 7310.2 7310.3 7400 7400.1 7400.2 7400.3 7400.5

Return

WORK REQUIRED Interval in Hours Interval in Days/Weeks/Months Prime-Trak Hydraulic System Check for leakage Check mountings Check for proper spring tension Check hoses and connections for leakage Check hoses for wear and damage Check micro switch Check Prime Trak system as a whole for proper operation Lift Cylinder Check for leakage Check mounting Lube all grease fittings Lifting device Check the clearance of the forks Check the forks for damage and cracks Check the forks for wear and cracks Lube all grease fittings

5 1d

Service Manual

25 1w

100 1m

300 3m

600 6m

1200 12 m

3600 36 m

X X X X X X X

1997-09-23

F-code

Section

P2.0 Service Schedule

Version no

T-code

000

CMX

C-code

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

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

Full charge battery

1/2

Half charged battery

Discharged battery

The battery guard has an integrated cut-out function that cuts out the truck’s 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’s capacity can then be used before the battery guard cuts out the lift function. 2.1.2. Hydraulic System 1. Inspect the entire truck for leaks, especially around the hydraulic pump assembly and the 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. 2. Report any problems to the proper authorities, and DO NOT operate the truck until it has been inspected and repaired by a qualified technician.

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PS P2.0 Service Schedule Version no

T-code

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CMX

2.1.3. Frame/Sheet Metal 1. Inspect the truck for loose, damaged or missing parts. All shields must be in place and functional. 2. Report any problems to the proper authorities. DO NOT operate the truck until it has been inspected and repaired by a qualified technician. 2.1.4. Wheels/Tires Inspect wheels and tires for wear and damage. Trash that is wrapped around wheels and axles will cause premature tire wear and bearing damage. The floors should be kept clear of trash to prevent damage to the wheels and tires. 2.1.5. Functions/Operations 1. Test the truck for the proper operation of all functions including the travel controls, lift and lower functions, the brakes and the emergency disconnect button. Safety devices must be operational. 2. Report any problems to the proper authorities. DO NOT operate the truck until it has been inspected and repaired by a qualified technician.

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P2.0 Service Schedule

Version no

T-code

000

CMX

C-code

2.2. Services to be Performed Monthly The monthly planned maintenance service should be performed by a qualified technician. 2.2.1. Inspection All of the services and inspections listed above for the daily inspection should be performed at this time. The inspection procedure should be more thorough, and minor deficiencies should be corrected. 2.2.2. Transmission Check the transmission fluid level. The level check point is a plug on the side cover of the transmission about 4 in. [100 mm] above the bottom of the transmission case. Remove the plug and inspect the level of the fluid inside the transmission case. The fluid level should come to about 3/8 in. [10 mm] below the plug and should never be above the level of the plug. 2.2.3. Brakes The brakes should stop a fully loaded truck at full speed in approximately one truck length. The brakes should fully release when the control handle is moved down 12 degree from the fully raised position and should apply at 28 degree 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. 2.2.5. Electrical Connections 1. All electrical connections should be checked that they are clean and tight. Plug-in connectors should be unplugged and plugged back in to clean the terminals. © BT Products

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PS P2.0 Service Schedule Version no

T-code

000

CMX

2. If the truck is equipped with any of the cold-storage, freezer use, or corrosive environment application packages, the di-electric compound in the plug-in connectors should be renewed. This compound is available through the parts department of your authorized dealer. 2.2.6. Contactor Tips (NOT Sealed) Inspect contactor tips for arcing, pitting, or burning. Minor pitting of the tips is not a problem. However, if the tips are pitted through the tip to the copper bar, the tips should be replaced. DO NOT file tips. Replace tips only in complete sets. Some contactors have concealed tips or are fully sealed so that tips cannot be replaced. 2.2.7. Motor Brushes Inspect the drive and pump motors for brush wear and condition of the commutator. Minimum brush lengths are given in the specifications section of this manual. As a rule of thumb, the brushes should be replaced if the brush spring is within 1/16 in. of touching the brush holder. 2.2.8. Drive Motor 1. Blow out the drive motor fan and vents. 2. Check for any signs of oil on the drive motor fan and air vents. 3. Check for any damage to the fan or air vents. WARNING Compressed air used for cleaning MUST be reduced to less than 30 psi., and then only with effective chip-guarding and personal protective equipment worn. 2.2.9. Hydraulic Reservoir Check the fluid level in the hydraulic reservoir. The level check point is the line on the side of the reservoir. 2.2.10. Frame Lube (“Lubrication Chart” on page57 ) The pressure type grease fittings (zerk fittings) should be lubricated with Texas Refineries #880 Crown and Chassis lubricating grease. The total number of grease fittings

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P2.0 Service Schedule

Version no

T-code

000

CMX

C-code

depends on the truck options when built. Cold-storage, freezer use, or corrosive environment application package will have more grease fittings than a standard truck. Look for flush-type grease fittings on the load wheel axles. Regular grease fittings are found on the transmission pivet bearings. 2.2.11. Pivot Points There are some pivot points and other items that need to be lubricated but do not have grease fittings. These include, but are not limited to, the control handle mounting shaft and the cylinder mounting pins. Lubricate these non-greasable wear points with a drip oil can using 10 wt. machine oil.

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PS P2.0 Service Schedule Version no

T-code

000

CMX

2.3. Services to be Performed Annually The annual planned maintenance service will take a longer period of time to complete than does the monthly service. This would be a good time to arrange other repairs that have been noted on the monthly service. 2.3.1. Inspection All of the services and inspections listed for the daily and monthly inspection should be performed at this time. The inspection procedure should be more thorough, and minor deficiencies should be corrected. 2.3.2. Transmission The transmission fluid should be drained. The drain port is the lower left hand bolt holding the side cover in place. 1. Remove the bolt to drain the transmission fluid. 2. Flush the transmission case with safety solvent. 3. Pour clean solution into the level check plug in the side cover. 4. With drive tire off the floor, allow solution to run out of drain port while transmission is running. Stop flushing when the solution run clean. Allow the solvent to drain well before replacing the drain plug bolt. 5. Replace the drain plug bolt. 6. Refill the transmission with the proper clean oil before operating truck. 2.3.3. Battery At approximately 1500 hours, contact an authorized battery dealer to determine the overall condition of the battery. Determine if the battery needs to be washed down. This can only be done by properly equipped and trained personnel. 2.3.4. Hydraulic System The hydraulic system should be drained, flushed and refilled, and the pressure relief valve setting should be checked and adjusted.

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Service Manual

1997-09-23

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Section

P2.0 Service Schedule

Version no

T-code

000

CMX

C-code

WARNING Before siphoning oil from reservoir, make certain siphon is clean. To drain reservoir, disconnect and remove the hydraulic pump assembly. 1. Remove hydraulic reservoir from assembly. 2. Drain the oil and clean the inside of the reservoir. 3. Drain oil from hydraulic hose and lift cylinder. 4. Assemble hydraulic pump assembly and install on truck. 5. Fill reservoir with proper clean oil. 6. Operate raise and lower function several times to purge air from system. 7. Check oil level, fill to line. 8. Put rated truck capacity load on forks and adjust pressure relief valve, if necessary, so that truck will lift rated load. 2.3.5. Brakes 1. Remove brake drum, and inspect brake shoe linings and brake drum for wear. If the brake drum is damaged or worn, a new drum should be fitted. 2. The brake shoes should be replaced if the linings have worn down so much that the brakes will not meet stopping and holding specifications. 3. See the procedures for adjusting brakes before replacing the brake shoes.

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Service Manual

1997-09-23

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Section

C-code

PS P2.0 Service Schedule Version no

T-code

000

CMX

Return

Service Manual

1997-09-23

F-code

Section

P3.0 Lubrication Chart

Version no

T-code

000

CMX

C-code

Lubrication Chart Interval/Running Hours Pos. No 1 2 3 4 5 6 7

Service Point Wheel bearings Handle pivot Lifting linkage Hydraulic syste Steering bearings Drive gear Drive gear drain

300 h

600 h

1200 h

Lubricant (See Chart in Section 6 for Code)

L L L C

O L O

L= Lubrication

C = Check

A A A B A C

O = Oil change

3 6 7

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Service Manual

1997-09-24

F-code

Section

C-code

PS P3.0 Lubrication Chart Version no

T-code

000

CMX

Return

Service Manual

1997-09-24

F-code

Section

C-code

PS P4.0 Oil and Grease Specifications Version no

T-code

000

Oil and Grease Specifications 1. Approved Oils and Grease Lubricant

Grease

B C

Hydraulic oil Transmission oil

Return

Specification

Application area

Above 5°F-15°C

Below 5°F-15°C

Below -10°F-23°C

Tex. Ref. C and C #880 Sunoco TH SAE 80w/90

Tex. Ref. C and C #880 Sunoco TH SAE 75w

Tex. Ref. C and C #880 Texaco 15 SAE 75w

Service Manual

1997-07-15

Bearings and bushings Hydraulic system Gears

F-code

Section

C-code

PS P4.0 Oil and Grease Specifications Version no

T-code

000

Return

Service Manual

1997-07-15

F-code

PS Version no

Section

C-code

S Contents, Section S T-code

000

Contents, Section S 1. Service Instructions NO FUNCTION GROUP

C-CODE

CHASSIS

0000

DRIVE MOTOR

1000

DRIVE GEAR / TRANSMISSION

2000

BRAKE / WHEEL SYSTEM

3000

STEERING SYSTEM

4000

ELECTRICAL / PNEUMATIC SYSTEM

5000

HYDRAULIC SYSTEM

6000

LIFTING MAST / CYLINDERS

7000

PERIPHERAL / INSTALLATION

8000

EQUIPMENT 9

Return

OPTIONS / ATTACHMENTS

Service Manual

1997-04-15

9000

F-code

Section

C-code

PS S Contents, Section S Version no

T-code

000

Return

Service Manual

1997-04-15

F-code

Section

C-code

S0.1

0000 Chassis

Version no

T-code

000

CMX

Chassis 1. General Information The chassis has several panels and covers that are removable. During operation of the truck these panels and covers must be secured to the chassis. The purpose of bolton panels and covers is for access of components when servicing the truck. 3 17

4 1

14 15 16 5

6 1 10 8

Removal/Installation of Chassis Panels & Covers

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1997-09-24

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Section

C-code

PS Chassis

S0.1

0000

Version no

T-code

000

CMX

POS. NO

DESCRIPTION

POS. NO

DESCRIPTION

POS. NO

Screw, flat head

Screw

Plate, latch

Pad, knee

Angle, platform

Screw

Cushion, with controls

Screw

Plate, cover

Cushion, NO controls

Cover

Screw

Pad, platform

Door

Bumper

Plate, platform

Latch

DESCRIPTION

2. Door 2.1. Removal 1. Park the truck on a level surface and make sure parking brake is applied. 2. Disconnect battery. 3. Open access door (11) fully and lift door off hinge pins.

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Service Manual

1997-09-24

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Section

C-code

S0.1

0300 Lift Frame

Version no

T-code

000

CMX

Lift Frame Valid from machine number: CMX__25334001

POS. NO

DESCRIPTION

POS. NO

DESCRIPTION

POS. NO

DESCRIPTION

1 2 3 4 5 6 7 8 9 10

Pin Frame, lift Isolator Bushing Bushing Fork, load wheel Pin, load wheel Pin, roll Fitting, grease Pin, roll

11 12 13 14 15 16 17 18 19 20

Fitting, grease Rod, pull Pin Isolator Screw, socket head Screw, cap Pin, lower link Fitting, grease Pin, lower link Pin

21 22 23 24 25 26 27 28 29 30

Link, lower Pin Link, upper Bearing Shim Link, upper Frame, carrier Screw Bracket, limit switch Pin, roll

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Service Manual

1997-09-24

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Section

C-code

PS Lift Frame

S0.1

0300

Version no

T-code

000

CMX

1. Pull rod To replace pull rods and/or bushings it is easiest to work with machine upside down. Remove battery before turning truck over. Some hydraulic oil may leak from hydraulic reservoir.

1.1. Removal NOTE! CLEANLINESS! Perform procedures in a clean environment. Make sure all parts are cleaned before disassembly and kept clean during assembly. 1. Park the truck on a level surface and make sure parking brake is applied. 2. Release pressure in hydraulic system by pressing the lowering button on steering control handle. 3. Disconnect and remove battery from unit to prevent accidental operation. 4. Open access door fully. 5. Before disassembly, thoroughly clean exterior in a cleaning solvent to remove all contamination. WARNING Be extremely careful when working with solvent. Even a small explosion or fire could cause injury or death. WARNING Compressed air used for cleaning MUST be reduced to less than 30 psi, and then only with effective chip-guarding and personal protective equipment. 6. Remove roll pins (8) that secure wheel fork pivot pins (1) and remove wheel fork pivot pins (1). 7. Remove cap screws (16) that secure lower link pins (17) and remove lower link pins (17). 8. Remove roll pins (8, 10) that secure lower link pins (19, 20) and remove lower link pins (19, 20). 9. Remove the wheel forks (6), pull rod (12), and 64

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Section

C-code

S0.1

0300 Lift Frame

Version no

T-code

000

CMX

lower links (21) as an assembly for disassembly later. 10. Remove roll pins (10) that secure wheel fork pins (13) and remove wheel fork pins (13). 11. Remove roll pins (8) that secures lower link pins (19) in pull rod (12) and remove lower link pins (19). 12. Remove all bushings and discard. Replace with new bushings.

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1997-09-24

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Section

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PS Lift Frame

S0.1

0300

Version no

T-code

000

CMX

1.2. Inspection 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. WARNING Be extremely careful when working with solvent. Even a small explosion or fire could cause injury or death. WARNING Compressed air used for cleaning MUST be reduced to less than 30 psi, and then only with effective chip-guarding and personal protective equipment. 2. 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 (6) for excessive wear or cracks. If cracks are found replace both wheel forks (6). 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. All bushings are to be replaced with new.

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Section

C-code

S0.1

0300 Lift Frame

Version no

T-code

000

CMX

1.3. Installation 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. WARNING Be extremely careful when working with solvent. Even a small explosion or fire could cause injury or death. WARNING Compressed air used for cleaning MUST be reduced to less than 30 psi, and then only with effective chip-guarding and personal protective equipment. 2. Install bushings (5) in pull rod (12). 3. Install bushings (4,5) in lower links (21). 4. Install lower link pins (19) and secure in place with roll pins (8). 5. Install pull rod (12) in wheel forks (6) and secure with pins (13) and roll pins (10). 6. Slide lower links (21) on lower link pins (19). 7. Install pull rods (12), lower links (21), wheels, and wheel forks (6) in lift frame forks. 8. Install pins (1) in lift frame (2) through wheel forks (6) and secure in place with roll pins (8). 9. Install pins (20) in carrier frame (27) through lower links (21) and secure in place with roll pins (10). 10. Install lower link pins (17) in lift frame (2) through lower links (21) and secure with cap screws (16). 11. Lubricate all grease fitting before turning truck back upright.

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C-code

PS Lift Frame

S0.1

0300

Version no

T-code

000

CMX

12. Return truck to the upright position. 13. Connect battery to truck. Add hydraulic oil to tank. 14. Operate the truck’s hydraulic system and check operation of system as a whole. Look for leak and tight places on the lifting linkage. WARNING DO NOT use your hands to check for hydraulic leakage. Use a piece of cardboard or paper to search for leaks. Escaping fluid under pressure can penetrate the skin causing serious injury. Relieve pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Keep hands and body away from pinholes and nozzles which eject fluids under high pressure. 15. Close access door.

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Service Manual

1997-09-24

F-code

Section

C-code

PS S0.1 0450 Drive Motor Mounting Points Version no

T-code

000

CMX,TMX

Drive Motor Mounting Points 1

2 4

8 7 3 6

POS. NO

Return

DESCRIPTION

POS. NO

DESCRIPTION

Key

Transmission

Brake assembly

Drive motor

Screw

Drum, brake

Bracket, cable

Nut

Service Manual

1997-09-22

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Section

C-code

PS S0.1 0450 Drive Motor Mounting Points Version no

T-code

000

CMX,TMX

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

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

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1997-09-22

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Section

C-code

PS S0.1 0450 Drive Motor Mounting Points Version no

000

T-code

CMX,TMX

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

2.2. Installation 1. Thoroughly clean all parts with safety solvent or other non-corrosive cleaning fluid. Air dry all parts. The transmission should be assembled in a dirt-free area. WARNING Be extremely careful when working with solvent. Even a small explosion or fire could cause injury or death. WARNING Compressed air used for cleaning MUST be reduced to less than 30 psi. and then only with effective chip-guarding and personal protective equipment. 2. Install brake assembly by lifting on brake shoe at a time and installing mounting bolts. (See Brake section for proper installation and adjustment of brakes). 3. Install brake drum on drive motor armature shaft over the key. © BT Products

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1997-09-22

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Section

C-code

PS S0.1 0450 Drive Motor Mounting Points Version no

T-code

000

CMX,TMX

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

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Service Manual

1997-09-22

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Section

C-code

S1.0

1700 Drive Motor

Version no

T-code

001

Drive Motor 1. General Information A routine maintenance schedule with recorded findings is the best way to reduce costly shut-downs and repair of equipment during operating hours. The goal of any maintenance program -- long-life and troublefree operations -- is related to the time spent making inspections and correcting minor problems as they occur. The key to planned maintenance of the brush and commutator is recognizing the undesirable brush and commutator conditions. If this is done, corrective action can be taken before a major component is damaged beyond serviceability. The brushes and commutator should be inspected for even wear and good commutation.

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

Basically an eight hour day of indoor material handling.

Severe Service:

Extended operating hours, or constant usage.

Extreme Service:

Chemical processing Freezer operation Processing plants (poultry, meat)

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

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Service Manual

1997-07-15

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Section

C-code

PS S1.0 Drive Motor

1700

Version no

T-code

001

TABLE #1 Drive Motor Troubleshooting

Indications, Causes. and Correction of Unsatisfactory Brush Performance Indications

Immediate Causes

Primary Faults

Sparking

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

1-2-3-43-44-45-46-49-59-60 7-12-31-33 7-12-30-32 7-12-30-32 8-9-11 6-14-15-16-17-18-19-20-21-2829 25-27-28-29-38-39-40-41-42

Wrong brush grade Fluctuating contact drop

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

Etched or burned bands on brush face

Overcommutation Undercommutation Too rapid reversal of current

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

Pitting of brush face

Glowing Embedded copper

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

Rapid brush wear

Commutator surface condition

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

Severe sparking Imperfect contact with commutator Wrong brush grade

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

Glowing at brush face

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

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

Copper in brush face

Commutator surface condition Bad service condition Wrong brush grade

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

Flashover at brushes

Machine condition Bad load condition Lack of attention

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

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S1.0

1700 Drive Motor

Version no

T-code

001

Chattering or noisy

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

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

Indications Appearing at Commutator Surface Indications

Immediate Causes

Primary Faults

Brush chipping or breakage

Commutator surface condition

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

Looseness in machine Vibration Chattering Sluggish brush movement Rough or uneven surface

1-2-3-4-17

Dull or dirty surface

5-44-60

Eccentric surface

1-19-22-52

High commutator bar

Sparking

Low commutator bar streaking or threading of surface

Sparking Copper or foreign material in brush face Glowing

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

Bar etching or burning

Sparking Flashover

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

Bar marking at pole pitch spacing

Sparking

25-37

Bar marking at slot pitch spacing

Sparking

7-12-30-57-60

Flat spot

Sparking Flashover Lack of attention

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

Discoloration of surface

High temperature Atmospheric condition Wrong brush grade

See “Heating at commutator” 44-46 60

Raw copper surface

Embedded copper Bad service condition Wrong brush grade

See “Copper in brush face” 43-45-47-49 59-61

Rapid commutator wear with blackened surface

Burning Severe sparking

2-3-11-14 See “Sparking”

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C-code

PS S1.0 Drive Motor

1700

Version no

T-code

001

Rapid commutator wear with bright surface copper dragging

Foreign material in brush face Wrong brush grade Brush vibration

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

Indications Appearing as Heating Indications

Immediate Causes

Primary Faults

Heating in windings

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

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

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

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

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

38-41-42 7-10-11-12-26 See “Sparking” See “Streaking or threading of surface” See “Copper in brush face” 57-58-59-61-62

Heating at commutator

Heating at brushes

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

1997-07-15

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Section

C-code

S1.0

1700 Drive Motor

Version no

T-code

001

TABLE # 2

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

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

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

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

Mechanical Fault in Machine 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.

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

Electrical Fault in Machine 25. 26. 27. 28. 29. © BT Products

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PS S1.0 Drive Motor

1700

Version no

T-code

001

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

Load or Service Condition 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50.

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

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

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

Service Manual

1997-07-15

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Section

C-code

S1.1 1700 Drive Motor Service

Version no

T-code

001

392,CMX,RMX,HMX,TMX

Drive Motor Service

POS. NO

Return

DESCRIPTION

POS. NO

DESCRIPTION

Coil, field

Endhead, commutator

Lead assembly

Band, head

Brus

Armature

Spring

Ring, retainer

Plate, brush

Bearing

Endhead, drive

Washer, wave

Seal, shaft

Service Manual

1997-09-22

F-code

Section

PS S1.1 Drive Motor Service Version no

C-code

1700

T-code

001

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

5. Remove the drive end head retaining screws, if necessary. Separate the armature and drive end head as an assembly from the frame and field coil assembly.

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PS Version no

001

Section

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S1.1 1700 Drive Motor Service T-code

392,CMX,RMX,HMX,TMX

6. Separate the armature from the drive end head. This operation is usually done by pressing the armature out of the drive end bearing. Remove with a puller. When a puller is used protect the end of the armature shaft with a nut or a thick flat washer. If the shaft, coupling, or spline is damaged when removing the end head the armature or the drive spline usually has to be replaced. Use caution, and DO NOT damage the armature.

Bearing Inner Race Snap ring

Press Ram

Pipe (same size as Inner Race)

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

Bearing Snap ring

Armature shaft Pressing end head back on armature shaft

End head

8. The ventilation fans are cast aluminum. Once these fans have been pressed onto the armature they must be heated to be removed without damage. A puller is installed and a slight pressure exerted against the fan. Use a small propane torch to heat the area of the fan around the shaft. When the fan becomes loose on the shaft, as evidenced by the puller becoming loose, it should be removed as quickly as possible.

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

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9. When the fan is assembled on the shaft, make sure it is a tight fit. Use “Loctite Retaining Compound 40” or equivalent on the inside of the fan hub when assembling fan.

Service Manual

1997-09-22

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PS S1.1 Drive Motor Service Version no

C-code

1700

T-code

001

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

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1997-09-22

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PS Version no

001

Section

C-code

S1.1 1700 Drive Motor Service T-code

392,CMX,RMX,HMX,TMX

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

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

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

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

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1997-09-22

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Section

PS S1.1 Drive Motor Service Version no

C-code

1700

T-code

001

2.4. Brush and Commutator The brushes and commutator should be inspected for even wear and good commutation. Good Commutation: A dark uniform coloring pattern at the brush wearing surface. Poor Commutation: The surface of the commutator appearing rough, pitted, scored or signs of burning or heavy arcing between bars. The color pattern will be:

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

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

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

2.5. Armature 1. Check security of fan. 2. Check for loose commutator bars. Loose commutator bars will usually be indicated by excessive wear or burning on one bar. The commutator can be checked for loose bars by lightly tapping all of the bars with the handle of a plastic or wooden handled screwdriver. A contrasting dull thud or vibration will indicate a loose bar, in which case the armature must be replaced. 3. Check for grounded circuits using a test light. Most commercial growlers incorporate a test light as shown in the illustration below. Check the armature for grounded circuits by placing one test lead of the test lamp on the commutator and the other test lead on the armature shaft. If the test light lights the armature is grounded. 4. Standard winding armatures are tested on a growler (see the illustration) using a steel strip or hacksaw 84

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1997-09-22

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PS Version no

001

Section

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S1.1 1700 Drive Motor Service T-code

392,CMX,RMX,HMX,TMX

blade to locate any shorted windings. Check for shorted windings by slowly rotating the armature in the growler while holding the strip or blade so that it passes over each armature core slot. If a winding is shorted the strip or blade will vibrate and the blade will get hot. NOTE! If the armature has been turned and undercut prior to testing, check for and remove any copper buildup or filings between commutator bars and at the commutator riser. This condition will cause an armature to check shorted and usually results from a dull undercutting tool. 5. Check commutator bars for any signs of burning. If deep burned sections are evident, either in the brush track or on the riser ends of the commutator bars, an open or short circuit in the armature windings is indicated.

2.6. Frame and Field Assembly Check the condition of all insulation. If the insulation on the field coils appears blackened or charred the serviceability of the coils is questionable. Burned or charred insulation is a result of coil overheating due to overloading conditions, grounded, or shorted coil windings. Check condition of all other insulation such as brush rigging under coil connections and around terminal studs. 2.6.1. Testing Frame and Field Assembly After thorough inspection, the Frame and Field Assembly should be checked for grounded, open, or shorted circuits. Grounded and open circuits can be checked using a test light. Most commercial growlers incorporate a test light as shown in opposite illustration.

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

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1997-09-22

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Section

PS S1.1 Drive Motor Service Version no

C-code

1700

T-code

001

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

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

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

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1997-09-22

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PS Version no

001

Section

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S1.1 1700 Drive Motor Service T-code

392,CMX,RMX,HMX,TMX

2.7. Assembly 2.7.1. Field Coil Installation Good solder connections are important due to the vibration characteristics encountered by these motors which can cause cold or poorly soldered connections to break. Prior to installing the field coils the connections which require soldering should be buffed or wire brushed clean to remove any oxidation. The connections should then be tinned with a soldering iron.

NOTE! We do not recommend using a soldering gun or torch. Soldering guns cannot provide the heat concentration required and soldering torches can damage the insulation.

After field coil installation connect the solder joint making sure the solder is flowing properly to avoid a cold soldered joint.

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

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1997-09-22

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Section

PS S1.1 Drive Motor Service Version no

C-code

1700

T-code

001

Press against the inner race when installing onto a shaft. 2. End heads having slip-fit bearings are normally retained by a snap ring. Always install new snap ring(s). 2.7.3. After Assembly

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

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

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

Return

Resurface the commutator by taking only light cuts each time, 0.005 in. [0.12 mm].

If reslotting/undercutting is necessary the final operation is to lightly sand the commutator with a fine sandpaper to remove any burrs left from the undercutting operation.

Service Manual

1997-09-22

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Section

S2.0 2550 Transmission

Version no

C-code

T-code

001

CMX,TMX

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

Technical data Gear Ratio

14.8:1

Oil Type

GL5 80W90

Oil Capacity

Approximately 1 quart

Drive Tire Size

10.5 in. x 5 in. x 6.5 in.

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

Return

Service Manual

1997-07-15

F-code

Section

C-code

PS S2.0 Transmission

2550

Version no

T-code

001

CMX,TMX

3. Removal Handle Stem assembly

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

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

Bearing Con

4. Remove kick panel around transmission.

Bearing Cup

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

Large Felt Seal

Bearing Cup

Bearing Cone

Transmission assembly

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

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Service Manual

1997-07-15

F-code

Section

S2.0 2550 Transmission

Version no

001

C-code

T-code

CMX,TMX

4. Installation Handle Stem assembly

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

Small Felt Seal

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

Bearing Con

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

Bearing Cup

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

Large Felt Seal

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

Bearing Cup

Bearing Cone

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

Transmission assembly

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Service Manual

1997-07-15

F-code

Section

C-code

PS S2.0 Transmission

2550

Version no

T-code

001

CMX,TMX

Return

Service Manual

1997-07-15

F-code

Section

C-code

S2.1 2550 Transmission Axle Seal

Version no

T-code

002

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

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

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

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Service Manual

1998-07-06

F-code

Section

C-code

PS S2.1 2550 Transmission Axle Seal Version no

T-code

002

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

Return

Service Manual

1998-07-06

F-code

Section

C-code

PS S2.1 2550 Transmission Disassembly / Assembly Version no

T-code

002

Transmission Disassembly / Assembly 1 2

15 14

6 5 11 10

Torque nut to 250 ft-lb while turning wheel.

12 9 6

POS. NO

Return

DESCRIPTION

POS. NO

DESCRIPTION

Case

Washer, drain bolt

Dowel pin

Bearing

Key

Gear, idler

Pinion gear

Axle bearing

Pinion nut

Axle spacer

Cover bolts

Axle seal

Cover

Axle nut

Fill plug

Gear, drive

Service Manual

1998-07-06

F-code

Section

C-code

PS S2.1 2550 Transmission Disassembly / Assembly Version no

T-code

002

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

2. Assembly Heat bearing cone on bearing heater to facilitate installation. 1. Install new bearings (10) on intermediate gear (11). 2. Install new inner bearings cones (12) on drive axle (16). 3. Install new bearings cups (12) in transmission case (1). NOTE! Bearing cups are slip fit in transmission case. 4. Position transmission on work bench with gear case side up. Place drive axle (16) and intermediate gear (11) in case (1) as a unit with gears (11,16) meshed. Because of gear size and bearing interference these pieces cannot be installed separately. 5. Use Loctite 515 ® gasket eliminator on mating surface and install gear case cover (7). Be sure that two dowel pins (2) are in case (1) to position 96

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Service Manual

1998-07-06

F-code

Section

C-code

PS S2.1 2550 Transmission Disassembly / Assembly Version no

T-code

002

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

Return

Service Manual

1998-07-06

F-code

Section

C-code

PS S2.1 2550 Transmission Disassembly / Assembly Version no

T-code

002

Return

Service Manual

1998-07-06

F-code

Section

C-code

S3.0 3300 Parking Brake System

Version no

T-code

001

CMX,TMX

Parking Brake System 1

2 4

8 7 3 6

POS. NO

Return

DESCRIPTION

POS. NO

DESCRIPTION

Key

Transmission

Brake assembly

Drive motor

Screw

Drum, brake

Bracket, cable

Nut

Service Manual

1997-07-15

F-code

Section

C-code

PS S3.0 3300 Parking Brake System Version no

T-code

001

CMX,TMX

1. Brake Theory of Operation Hand Operated Levers

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

Disengaged Position (Brake OFF)

Engaged Position (Brake ON)

Parking Brake Lever

100

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Service Manual

1997-07-15

F-code

PS Version no

001

Section

C-code

S3.0 3300 Parking Brake System T-code

CMX,TMX

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

Engaged Position (Brake ON)

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

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Service Manual

1997-07-15

101

F-code

Section

C-code

PS S3.0 3300 Parking Brake System Version no

T-code

001

CMX,TMX

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

60°

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

POS. NO 1 2

3 4

DESCRIPTION

Cam

Plate

Lever

Clip

Spring

Shoe

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

102

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Service Manual

1997-07-15

F-code

Section

C-code

S3.0 3300 Parking Brake System

Version no

001

T-code

CMX,TMX

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

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Service Manual

1997-07-15

103

F-code

Section

C-code

PS S3.0 3300 Parking Brake System Version no

T-code

001

CMX,TMX

104

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Service Manual

1997-07-15

F-code

Section

C-code

S3.1

3500 Drive Wheel

Version no

T-code

001

Drive Wheel 4.1. Removal The drive wheel can be removed, without removing the transmission by following these steps. 1. Park truck on level surface and block truck from moving. 2. Disconnect the battery. 3. Hoist machine and securely block truck with drive tire about 1 in. [25.4 mm] off floor. 4. Remove axle hub and wheel retaining nut. Pull tire and wheel from axle.

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

1 3

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Service Manual

1997-07-15

105

F-code

Section

C-code

PS S3.1 Drive Wheel

3500

Version no

T-code

001

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

1 3

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

Torque to 250 ft-lb [339 N•m]

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

106

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Service Manual

1997-07-15

F-code

Section

C-code

S3.2

3500 Load Wheels

Version no

T-code

001

Load Wheels 4 2 3 1 Raised edges to the inside.

3 2 4

Seals to the outside. POS. NO

DESCRIPTION

POS. NO

DESCRIPTION

Wheel, load

Bearing, No seal

Bearing, sealed

Guard, string

1. Park truck on level surface, and apply the brake. 2. Hoist machine so load wheels are approximately two inches off of the floor, and securely block. 3. Remove roll pin from under side of support arm. 4. Remove axle and load wheel assembly from support arm. 5. Inspect bearings. 6. Install new load wheel and bearing as needed. 7. Install load wheel assembly in support arm. Install axle and roll pin. © BT Products

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Service Manual

1997-07-15

107

F-code

Section

C-code

PS S3.2 Load Wheels

3500

Version no

T-code

001

108

Return

Service Manual

1997-07-15

F-code

Section

C-code

S3.3 3540 Support / Swivel Wheel

Version no

T-code

000

CMX

Support / Swivel Wheel 1. Stabilizing Caster

14 13

11 12 5

4 6 5

8 3

POS. NO

Return

DESCRIPTION

POS. NO

DESCRIPTION

Nut

Caster assembly

Frame, rider

Nut

Pivot

Spring, suppression

Screw, cap

Prime-Trak Cylinder assembly

Bushing

Retainer, spring

Bar, torsion

Nut

Screw, cap

Service Manual

1997-09-26

109

F-code

Section

C-code

PS S3.3 3540 Support / Swivel Wheel Version no

T-code

000

CMX

1.1. Removal NOTE! CLEANLINESS! Perform procedures in a clean environment. Make sure all parts are cleaned before disassembly and kept clean during assembly. 1. Park the truck on a level surface and make sure parking brake is applied. WARNING Be extremely careful when working with solvent. Even a small explosion or fire could cause injury or death. WARNING Compressed air used for cleaning MUST be reduced to less than 30 psi, and then only with effective chip-guarding and personal protective equipment. 2. Release pressure in hydraulic system by pressing the lowering button on steering control handle. 3. Disconnect battery from unit to prevent accidental operation. 4. Raise and block drive end of truck so caster wheels (8) are 2 - 3 in. [50 - 75 mm] off the floor. 5. Open access door fully. 6. Release pressure on springs (10) before removing caster assembles (8) from torsion bar (6). WARNING Risk of injury. Spring pressure is under spring base. When unbolted spring base may fly free and cause injury or death. Release spring tension before removing spring base mounting bolts. 7. Remove four cap screws (7) and nuts (9) securing caster assembly (8) to torsion bar (6). 110

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Service Manual

1997-09-26

F-code

Section

C-code

S3.3 3540 Support / Swivel Wheel

Version no

T-code

000

CMX

8. Remove caster assembly (8) from truck. 9. Before disassembly thoroughly clean exterior of the caster assembly (8) in a cleaning solvent to remove all contamination. WARNING Be extremely careful when working with solvent. Even a small explosion or fire could cause injury or death. WARNING Compressed air used for cleaning MUST be reduced to less than 30 psi, and then only with effective chip-guarding and personal protective equipment.

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Service Manual

1997-09-26

111

F-code

Section

C-code

PS S3.3 3540 Support / Swivel Wheel Version no

T-code

000

CMX

New Free Length is 6.45 in. (164 mm)

2. Inspect torsion bar (6) for excessive wear or bending. No cracks are allowed in torsion bar (6) and must be replaced if found. If heavy wear or bending is found replace torsion bar (6). 3. Inspect pivots (3) for excessive wear or cracks. If cracks are found replace both pivots (3). 4. Inspect all bolts (4) and replace if needed. 5. All bushings are to be replaced with new.

Worn Free Length is 6.25 in. (159 mm) or Less.

6. Inspect cylinder assembly (11) for excessive wear or scoring. If heavy scoring is found replace entire cylinder assembly. Cylinder assembly (11) can be serviced if needed. 7. Inspect hydraulic hose and replace if worn. 8. Inspect springs (10) for wear or compression. A new spring free length measures 6.45 inches. Replace a spring that measures 6.25 in. or less. NOTE! Free length is the length of the spring with no spring tension or a spring at rest.

112

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Service Manual

1997-09-26

F-code

Section

C-code

S3.3 3540 Support / Swivel Wheel

Version no

T-code

000

CMX

1.3. Installation 1. Install caster assembly (8) under torsion bar (6), and secure with cap screws (7) and nuts (9). 2. Lift truck and remove all blocking. 3. Tighten cap screw (14) until it makes contact with the spring retainer (12) or Prime-Trak cylinder assembly (13), then further rotate cap screw (14) four full turns for proper caster adjustment. 4. Tighten nut (13) to secure cap screw (14) from backing off. 5. Connect battery to truck. Add hydraulic oil to tank. 6. Operate the truck’s hydraulic system and check operation of system as a whole looking for leaks and tight places on the lifting linkage. WARNING DO NOT use your hands to check for hydraulic leakage. Use a piece of cardboard or paper to search for leaks. Escaping fluid under pressure can penetrate the skin causing serious injury. Relieve pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Keep hands and body away from pinholes and nozzles which eject fluids under high pressure. 7. Close access door.

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Service Manual

1997-09-26

113

F-code

Section

C-code

PS S3.3 3540 Support / Swivel Wheel Version no

T-code

000

CMX

1.4. Maintenance Normal maintenance of the truck frame consists of lubricating the stabilizing caster periodically. (See Planned Maintenance Schedule.) If the optional lube or cold storage package has not been fitted on the truck during production then lubrication consists of dripping 10 wt. machine oil onto the pivot points so that it soaks into the bushings. In wet or corrosive environments it will be necessary to reduce the time between planned maintenance intervals.

114

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Service Manual

1997-09-26

F-code

Section

S3.4 3560 Stabilizing Caster

Version no

C-code

T-code

000

392,393,394,CMX,HMX

Stabilizing Caster 1. Stabilizing Caster 1 2 3 16 4 15 6 5

6 7

8 9

13 12 11

POS. NO

Return

DESCRIPTION

POS. NO

DESCRIPTION

POS. NO

DESCRIPTION

Base, plate

Washer

Wheel

Bearing, thrust

Nut, slotted

Bearing, roller

Seal, felt

Pin, roll

Washer, spacer

Yoke, caster

Cap, hub

Screw, cap

Axle, caster

Washer, spacer

Fitting, grease

Bushing, ball

Service Manual

1997-09-24

115

F-code

Section

PS S3.4 Stabilizing Caster

C-code

3560

Version no

T-code

000

392,393,394,CMX,HMX

1.1. Disassembly NOTE! CLEANLINESS! Perform procedures in a clean environment. Make sure all parts are cleaned before disassembly and kept clean during assembly. 1. Before disassembly thoroughly clean exterior of the caster assembly in a cleaning solvent to remove all contamination. WARNING Be extremely careful when working with solvent. Even a small explosion or fire could cause injury or death. WARNING Compressed air used for cleaning MUST be reduced to less than 30 psi. and then only with effective chip-guarding and personal protective equipment. 2. Remove screw (16) and washers (15) securing axle (5) in yoke (4). Drive axle (5) from yoke (4) slide though wheel assembly. 3. Remove hub cap (10), roll pin (9), slotted nut (8), washer (7), and roller bearing (14) from yoke (4). 4. Separate base (1) and yoke (4) removing felt seal (3) and thrust bearing (2). 5. Remove spacer washers (11) and ball bearings (12) from wheel (13).

116

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Service Manual

1997-09-24

F-code

Section

S3.4 3560 Stabilizing Caster

Version no

000

C-code

T-code

392,393,394,CMX,HMX

1.2. Inspection 1. Thoroughly clean all parts and remove all nicks and burrs with emery cloth. WARNING Be extremely careful when working with solvent. Even a small explosion or fire could cause injury or death. WARNING Compressed air used for cleaning MUST be reduced to less than 30 psi. and then only with effective chip-guarding and personal protective equipment. 2. Inspect all bearings and replace as needed. 3. Inspect wheel(s) for flat spots or pieces of material missing from tire. 4. Inspect axle shaft for scoring or rust. If it can not be removed with emery cloth replace axle.

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Service Manual

1997-09-24

117

F-code

Section

PS S3.4 Stabilizing Caster

C-code

3560

Version no

T-code

000

392,393,394,CMX,HMX

1.3. Assembly 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. WARNING Be extremely careful when working with solvent. Even a small explosion or fire could cause injury or death. WARNING Compressed air used for cleaning MUST be reduced to less than 30 psi. and then only with effective chip-guarding and personal protective equipment. 2. Install ball bearings (12) and spacer washers (11) in wheel(s) (13). 3. Install new felt seal (3) into groove on yoke (4). 4. Install thrust bearing (2) on shaft of base (1). Slide base (1) though hole in yoke (4) making sure that the felt seal (3) is not damaged. 5. Press roller bearing (14) on shaft of base and install washer (7) and slotted nut (8). Tighten slotted nut (8) while rotating base (1) around yoke (4) until base (1) can not move. Back off slotted nut (8) one turn to nearest hole and install roll pin (9). 6. Tap hub cap (10) on over slotted nut (8). 7. Install wheel assembly in yoke assembly and slide axle (5) though yoke (4) and wheel (13). Install washers (15) and secure with cap screw (16). 8. Grease all grease fittings.

118

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Service Manual

1997-09-24

F-code

Section

C-code

S4.0 4100 Steering Control Arm

Version no

T-code

000

CMX

Steering Control Arm 12 1

10 2

6 7

14 16

4 40

20 22

19 18

21 17 23 24 25

27 2

31 37 38

CONNECT TO BRAKE

POS. NO

DESCRIPTION

POS. NO

DESCRIPTION

POS. NO

DESCRIPTION

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

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

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

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

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

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

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Service Manual

1997-09-24

119

F-code

Section

PS S4.0 Steering Control Arm Version no

T-code

000

CMX

C-code

4100

1. Control Handle Stem 1.1. Removal 1. Park the truck on a level surface and make sure parking brake is applied. 2. Release pressure in hydraulic system by pressing the lowering button on steering control handle. 3. Disconnect battery from unit to prevent accidental operation. 4. Remove the six retaining screws from outer edge of the switch cover. NOTE! Do not remove the center screw and nut. 5. Lift switch cover off assembly and lay to one side. 6. Remove the two socket head screws from inside head that secure head and handle stem together. 7. Lift entire head assembly from handle stem and disconnect wiring harness plug. The head assembly is free to be disassembled on a bench. 8. Pull knob on side of control handle and tilt control handle back to get more room for disassembly. 9. Remove screws (2) securing the brake cover (28) and disconnect wires from gauge. 10. From inside handle stem disconnect the clevis (20) and spring (29). 11. Remove screw (39) from inside of handle stem. 12. Open access door fully and remove the handle pivot shaft (40) by driving from one side. Remove handle stem while guiding out wiring harness and brake cable.

120

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CAUTION

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

Service Manual

1997-09-24

F-code

Section

C-code

S4.0 4100 Steering Control Arm

Version no

T-code

000

CMX

1.2. Installation 1. Install bushings (38) in handle stem base (34). 2. Thread wiring harness and brake cable up through handle stem and place handle stem in handle base (34). 3. Aligning handle stem (1) and base (34) install pivot shaft (40) and secure with screw (39). 4. Install clevis (20) using yoke pin (3) and secure with cotter pin (4). 5. Install spring (29). 6. Connect wires to gauge and install brake cover (28) using six screws (2). 7. Connect head assembly wiring harness to main wiring harness plug in handle stem. 8. Install two socket head screws inside head assembly and secure head assembly to handle stem. 9. Move switch cover plate assembly back in place and secure with six screws. 10. Test operation of all control handle functions.

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Service Manual

1997-09-24

121

F-code

Section

PS S4.0 Steering Control Arm Version no

T-code

000

CMX

C-code

4100

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

2.2. Disassembly 1. Place assembly on bench with pivot link (5) up and brake lever toward rear. 2. Remove spring (19). 3. Remove spring pins (9) from hand brake bracket plate and pivots (17). 4. Using a punch, remove groove pins (8) from pivots (17). 5. Remove brake levers (14) from assembly. Washer shims (7), pivots (17), and pivot link (5), will come out at this time.

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

122

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Service Manual

1997-09-24

F-code

Section

C-code

S4.0 4100 Steering Control Arm

Version no

T-code

000

CMX

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

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

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PS S4.0 Steering Control Arm Version no

T-code

000

CMX

124

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C-code

4100

Service Manual

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Section

C-code

S4.1 4100 Steering Handle Head

Version no

T-code

000

CMX

Steering Handle Head 1 2 3 4 5 6 38

7 10 5 12

15 16 17

13 14

20 26

36 30 28 29 24 18

28 4

27 22

19 21

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T-code

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CMX

POS. NO

126

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4100

DESCRIPTION

POS. NO

DESCRIPTION

POS. NO

DESCRIPTION

Cover

Pin, roll

Nut

Spring

Grip, handle

Switch, Forward

Bracket

Knob assembly

Spacer

Screw

Screw, flat head

Switch, Rearward

Pin, roll

Screw, socket

Screw, machine

Cam

Guard, wide

Heater, freezer pkg.

Return

Bolt, shoulder

Switch, Lower

Spring

Pin, roll

Screw, flat head

Housing, switch

Potentiometer assembly

Cover

Bushing

Gear

Switch, Lift

Shaft, cam

Spring

Control, thumb

Screw, machine

Switch, Horn

Pin, threaded

Lockwasher

Bracket, switch

Block

Bracket

Nut

Coupler

Switch, Prime-Trak

Clamp, cable

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Section

C-code

S4.1 4100 Steering Handle Head

Version no

T-code

000

CMX

1. Control Handle Head 1.1. Removal 1. Park the truck on a level surface and make sure parking brake is applied. 2. Release pressure in hydraulic system by pressing the lowering button on steering control handle. 3. Disconnect battery from unit to prevent accidental operation. 4. Remove six retaining screws (38) from outer edge of the switch cover (39). NOTE! Do not remove center screw (37) and nut (30). 5. Lift switch cover (39) off assembly and lay to one side. 6. Remove two socket head screws (20) from inside head that secure head and handle stem together. 7. Lift entire head assembly from control stem and disconnect wiring harness plug. The head assembly is free to be disassembled on a bench.

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

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000

CMX

C-code

4100

2. Direction Control Switches The direction control switches are mounted in the control handle head. It is not necessary to remove the head to change the switches. 1. Park the truck on a level surface and make sure parking brake is applied. 2. Release pressure in hydraulic system by pressing the lowering button on steering control handle. 3. Disconnect battery from unit to prevent accidental operation. 4. Remove six retaining screws (38) from outer edge of the switch cover (39). NOTE! Do not remove center screw (37) and nut (30). 5. Lift switch cover assembly plate off assembly and lay to one side. 6. Remove two screws (44) holding forward/rearward switch bracket (29) to housing. 7. Remove switch wires from wire harness plug and remove switches and bracket (29). 8. The switches (30,32,34) may now be replaced by unbolting them from the bracket (29). 9. Reconnect switch wires and reinstall bracket (29) in housing. 10. Test switch operation and adjust bracket (29) before installing switch cover plate (39). 11. Move switch cover (39) plate assembly back in place and secure with six screws (38). 12. Connect battery and test operation of all control handle functions. WARNING Testing drive function is made with drive wheel blocked off the floor. Risk of serious personal injury or possibly death may occur from run way truck.

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S4.1 4100 Steering Handle Head

Version no

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000

CMX

3. Horn, Raise, and Lower Switches There are raise, lower, and horn switches mounted in the switch cover plate on the control handle head. There are also a set of raise and lower switches mounted in the hand grips on the operator compartment backrest. 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 is not necessary to remove the head to change the switches. 1. Park the truck on a level surface and make sure parking brake is applied. 2. Release pressure in hydraulic system by pressing the lowering button on steering control handle. 3. Disconnect battery from unit to prevent accidental operation. 4. Remove six retaining screws (38) from outer edge of the switch cover (39). NOTE! Do not remove center screw (37) and nut (30). 5. Lift switch cover assembly plate from hand head assembly and lay to one side. 6. Remove center screw (38) and nut (44) securing switch bracket (43) to cover (39). Remove switch bar (37,40,42) and springs (41). 7. Disconnect head wiring harness from stem wiring harness and remove switch wires from head wiring harness plug. The wires are removed by pushing terminals out the back of head wiring harness plug. NOTE! Remember to mark wire terminals position when removing to make installation easier. 8. Install switch bar (37,40,42) in cover (39) making sure that switch bar (37,40,42) is placed in its proper location. Next install return springs (41) in wells on each of the switch bar (37,40,42). Place switch bracket (43) on springs (41) making sure spring align with dimples in switch bracket (43) and wires from switch go though holes. This whole © BT Products

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assembly is secured with one screw (38), clamp (45), and nut (44) placed in center. 9. Test switch operation that switch bar (37,40,42) will return and dose not bind before installing switch cover plate assembly on handle head. 10. Install new switch wire terminals in head wiring harness plug. 11. Install switch cover plate assembly back in place and secure with six screws (38). 12. Connect battery and test operation of all control handle functions.

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S4.1 4100 Steering Handle Head

Version no

T-code

000

CMX

4. Potentiometer The accelerator potentiometer is accessible inside the control handle head by removing the switch plate. The accelerator potentiometer operates off a gear toothed shaft (rack) that is moved when the travel controls are twisted. 1. Park the truck on a level surface and make sure parking brake is applied. 2. Release pressure in hydraulic system by pressing the lowering button on steering control handle. 3. Disconnect battery from unit to prevent accidental operation. 4. Remove the six retaining screws (38) from outer edge of the switch cover (39). NOTE! Do not remove center screw (37) and nut (30). 5. Lift switch cover assembly plate off assembly and lay to one side. 6. Disconnect head wiring harness from stem wiring harness and remove potentiometer wires from head wiring harness plug. The wires are removed by pushing terminals out the back of head wiring harness plug. NOTE! Remember or marking the wire terminals position when removing to make installation easier. 7. Remove two screws (4) securing potentiometer assembly (24) to the control head housing (9). Remove and discard potentiometer assembly (24) and gear (25). Replace with new. 8. Install new potentiometer assembly (24) and gear (25) on control head housing (9) and hold in place with screws (4). Do Not tighten completely. 9. Connect ohmmeter leads to potentiometer wires. 10. While holding potentiometer bracket (24) against control head housing (9) and make sure gear (24) on potentiometer are engaged with return (7) gears © BT Products

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teeth. In neutral ohmmeter reading should be 5500 to 6000 ohms and will reduce to below 50 ohms as the travel controls are operated to high speed. By sliding potentiometer assembly (25) up or down as necessary taking measurements and make adjustments. If slotted holes in potentiometer bracket (24) do not allow enough adjustment bracket may be lifted slightly and potentiometer drive gear (25) can be rotated by one tooth. 11. Tighten potentiometer assembly (24) mounting screws (4) and install potentiometer wire terminals in head wiring harness plug. 12. Test operation of potentiometer gear (25) and return (7) by moving travel controls before installing switch cover plate assembly on head. 13. Install switch cover plate assembly back in place and secure with six screws (38). 14. Connect battery and test operation of all control handle functions. WARNING Testing drive function is made with drive wheel blocked off the floor. Risk of serious personal injury or possibly death may occur from run way truck.

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S5.0 5190 300/400 Amp Contactor

Version no

T-code

000

300/400 Amp Contactor 1 7

3 6 4

8 POS. NO

Return

DESCRIPTION

POS. NO

DESCRIPTION

Screw

Coil & frame

Cover

Contactor tip, fixed

Return spring

Nut & lockwasher

Contactor tip, moving

Armature cap

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

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000

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

1.1. Removal/Replacement of Contact Tips NOTE! Before attempting to disassemble a contactor to install a new contact tip set carefully observe location and orientation of each part. 1. Loosen and remove two cover screws (1) securing cover (2) to coil frame (5). Observe position of positive (+) marking on the cover. 2. Remove cover (2). Be sure to note location of spring seat and spring (3) under cover. 3. Remove nut and lockwasher (7) from each stationary contact tips (6). 4. Remove contact tips (6) from cover (2). 5. Install new contact tips (6) and secure with lockwashers and nuts (7). Tighten nuts firmly on each contact tips (6). 6. Remove moving contact tip assembly (4) from coil frame (5). Observe location of components upon removal. 134

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S5.0 5190 300/400 Amp Contactor T-code

000

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

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000

136

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S5.1 5190 “EE” Contactor

Version no

C-code

T-code

000

“EE” Contactor

3 11

4 5 6 7 8

10 9

POS. NO

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Service Manual

DESCRIPTION

POS. NO

DESCRIPTION

Shroud

Return spring

Screw

Contactor tip, moving

Insulator

Coil & frame

Screw

Contactor tip, fixed

Shield

Nuts & lockwasher

Cover

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PS S5.1 “EE” Contactor

5190

Version no

T-code

000

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

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000

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

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PS S5.1 “EE” Contactor

5190

Version no

T-code

000

140

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Section

C-code

PS S5.3 5230 Battery Controller / Hourmeter / Lift Interrupt Version no

T-code

001

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

Hourmeter LCD

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

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PS S5.3 5230 Battery Controller / Hourmeter / Lift Interrupt Version no

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001

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

Open Contact Voltage

200

VDC

Max

Closed Contact Current

ADC

Max

Volt Ampere Product

Max

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

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

0 - empty battery

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

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PS S5.3 5230 Battery Controller / Hourmeter / Lift Interrupt Version no

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Battery Ah 180 210 240

L-M M-N N-O

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

SETTING

VPC

SETTING

VPC

1.57

1.82

1.63

1.84

1.68

1.86

1.73

1.91

1.78

1.93

O P Q R S K DISCHARGE T

N M L

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PIN NO:

FUNCTION

Hourmeter (-)

Key switch (+)

Relay arm (+)

Relay NC (-)

Battery (-)

Hourmeter (+)

24 Volt (+)

48 Volt (+)

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001

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

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

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

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

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PS S5.3 5230 Battery Controller / Hourmeter / Lift Interrupt Version no

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001

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

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

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001

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

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001

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

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

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001

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

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

T-code

000

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

1/2

Power pin 1 Power pin 5

Battery negative 1

Key switch

1 10

Hourmeter LCD

Brake switch (Hourmeter input)

Not Used

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

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

T-code

000

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

0 - empty battery

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

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

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

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

T-code

000

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

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

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

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

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

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

3 (A1)

1 (F1)

4 (H1)

5 (F50)

POS. NO

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DESCRIPTION

Breaker, Power circuit

Contactor, line

Controller

Horn

Breaker, Control circuit

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2. List of Symbols

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Symbol

Description

Function

Remark

Transistor controller

A22

Driver Module

A60

Time Delay

Battery

Circuit Breaker

Drive motor circuit

150 amp

F50

Circuit Breaker

Control circuit

12 amp

E10

Heater

Circuit Breaker

Pump motor circuit

105 amp

Horn

Flashing Light

Travel Alarm

K10

Contactor

Main

K30

Solenoid

Pump motor

K32

Solenoid

Prime-Trak

K33

Relay

Prime-Trak

Motor

Drive

Motor

Pump

M10

Motor

Prime-Trak

Prime-Trak 24 volt

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Symbol

Description

Function

Indicator

Hourmeter

Indicator

Battery indicator/Hourmeter

Indicator

BDI/HR/Lift Interrupt

Potentiometer

Speed

S10

Switch

Brake

S14

Switch

Platform high speed

S15

Switch

Load wheel direction

Reverse

S16

Switch

Steer wheel direction

Forward

S17

Switch

Key

S18

Switch

Horn

S20

Switch

Reverser

S21

Switch

Emergency stop

S36

Switch

Lift limit

S41

Switch

Fork lower

S52

Switch

Fork lift

S59

Switch

Prime-Trak toggle

S60

Thermostat

Heater

S61

Switch

Prime-Trak throttle

S63

Switch

Prime-Trak limit

Coil

Prime-Trak

Y41

Coil

Fork lower

Diode

Prime-Trak

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Remark

5k - 0 Ohm

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2.1. Circuit Diagram 1(5)

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158

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

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2.3. Circuit Diagram 3(5)

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000

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

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

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

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

3.4. Brake released, S10 Brake Switch Closed When brake is released in driving position S10 is activated and closes. Voltage is supplied to J1-2.

3.5. Driving, Fork Direction When thumb control is activated for driving in the fork direction, S15 will close. Transistor controller checks that S10 © BT Products

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is closed before S15 closes. If not, driving is blocked. Battery voltage to terminal A1 J1-11. The voltage at M- on A1 will vary from 24 volt to 1 volt. This voltage is proportional to the position of the speed potentiometer R1.

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

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

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

3.9. Lifting the Forks The micro switch S52 closes. K30 receives positive voltage through wire number 5, lift limit switch, wire number 17. Negative return through wire number 13. K30 closes, and the pump motor M3 starts.

3.10. Lowering the Forks The micro switch S41 closes. The lower valve Y41 receives voltage through wire number 4. 164

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Negative return through wire number 13. Y41 energizes and forks lower.

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

3.12. Prime-Trak; operator off of the truck With platform high speed switch S14 open and toggle switch S59 closed. Voltage is available through S59, wire number 51 to Prime-Trak relay coil K33 to wire number 13 to battery. Since relay coil K33 is connected to battery negative on the other side the relay. Relay will energize, which closes the normal open tips of K33. Voltage is also available through tips to Prime-Trak time delay A60 and then to Prime-Trak limit switch K32. Negative returns through wire number 13 to battery. K32 closes and Prime-Trak pump motor starts operating. PrimeTrak pump motor will continue to run until the stabilizing caster linkage opens caster limit switch. Stabilizing caster cylinders and linkage will remain in the raised position to reduce the load on the drive wheel, which allows easier steering when the truck is used for order picking.

3.13. Prime-Trak; operator on the truck With platform high speed switch S14 closed voltage is available through S14, wire number 35, and to throttle switch S61. With S61 closed voltage is available through S61, wire number 43 to diode V7, and to toggle switch S59. With S59 closed voltage is available through S59, wire number 51 to Prime-Trak relay coil K33 and out wire number 13 to battery. Relay K33 is energized, which closed the normal open tips of K33. Voltage is also available through tips to Prime-Trak time delay A60 and then to Prime-Trak limit switch K32.

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Negative returns through wire number 13 to battery. K32 closes and Prime-Trak pump motor starts operating. PrimeTrak pump motor will continue to run until the stabilizing caster linkage opens caster limit switch. Stabilizing caster cylinders and linkage will remain in the raised position to reduce the load on the drive wheel, which allows easier steering. When travel (speed) controls in control handle are turned far enough to engage a higher travel speed S61. S61 opens in control handle and caster wheels are lowered to full contact on floor. Allowing more stability at high speed.

3.14. Lift Interrup When equipped with lift interrupt, micro switch S52 closes. K30 receives positive voltage through wire number 5, lift limit switch, wire number 17, lift interrupt, wire number 18. Battery voltage must be sufficient for the lift interrupt system to allow lift function to operate.

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

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

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

Warnin

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

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

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

1.3. Diagnostics and Troubleshooting The 1244 controllers provide diagnostics information to assist technicians in troubleshooting drive system problems. The diagnostics information can be obtained by reading the appropriate display on the PMC handset. The information can also be obtained by looking at the status LED built in the controller that is visible thought the window in label. 1.3.1. Handset Diagnostics The handset presents complete diagnostic information. Faults are displayed in the Diagnostic Menu, and the status of the controller inputs/outputs is displayed in the Test Menu. Accessing the Diagnostic History Menu provides a list of the faults that have occurred since the diagnostic history file was last cleared. Checking (and clearing) the diagnostic history file is recommended each time the unit is brought in for maintenance. See C-code 5710 for complete operating instruction for the PMC handset. Refer to the troubleshooting chart for suggestions covering a wide range of possible faults. 1.3.2. Troubleshooting Troubleshooting can be broken down into three sections: 1. Handset 2. Status LED on the controller 3. Electrical circuits These can be broken down into control circuit and power circuit. By knowing the exact symptoms of the truck operation, many hours of troubleshooting time can be saved. If the proper switch operates for the chosen direction and speed, then the problem can be found in the controller or the power circuit of that function. 168

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

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

2. Basics Of Circuit Operation The Curtis® PMC SepEx model 1244 is a microprocessor based, programmable motor controller designed for separately excited motors. It is a true MultiMode controller capable of four distinct operating modes, or personalities, and is programmable with a Curtis® 1307 Programmer. In addition to programming the controller, the 1307 has Diagnostic and Test modes to display error codes and display the status of the controller’s inputs and outputs. The 1244 controller includes an armature controller and a field controller. Both of which regulate the voltage and current applied to the motor according to a preprogrammed motor control algorithm. This motor control algorithm allows the user to select programmable speed and torque profiles that can be tailored to almost any material handling vehicle traction system. The polarity and magnitude of the field current is also controlled to provide solid state, contactorless direction control and regenerative braking. The 1244 is energized by applying power to the keyswitch input, pin number 1. At that time the controller is powered up and performs an internal self test. The controller becomes active by applying power to the interlock input, pin number 2. At that time, the following start-up checks are performed: 170

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1. Checks to see if there is a short between M- and Ground. This insures that the M- output or power MOSFETs are not shorted. 2. Checks to see if there is continuity in the field coil. This also occurs each time forward or reverse is selected. 3. Checks to see if the main contactor coil has actually closed, when commanded, by checking for battery voltage at the B+ terminal. 4. Checks to see if the throttle is below 25 percent. Selecting either forward or reverse will apply battery voltage to the respective input pin and select the direction of current flow in the field. Increasing throttle increases the voltage and current in the armature circuit. The field current will then follow a predetermined current map to match the armature current. In this manner, the motor is kept in its commutation range and arcing on the commutator is minimized. As the throttle is increased, and the motor speeds up the armature voltage will approach the battery maximum. If further increases in speed are commanded, the field will weaken automatically as directed by the field current map to provide the desired speed. Top speed is limited by limiting the minimum allowable field current. Further top speed limiting can be obtained by limiting the maximum armature voltage through the MAX SPEED Parameter. Regenerative braking is initiated by selecting the opposite direction and applying throttle. The amount of regen braking is regulated by controlling the field and, consequently, the armature current, based on the amount of throttle applied. In this manner, smooth controlled braking force is controlled by the operator. A feature called “neutral braking” provides automatic in neutral. Whenever neutral is selected (releasing the throttle lever), a programmable amount of regen braking is automatically applied to bring the vehicle to a gentle stop. The neutral braking feature simulates the feel of compression braking in an internal combustion engine vehicle.

2.1. Control Feature

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•

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

•

Fully compatible with the 1307 Programmer for

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programming, diagnostic and test information.

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

•

Regenerative braking increased usable battery energy and reduces motor heating.

•

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

•

MultiMode allows up to four user selectable vehicle operating profiles.

•

Programmable to match individual separately excited motor characteristics.

•

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

•

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

•

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

•

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

•

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

•

PWM drivers for contactors are programmable for pull-in and holding currents to reduce power dissipation and allow the use of common contactors.

•

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. Service Manual

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•

Fully protected inputs and outputs.

•

Active power on self test and continuous diagnostics during operation.

•

Internal watchdog circuits ensure proper software operation.

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3. Motor Circuit

Control plug J2

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

B-

M-

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

4. Control Circuit Terminal

Connecting

B-

Negative connection to battery

B+

Positive connection to battery and motor armature A1

M-

Motor armature A2

Motor field

The transistor controller has an integrated 16-pin connector to provide the low power logic control connections. The designation of the pins are according to the table below. 174

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24 23 22

21 20 19 18

17 16 15 14 13

12 11 10

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

Connecting

CONTACTOR DRIVERS P1

Key switch input

Brake switch input

Mode select 1

Mode select 2

THROTTLE CONNECTIONS P5

Not Used

BASIC CONTROL SIGNALS

Return

Coil return

P10

Drive steer wheel direction input

P11

Drive fork direction input

P12

Hourmeter

P13

Not Used

P14

Throttle pot low

P15

Not Used

P16

Throttle: wiper/resistor pot

P17

Negative main contactor

P18

Not Used

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Pin No

Connecting

P19

Not Used

P20

Not Used

P21

Not Used

P22

Not Used

P23

Not Used

P24

Not Used

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

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

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

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

LED Codes

2,2

178

Programmer Fault LCD Display Category

Explanation

(3,2) Possible Cause

Controller or microprocessor fault

1,3

(3,2)

solid on

2,1

1,2

(3,2)

No power or defective controller

1,4

1,1

LED off

0,1

Return

No known faults

Controller operational; no fault

Current shunt fault

Current sensor error

1. Controller defective

HW fail-safe 1-2-3

Self- or watchdog fault

1. Controller defective

M- shorted

Internal M- short to B-

1. Controller defective

Field open Arm sensor Field sensor

Field winding fault Armature current sensor fault Field current sensor fault

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

Throttle fault 1 Throttle fault 2

Wiper signal out of range Pot low fault

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

SRO

SRO fault

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

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LED Codes

Programmer Fault LCD Display Category

2,3

HPR

HPD sequencing fault

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

2,4

E/R wiring check

Emergency reverse wiring fault

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

3,1

Contactor coil / FLD short

Contactor driver output overcurrent

1. Contactor coil shorted

3,2

Main Contactor welded

Welded main contactor

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

3,3

Precharge fault

Internal voltage too low at startup

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

3,4

Missing contactor

Missing contactor or did not close

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

4,1

Low battery

Low battery voltage

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

4,2

Overvoltage

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

4,3

Thermal cutback

Over / under-temperature cutback

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

4,4

Anti-tiedown

Mode 2 or Mode 4 selected at start-up

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

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Test Menu THROTTLE %

Throttle reading, as % of full throttle

ARM CURRENT

Motor armature current, in amps

FIELD CURRENT

Motor field current, in amps

ARM PWN

Motor armature applied duty cycle, as

FIELD PWM

Motor field applied duty cycle, as

BATT VOLTAGE

Battery voltage across the capacitors

CAP VOLTAGE

Capacitor voltage

HEATSINK °C

Heatsink temperature

FORWARD INPUT

Forward switch: on/off (Drive wheel direction)

REVERSE INPUT

Reverse switch: on/off (Load wheel direction)

MODE

Controller operating mode: 1 to 4

INTLCK INPUT

Interlock switch: on/off

INTERLOCK

Bake 1 switch: on/off

PEDAL INPUT

Pedal switch: on/off

EMR REV INPUT

Emergency reverse switch: on/off

MOTOR RPM

Tachometer input: pulser per second

MAIN CONT

Main contactor: open/closed

AUX DRIVER

Auxiliary driver: open/close

REV OUTPUT

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

BRAKE OUTPUT

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

FAULT 1 OUTPUT

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

FAULT 2 OUTPUT

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

CONTROL STATE

Controller state: 0 to 7

SPARE 1

Not used

MODSEL 1

Mode select 1

MODSEL 2

Mode select 2

SPARE ANALO

Not used

Special Program Menu

180

Return

RESET ALL SETTING

Revert to original settings

CONT SETTINGS > PROG

Save controller settings in programer

PROG SETTINGS > CONT

Load programmer settings in controller

CLEAR DIAG HISTORY

Clear diagnostics history memory

CONTRAST ADJUSTMENT

Adjust display contrast

LANGUAGE SELECTION

Select displayed language

PROGRAMMER INFO

Display programmer information

CONTROLLER INFO

Display controller information

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Controller parameter settings Parameter

Setting

M1 Drive Current Limit

400

M2 Drive Current Limit

400

M3 Drive Current Limit

400

M4 Drive Current Limit

400

M1 Brake Current Limit

200

M2 Brake Current Limit

200

M3 Brake Current Limit

200

M4 Brake Current Limit

200

M1 Neutral Brake Percent

M2 Neutral Brake Percent

M3 Neutral Brake Percent

M4 Neutral Brake Percent

M1 Acceleration rate

0.5

M2 Acceleration rate

0.5

M3 Acceleration rate

0.5

M4 Acceleration rate

0.5

M1 Maximum speed

Maximum setting 40

M2 Maximum speed

Maximum setting 80

M3 Maximum speed

Maximum setting 40

M4 Maximum speed

Maximum setting 90

M1 Brake Rate

0.5

M2 Brake Rate

0.5

M3 Brake Rate

0.5

M4 Brake Rate

0.5

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

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

RANGE

STD SETTING

UNITS

DESCRIPTION

M1 Drive C/L

200 - 400

400

Amp

Main current limit

M1 Brake C/L *

100 - 400

200

Amps

Brake current limit

M1 Neut Brk % *

0 - 50

% of braking C/L

Neutral braking %

M1 Accel Rate *

0.1 - 5.0

0.5

Sec

Acceleration rate

M1 Max Speed *

0 - 44

% PWM duty cycle

Maximum speed

Seconds

Time to reach full drive output from zero output

M1 Brake Rate

182

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0.1 - 5.0

0.5

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5.4. Troubleshooting Chart Using the Handset Disable Controller When

Recover When

Fault

Test When

BB circuit check (BB = Belly Button)

Continuous after brake release

Circuit found open

Brake released

Coil open/shorted driver

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

Immediate

Cycle Brake S10

Contactor driver overcurrent

Continuously while contactor being driven

Immediate

Cycle Brake S10

Overvoltage

Continuous after brake released

Immediate

Cycle Brake S10

Power supply out of range

Once upon activating S17 and continuous after brake release

Immediate

Cycle Brake S10

M-fault

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

Immediate

Cycle Brake S10

M-circuit check

Brake released

Immediate

Cycle Brake S10

Start-up checks

Once upon activating S17

RAM & EEPROM failure only

Cycle S17

Throttle fault

Continuous after brake released

Set throttle input to zero, decel output PWM to zero

Condition clears

Under voltage, Severe

Once upon activating S17 and continuous after brake release

Immediate

Cycle Brake S10

Current sensor fault

Continuous while PWM on

Immediate

Cycle Brake S10

Vds over current

Continuous while PWM on

Immediate

Cycle Brake S10

Watchdog, Ext.

Continuous while S17 on

Immediate

Cycle Brake S10

Watchdog, Int.

Continuous while S17 on

Immediate

Cycle Brake S10

Welded contactor

Continuous while brake released Immediate & no contactor driven

Cycle Brake S10

Parameter block check

Initiating serial communication

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Never - disable serial interface

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The following are indicated and handled similarly:

Fault

184

Test When

Action

Recover When

Emergency reverse

BB pressed forces E/R

E/R action (see text)

BB re-applied or brake released

HPD

Depends on type, see text

Disable PWM output

throttle cycled

Thermal cutback

Brake released

See text

Undervoltage

Continuous while S17 on

Immediate

Condition clears

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

Dead truck, nothing functions. No travel, Prime-Trak does not engage, no lift, no lower, no horn.

No travel, line contactor does not close. Prime-Trak, Lift, lower, and horn function.

No load wheel direction travel (forks leading). Line contactor closes when control handle is pulled down to operating position. Drive wheel direction travel, Prime-Trak, lift, lower, and horn function.

No drive wheel direction travel (forks trailing). Line contactor closes when control handle is pulled down to operating position. Load wheel direction travel, Prime-Trak, lift, lower, and horn function.

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

No high speed travel.

Prime-Trak pump will not function when truck is not moving, and operator is off platform. Lift, lower, and horn function.

Prime-Trak pump runs, but cylinders will not extend.

Prime-Trak pump will not function when operator is on truck and with direction switch in neutral. Travel in both directions, lift, lower, and horn function.

10. Prime-Trak pump runs when high speed travel is selected. Travel in both directions, lift, lower, and horn function. 11. Prime-Trak pump motor will not function. Travel in both directions, lift, lower and horn function. 12. Lift function will not function. 13. Lift motor does not turn off at full lift height. 14. Lowering function does not function.

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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 functions. No travel, Prime-Trak does not engage, 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.

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

No travel; line contactor does not close. Lift, lower, and horn function and Prime-Trak engages properly. 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”. Brakes released and S10 closed. Test for battery voltage at: A. Plug J1-1, wire number 6 on transistor controller. Repair open wire number 6 between S17 and A1. B. Positive side of K10 coil, wire number 6. Repair open wire number 6 between S17 and K10. C. Positive side of S10, wire number 6. Repair open wire number 6 between S17 and S10. D. Negative side of S10, wire number 7. Adjust or replace S10. E. Plug J1-2; wire number 7 on A1. Repair open wire number 7 between S10 and A1. F. Negative of K10 coil If battery voltage is NOT measured here then verify line contactor coil and replace line contactor

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coil. G. Test with handset H. Replace A1. 3.

No load wheel direction travel (forks leading). Line contactor closes when S21, S17 and S10 is closed. Drive wheel direction travel and lift, lower, and horn function and Prime-Trak engages properly. 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”. Brakes released and S10 closed. Travel controls operated to travel in the load wheel 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.

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

No drive wheel direction travel (forks trailing). Line contactor closes when S21, S17 and S10 is closed. Load wheel direction travel and lift, lower, and horn function and Prime-Trak engages properly. 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”.

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Brakes released and S10 closed. Travel controls operated to travel in the drive wheel direction (forks trailing). Test for battery voltage at: A. Positive side of S16, wire number 7. Repair open wire number 7 between S10 and S16. B. Negative side of S16, wire number 2. Adjust or replace S16. C. Plug J1-10, wire number 2, A1. Repair open wire number 2 between S15 and A1. D. Power circuit breaker positive side of F2. Repair power cable between battery positive and F1. E. Power circuit breaker negative side of F1. Replace F1. F. Power circuit positive side of K10. Repair power cable between F1 and K10. G. Power circuit negative side of K10. If battery voltage is NOT measured here then verify line contactor operation and replace line contactor. H. B+ terminal on A1. Repair open power cable between K10 and B+ at the transistor controller. I. A1 terminal on drive motor. Repair open A1 cable between K10 and M1. 190

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J. M- terminal on A1: Voltage should be battery voltage in neutral and decrease with throttle input down approximately 1 volt. K. A2 terminal on drive: Voltage should be battery voltage in neutral and decrease with throttle input down approximately 1 volt. L. Test with handset M. Replace A1 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”. Brakes released and S10. Travel controls to be operated from neutral to full speed in both directions as tests are made. A. Test voltage at plug J1-16, wire number 9, on A1. This voltage should start out between 3 and 4 volts in neutral and decrease smoothly to 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 then adjust or replace accelerator potentiometer. B. Transistor controller may be in thermal cutback. Allow controller to cool and retest.

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C. Test handset D. Replace A1. 6.

No high speed travel. 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”. Brakes released and S10 closed. Stand on platform to closed S14. Travel controls to be operated from neutral to full speed in both directions as tests are made. Test for voltage at: A. Positive side of S14. Repair open wire number 7 between S10 and S14. B. Negative side of S14. Replace S14. C. J1-3 on A1 Repair open wire number 35 between S10 and J13 on A1. D. J1-4 on A1. Repair wire number 35, jumper or lift interrupt, wire number 23 between S10 and J1-4. E. Test with handset F. Replace A1.

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CMX80 only A. Positive side of the pressure switch. Repair open wire number 7 between S10 and the pressure switch B. Negative side of pressure switch with forks lowered. Replace pressure switch C. J1-4 on A1 Repair open wire number 23 between pressure switch and J1-4 on A1. D. Test with handset E. Replace A1. 7.

Prime-Trak pump will not function. when truck is not moving, and operator off of the platform. Lift, lower, and horn function. Conditions for test: Battery fully charged and connected to truck. S21 in the run position. S17 Key switch closed. S10 Brake switch closed. S59 Toggle Switch closed. S14 Platform switch normal position. Directional control in neutral. Test for voltage at: A. Positive side of S14. Repair open wire number 6 between S10 and S14 B. Normally closed negative side of S14

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Replace S14 C. Positive side of S59. Repair wire number 36 between S59 and S14. D. Negative side of S59. Replace S59. E. Positive side of K33 coil. Repair open wire number 51 between S59 and K33. F. Negative side of K33 solenoid coil. Zero volts - Replace solenoid. If battery voltage IS measured here then repair wire number 13 between K33 coil and battery negative. With K33 energized test for voltage at: G. Positive side of K33 tips wire number 6. Repair wire number 6 between S14 and K33. H. Negative side of tips K33. Replace K33. I. Positive side of A60. Repair open wire number 40 between K33 tips and A60. J. Negative side of A60 after 2 seconds. Replace A60. K. Positive side S63. Repair wire number 41 between A60 and K32. L. Negative side of S63. 194

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Adjust or replace S63 M. Positive side of K32. Repair open wire number 42 between S63 and K32. N. Negative side of K32. Zero volts - Replace solenoid. If battery voltage IS measured here repair wire number 13 between K32 and battery negative. 8.

Prime-Trak pump runs, but cylinders do not extend. Conditions for test: Battery fully charged and connected to truck. S21 in the run position. S17 Key switch closed. S10 Brake switch closed. S59 Toggle Switch closed. S14 Platform switch normal position. Directional control in neutral Test for voltage at: A. Positive side of Y7 coil. Repair wire number 41 from A60. B. Negative side of Y7 coil. Zero volts - Replace the coil. If battery voltage IS measured here repair wire number 13 between Y7 and battery negative.

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Conditions for test: Battery fully charged and connected to truck. S21 in the run position. S17 Key switch closed. S10 Brake switch closed. S59 Toggle Switch closed. S14 Platform switch actuated. S61 Prime-Trak throttle switch closed Directional control in neutral Test for voltage at: A. Negative side of S14. Replace S14. B. Positive side of S61 Repair open wire number 35 between S14 and S61 C. Negative side of S61 Adjust or replace S61 D. Positive of V7 diode Repair open wire number 43 between S61 and V7 E. Negative side of V7 Replace V7 F. Positive side of S59 Repair open wire number 36 between V7 and S59 G. Perform test 8 steps D through N 10. Prime-Trak pump runs when high speed travel is 196

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selected. Travel in both directions, lift, lower, and horn function. Conditions for test: Battery fully charged and connected to truck. S21 in the run position. S17 Key switch closed. S10 Brake switch closed. S59 Toggle Switch closed. S14 Platform switch actuated. S61 Prime-Trak throttle switch closed S15 or S16 closed S61 Prime-Trak throttle open Test for voltage at: A. Negative side of S61 Adjust or replace S61 Prime-Trak electrical power circuit 11. Prime-Trak pump motor will not function. Travel in both directions, lift, lower and horn function. Conditions for test: K32 solenoid closed Test for voltage at: A. Power positive side of K32 solenoid. Repair power wire between 105A fuse and K32 solenoid. B. Power negative side of K32 solenoid. Replace K32 solenoid C. A1 terminal on Prime-Trak pump motor © BT Products

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Repair open power cable between K32 and Prime-Trak pump motor D. S2 terminal on Prime-Trak pump motor If battery voltage IS measured here repair open power cable between Prime-Trak pump motor and battery negative. If battery voltage IS NOT measured here then repair Prime-Trak pump motor 12. Lift function does not function. 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”. Stand on platform to closed S14. Lift switch bar pushed to close lift switch.

Test for battery voltage at: A. Positive side of lift switch, wire number 35 Repair open wire number 35 between high speed and lift switch. B. Negative side of lift switch, wire number 5. Adjust or replace lift switch and bar assembly. C. Positive side of lift limit switch, wire number 5. Repair open wire number 5 between lift switch and lift limit switch. D. Negative side of lift limit switch, wire number 17.

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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 and lift solenoid coil. F. Negative side of lift solenoid coil, wire number 13 (Wire number 43 if truck is equipped with Lift Interrupt System). 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 then 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 pin 3 on back of BDI gauge, wire number 17. Repair open wire number 17 between lift limit switch and BDI gauge.

(c). Test for battery voltage at negative pin 4 on back of BDI gauge, wire number 18. If battery voltage is NOT measured here verify that battery voltage is sufficient for Lift Interrupt System to allow lift function to operate. © BT Products

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Replace BDI gauge which contains the Lift Interrupt System. Positive side of lift solenoid coil, wire number 18. Repair open wire number 18 between BDI and lift solenoid coil. Negative side of lift solenoid coil, wire number 13. If battery voltage is measured here then repair open wire number 13 between lift solenoid coil and battery negative. If battery voltage is not measured battery NOT measured here continue testing with test G. G. Positive side of 105 amp circuit breaker. Repair open power cable between battery positive terminal and 105 amp circuit breaker. H. Negative side of 105 amp circuit breaker. Replace 105 amp circuit breaker. I. Positive side of lift solenoid tips. Repair open power cable between 105 amp circuit breaker and lift solenoid. J. Negative side of lift solenoid tips. Replace lift solenoid. K. A1 terminal on lift motor. Repair open power cable between lift solenoid and lift motor. L. S2 terminal on lift motor. Special Instructions:

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If battery voltage IS measured here then repair open power cable between lift motor and battery negative. If battery voltage is NOT measured here then repair lift motor. Lift motor does not turn off at full lift height. Adjust or replace lift limit switch. 13. Lowering function does not function. 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”. Stand on platform to closed S14.

Lowering switch bar pushed to close lowering switch.

Test for battery voltage at: A. Positive side of lowering switch, wire number 35. Repair open wire number 35 between high speed 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. © BT Products

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Special Instructions: If battery voltage IS measured here then repair open wire number 13 between lowering valve coil and battery negative. If battery voltage is NOT measured here then 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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S5.14

Version no

C-code

5710

T-code

000

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PS S5.14 Handset Operation Version no

5710

T-code

000

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

Item Number

Part Number

Description

306415-000

PMC handset

306416-000

Cable

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

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

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

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

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

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

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S5.14 5710 Handset Operation T-code

000

CHANGE VALVE

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

SCROLL DISPLAY

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

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PS S5.14 Handset Operation Version no

C-code

5710

T-code

000

Scroll bar

M1 ACCEL RATE M1 ACCEL RATE M1 DECEL M1 DECEL

1.5 2.0 1.0 1.0

Selected item

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

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

PROGRAM

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

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

RATE,

SECS

1.3 MIN 0.2

MAX 3.0

Minimum value

Maximum value

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

TEST

Return

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

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T-code

000

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

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

* MORE INFO

PROGRAM

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

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

* MORE INFO

PROGRAM

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

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T-code

000

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

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

3. Handset Self Test SCROLL DISPLA

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

…

210

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

Service Manual

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F-code

Section

S5.15 5810 Pump Motor

Version no

C-code

T-code

000

Pump Motor 1 3

2 4

5 6

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

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POS. NO

DESCRIPTION

POS. NO

DESCRIPTION

Cover

End, commutator

Bearing

Bolt

Armature

Cover, end

Bearing

Set, spring and brush

Housing

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C-code

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T-code

000

1. Component Repair 1.1. Motor Disassembly 1. Remove the cover band from the commutator end of the motor. 2. Use a brush hook to reach into the motor and lift the brush springs. Pull the brushes out of the brush holders. Either position the brushes outside the motor or remove the brush retaining screws, and remove the brushes from the motor. 3. Scribe or center punch locating marks in the end head and the frame. Although locating marks are not always necessary, they can save time when the motor does not have locating pins. 4. Remove the commutator end head retaining screws. Most motors have a slip fit bearing at the commutator end, and the end head can be removed with very little trouble. On motors that have a shaft extension on both ends of the armature, the attachment on the commutator end of the shaft must be removed before the end head can be separated from the motor. 5. Remove the drive end head retaining screws if necessary. Some of the smaller pump motors retain the drive end head with the motor through bolts. Separate the armature and drive end head as an assembly from the frame and field coil assembly. 6. Separate the armature from the drive end head. This operation is usually done by pressing the armature out of the drive end bearing. On some of the larger motors the end head and bearing will have to be removed with a puller. When a puller is used, protect the end of the armature shaft with a nut or a thick flat washer. If the shaft, coupling, or spline is damaged when removing the end head, the armature or the drive spline usually has to be replaced. Use caution, and DO NOT damage the armature. 7. Separate the bearing from the end head. On larger 212

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000

motors, the bearing is retained with a snap ring. Remove the snap ring. Then press the bearing out of the end head.

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C-code

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T-code

000

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

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

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

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

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C-code

T-code

000

2.4. Brush and Commutator The brushes and commutator should be inspected for even wear and good commutation. Good Commutation: A dark uniform coloring pattern at the brush wearing surface. Poor Commutation:The surface of the commutator appearing rough, pitted, scored or signs of burning or heavy arcing between bars. The color pattern will be:

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

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

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

2.5. Armature 1. Check for loose commutator bars. Loose commutator bars will usually be indicated by excessive wear or burning on one bar. The commutator can be checked for loose bars by lightly tapping all of the bars with the handle of a plastic or wooden handled screwdriver. A contrasting dull thud or vibration will indicate a loose bar in which case, the armature must be replaced. 2. Check for grounded circuits using a test light. Most commercial growlers incorporate a test light as shown in illustration below. Check the armature for grounded circuits by placing one test lead of the test lamp on the commutator and the other test lead on the armature shaft. If the test light lights, the armature is grounded. 3. Standard Winding Armatures are tested on a growler (see illustration) using a steel strip or hacksaw blade to locate any shorted windings.

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C-code

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T-code

000

Check for shorted windings by slowly rotating the armature in the growler while holding the strip or blade so that it passes over each armature core slot. If a winding is shorted, the strip or blade will vibrate and the blade will get hot. NOTE! If the armature has been turned and undercut prior to testing, check for and remove any copper buildup or filings between commutator bars and at the commutator riser. This condition will cause an armature to check shorted and usually results from a dull undercutting tool. 4. Check commutator bars for any signs of burning. If deep burned sections are evident, either in the brush track or on the riser ends of the commutator bars, an open or short circuit in the armature windings is indicated.

2.6. Frame and Field Assembly Check the condition of all insulation. If the insulation on the field coils appears blackened or charred, the serviceability of the coils is questionable. Burned or charred insulation is a result of coil overheating due to overloading conditions, grounded or shorted coil windings. Check condition of all other insulation such as brush rigging, under coil connections and around terminal studs. 2.6.1. Testing Frame and Field Assembly After thorough inspection, the Frame and Field Assembly should be checked for grounded, open or shorted circuits. Grounded and open circuits can be checked using a test light. Most commercial growlers incorporate a test light as shown in opposite illustration.

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

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Version no

C-code

T-code

000

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

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

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C-code

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T-code

000

Prior to installing the field coils the connections which require soldering should be buffed or wire brushed clean to remove any oxidation. The connections should then be tinned with a soldering iron. NOTE! We do not recommend using a soldering gun or torch. Soldering guns cannot provide the heat concentration required and soldering torches can damage the insulation.

After field coil installation, connect the solder joint making sure the solder is flowing properly to avoid a cold soldered joint.

Pole Shoe Screw Removal & Installation (Field Coil Removal & Installation) Continue assembly in the reverse of disassembly, paying particular attention to the following points. 2.7.2. Bearing Installation 1. Whenever ball bearings are pressed into an end head or onto a shaft, always press against the race that is absorbing the pressure. Press on the outer race when installing into end heads. 218

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000

Press against the inner race when installing onto a shaft. 2. End heads having slip-fit bearings are normally retained by a snap ring. Always install new snap ring(s). 2.7.3. After Assembly

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

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

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

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Resurface the commutator by taking only light cuts each time, 0.005 in. [0.12 mm].

If reslotting/undercutting is necessary, the final operation is to lightly sand the commutator with a fine sandpaper to remove any burrs left from the undercutting operation.

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Section

M6.0 6000 Hydraulic System

Version no

T-code

001

CMX

C-code

Hydraulic System 1. Hydraulic 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

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

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T-code

001

CMX

C-code

6000

3. Description 3.1. Lift When the lift button on the handle is pushed, the pump contactor 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 reservoir by the closed relief valve and lowering valve. The oil continues to flow to the base of the cylinder and pushes against the end of the cylinder rod to extend the rod from the cylinder tube. When the motor is shut off and the gear pump is not turning, the cylinder is held extended by the closed check valve and normally closed lowering valve.

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

3.3. Relief Pressur The relief pressure is set at 4000 psi.

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M6.0 6000 Hydraulic System

Version no

T-code

001

CMX

C-code

4. Maintenance The hydraulic fluid level must be checked periodically. (See the Planned Maintenance Schedule.) If the reservoir regularly requires the addition of oil to maintain the proper level, then 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 the lift, lower and other hydraulic functions for proper operation. If the truck will not lift a full load, then the pressure relief setting should be checked and adjusted. During normal operation, the pressure relief setting will not change. As the pump wears with age, some loss performance will be experienced. When this loss becomes severe, the pump should be replaced.

5. Adjustments The only adjustment to the hydraulic system is the pressure relief setting. This adjustment is made by removing the screw cap on the pressure relief valve and turning the screw to make the adjustment. Turning the screw in clockwise, will increase the pressure relief setting.

6. Lift Limit Switch The lift limit switch is accessible by removing the sheet metal and molded plastic shields from the front of the truck. The switch operates off a cam lobe formed into the shield mounting bracket. To adjust switch: 1. Park truck on level surface and block truck from moving. 2. Disconnect battery. 3. Open access door on front of truck 4. Loosen mounting screws and move lift limit switch away from operating cam so that it will not operate. 5. Connect battery and raise pallet forks to maximum height. Do not stall hydraulics against relief for longer then necessary. © BT Products

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T-code

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CMX

C-code

6000

6. Lower pallet forks until the tops of the forks are 9 in. [230 mm] above the floor. WARNING Before adjustments are make disconnect battery from truck to prevent accidental operation. 7. Disconnect battery. 8. Adjust lift limit switch to operate at this point and tighten mounting screws. 9. Connect battery and test lift limit switch operation. Lift limit switch must close and stop hydraulic pump when 9 in. [230 mm] is reached. 10. Close access door.

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Section

M6.0 6000 Hydraulic System

Version no

T-code

001

CMX

C-code

7. Troubleshooting NOTE! Proper care and cleanliness should be observed in servicing to insure the oil does not become contaminated with dirt or other foreign material. Contaminants can be drawn into the pump so as to stick or score pump which will cause failure of the pump assembly. IF HYDRAULIC PUMP ASSEMBLY DOES NOT OPERATE PROPERLY, A FEW PRELIMINARY CHECKS SHOULD BE MADE: 1. Proper oil level 2. All electrical connections tight 3. Battery fully charged After the preliminary check is accomplished, install a 0-5000 PSI pressure gauge in the pressure line near the 3/8 in. NPTF outlet port in the adapter. The installation of the pressure gauge is required to insure proper observation of what is occurring in the unit during trouble shooting. Start the pump and raise the cylinder to its upper limit stops to develop maximum pressure of the unit, which will normally be passing all flow over the relief valve. The pressure gauge should be reading the set pressure of the relief valve. Remove pressure on the system by actuating the solenoid operated lowering valve. The normal troubles that may occur with the pump assembly have been grouped under three headings: Failure to (A) Raise (B) Hold (C) Lower the load. One or more of the listed trouble sources may be causing improper operation. Refer to the proper heading (i.e. relief valve) for detailed instructions for disassembly, check and adjustment of parts to remedy the trouble. A. If pump operates but will only develop low pressure or slow lift: 1. Relief valve seat scored, foreign particles under ball or relief valve out of adjustment (See relief valve). 2. Dirt in solenoid-operated release (See solenoid operated release valve). © BT Products

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PS M6.0 Hydraulic System Version no

T-code

001

CMX

C-code

6000

3. Pump worn - replace pump. B. If pump develops pressure but will not hold: 1. Dirt in solenoid-operated release (See solenoid operated release valve). 2. Relief valve seat scored, foreign particles under ball or relief valve out of adjustment (See relief valve). C. If pump develops pressure but will not release load: 1. No electrical contact to solenoid operated release valve (See solenoid operated release valve). 2. Solenoid in burned out.

solenoid-operated

release valve

3. Relief valve bottomed causing pressure to go beyond the unloading limit of the solenoid release valve (See relief valve).

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Section

C-code

PS M6.1 6125 Prime-Trak Hydraulic System Version no

T-code

000

CMX

Prime-Trak Hydraulic System 1. Prime-Trak Hydraulic Schematic

Prime-Trak Cylinders Component Enclosure Hydraulic Lines Joining Out Motor (Electric) Hydraulic Pump

250 PSI

Filter

Reservoir (Vented) Cylinder (Single Acting) Cylinder (Double Acting)

Hydraulic Pump

Check Valve

Hydraulic Lines Crossing

Tank

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PS M6.1 6125 Prime-Trak Hydraulic System Version no

T-code

000

CMX

2. General Information The Prime-Trak traction control system is a hydraulic powered linkage that changes the pressure of the stabilizing casters depending on the travel speed of the truck. The system is controlled by a switch in the accelerator control linkage. When the truck is at rest with the brakes released power is supplied to close a normally open hydraulic solenoid (L2), and the Prime-Trak hydraulic motor is engaged after a short time delay. When the hydraulic motor runs, fluid is forced by the pump into the Prime-Trak caster cylinders causing the casters to carry more of the truck weight thus making the truck easier to steer as weight is taken off the steer wheel. The pump motor is turned off when the Prime-Trak linkage opens a limit switch at its full lift height. When the travel controls are operated to select a faster travel speed a switch in the control handle opens and removes electrical power from the Prime-Trak lift contactor and from the solenoid valve. The valve returns to its normally open state and allows fluid to leave the caster cylinders. This allows more weight on the drive tire to assure good traction for stopping.

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T-code

000

CMX

3. Maintenance The hydraulic fluid level must be checked periodically. (See the Planned Maintenance Schedule.) If the reservoir regularly requires the addition of oil to maintain the proper level, then 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 the lift, lower and other hydraulic functions for proper operation. If the truck will not lift a full load, then the pressure relief setting should be checked and adjusted. During normal operation, the pressure relief setting will not change. As the pump wears with age, some loss of performance will be experienced. When this loss becomes severe, the pump should be replaced.

4. Adjustments The only adjustment to the hydraulic system is the pressure relief setting. This adjustment is made by removing the screw cap on the pressure relief valve and turning the screw to make the adjustment. Turning the screw in clockwise, will increase the pressure relief setting. Prime-Trak relief pressure.

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229

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C-code

PS M6.1 6125 Prime-Trak Hydraulic System Version no

T-code

000

CMX

5. Prime-Trak Lift Limit Switch Prime-Trak lift limit switch is access by opening the front door of the truck. The switch operates off the Prime-Trak cylinder rod. To adjust switch: 1. Park truck on level surface and block truck from moving. 2. Disconnect battery. 3. Open access door on front of truck 4. Loosen mounting screws and move Prime-Trak lift limit switch away from cylinder rod so that it dose not operate. 5. Connect battery and engerize Prime-Trak so that cylinder extends. Do not stall hydraulics against relief for longer then necessary. 6. Adjust Prime-Trak lift limit switch to operate at this point and tighten switch mounting screws. WARNING Before adjustments are make disconnect battery from truck to prevent accidental operation. 7. Connect battery and test Prime-Trak lift limit switch operation. 8. Close access door.

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PS M6.1 6125 Prime-Trak Hydraulic System Version no

T-code

000

CMX

6. Troubleshooting NOTE! Proper care and cleanliness should be observed in servicing to insure the oil does not become contaminated with dirt or other foreign material. Contaminants can be drawn into the pump sticking or scoring pump which will cause failure of the pump assembly. IF HYDRAULIC PUMP ASSEMBLY DOES NOT OPERATE PROPERLY, A FEW PRELIMINARY CHECKS SHOULD BE MADE: 1. Proper oil level 2. All electrical connections tight 3. Battery fully charged After the preliminary check is accomplished, install a 0-3000 PSI pressure gauge in the pressure line near the 3/8 in. NPTF outlet port in the adapter. The installation of the pressure gauge is required to insure proper observation of what is occurring in the unit during trouble shooting. Start the pump and raise the cylinder to its upper limit stops to develop maximum pressure of the unit, which will normally be passing all flow over the relief valve. The pressure gauge should be reading the set pressure of the relief valve. Remove pressure on the system by actuating the solenoid operated release valve. The normal troubles that may occur with the pump assembly have been grouped under three headings: Failure to (A) Raise (B) Hold (C) Lower the load. One or more of the listed trouble sources may be causing improper operation. Refer to the proper heading (i.e. relief valve) for detailed instructions for disassembly, check and adjustment of parts to remedy the trouble. A. If pump operates but will only develop low pressure or slow lift: 1. Relief valve seat scored, foreign particles under ball or relief valve out of adjustment (See relief valve). 2. Dirt in solenoid-operated release (See solenoid operated release valve). © BT Products

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PS M6.1 6125 Prime-Trak Hydraulic System Version no

T-code

000

CMX

solenoid-operated

release valve

3. Relief valve bottomed causing pressure to go beyond the unloading limit of the solenoid release valve (See relief valve).

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Section

C-code

M6.2 6140 Lift Pump Assembly

Version no

T-code

001

Lift Pump Assembly 6

7 1 38 37

34 36

9 39

5 4

28 12

29 31

24 25

23 22 20

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PS M6.2 Lift Pump Assembly Version no

6140

T-code

001

POS. NO

234

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DESCRIPTION

POS. NO

DESCRIPTION

POS. NO

DESCRIPTION

Wire

Washer

Ball

Valve, NC solenoid

Bolt

Spring

Coil

Magnet

Screw

Valve, check

Screw

Cap

O ring

Reservoir

O ring

Wire

Elbow, 90°

Plug

Motor

Breather

O ring

Coupler

Filter

Cable

Pin, dowel

Tube, 4 in. long

Plug

Endhead

Screw

Connector

O ring

Pump

Screw

Seal

Bolt

Solenoid

Cover

Tube, 7 in. long

Valve

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PS Version no

Section

C-code

M6.2 6140 Lift Pump Assembly T-code

001

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. 1. Park the truck on a level surface and make sure parking brake is applied. 2. Lower lifting frame to release pressure in hydraulic system. 3. Disconnect and remove battery from unit to prevent accidental operation. 4. Open access door fully to gain 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 position. Disconnect solenoid control wiring also noting their position. 7. Remove three socket head screws located inside battery compartment securing hydraulic pump and motor assembly to battery side of frame. 8. Thoroughly clean exterior of hydraulic pump and motor assembly before disassembly can begin. WARNING Be extremely careful when working with solvent. Even a small explosion or fire could cause injury or death. WARNING Compressed air used for cleaning MUST be reduced to less than 30 psi. and then only with effective chip-guarding and personal protective equipment.

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235

F-code

Section

PS M6.2 Lift Pump Assembly Version no

C-code

6140

T-code

001

2. Disassembly NOTE! CLEANLINESS! Perform procedures in a clean environment. Make sure all parts are cleaned before disassembly and kept clean during assembly. 1. Before disassembly, clean exterior of the hydraulic pump and motor assembly in a cleaning solvent to remove all contamination. WARNING Be extremely careful when working with solvent. Even a small explosion or fire could cause injury or death. WARNING Compressed air used for cleaning MUST be reduced to less than 30 psi. and then only with effective chip-guarding and personal protective equipment. 2. Drain the reservoir (18) of oil. 3. Set unit in vertical position with reservoir (18) end up. 4. Remove four screws (17) holding on reservoir (18). 5. Tap reservoir (18) lightly to loosen. Wiggle the reservoir (18) sideways while pulling up at the same time. 6. Remove pump inlet tube (22) and screen (21). 7. Remove two screws (25) holding pump to endhead (10) and lift pump (24). 8. Disconnect wires from terminals on coil (3). 9. Remove nut securing coil (3) and remove coil (3) from valve assembly (2). Remove valve assembly (2) from endhead (10). 10. Scribe a line on both endhead (10) and base of pump motor (7) to aid when reassembling. Pump motor (7) can be removed at this time by removing two screws on top of the motor (7). These screws secure motor to endhead (10). 236

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F-code

PS Version no

Section

C-code

M6.2 6140 Lift Pump Assembly T-code

001

3. Inspection 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. WARNING Be extremely careful when working with solvent. Even a small explosion or fire could cause injury or death. WARNING Compressed air used for cleaning MUST be reduced to less than 30 psi. and then only with effective chip-guarding and personal protective equipment. 2. Inspect all parts for excessive wear or scoring. If heavy scoring is found replace part. 3. Inspect inlet strainer (21) for clogging or excessive wear. Wash in solvent and air dry from inside out. 4. Inspect inlet tube (22) for clogging or excessive wear. Wash in solvent and air dry. 5. Inspect inside edges of reservoir (18) for any burrs or nicks that may cut the O ring (11) during installation. Wipe inside of reservoir (18) clean. 6. Clean and inspect valve cavity to be sure it is free of all foreign matter. Inspect solenoid operated valve (2) strainer. CAUTION DO NOT bend or apply pressure to center stud or hold cartridge body any place but on flat sides of sub-assembly. 7. Inspect hydraulic hose and replace if worn.

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237

F-code

Section

PS M6.2 Lift Pump Assembly Version no

C-code

6140

T-code

001

4. Assembly 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. WARNING Be extremely careful when working with solvent. Even a small explosion or fire could cause injury or death. WARNING Compressed air used for cleaning MUST be reduced to less than 30 psi. and then only with effective chip-guarding and personal protective equipment. 2. If pump motor was removed from endhead (10), install pump motor (7) by aligning scribe marks that were made earlier and secure with screws. 3. Connect power cables from pump motor to pump main solenoid (38) if this solenoid (38) was replaced. 4. Install coupler (8) on motor drive shaft. 5. Align splines on pump (24) shaft to splines on motor coupler (8). Gently push pump (24) shaft in coupler (8) and align pump (24) mounting holes in endhead (10). When pump (24) is flush with endhead (10), pump and motor are connected. 6. Install two cap screws (25) securing pump (24) to endhead (10) and tighten cap screws to 10-12 ft-lb. 7. Install strainer (21) on inlet tube (22) and thread on pump (24). 8. Oil O ring (11) lightly and install on endhead (10). 9. Start reservoir (18) over flange on endhead (10) up to O ring (11). Make sure it is aligned properly with holes as well as not cocked. 238

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PS Version no

Section

C-code

M6.2 6140 Lift Pump Assembly T-code

001

10. Rest a block of wood on the back of the reservoir (18) and strike it squarely with a sharp blow in the center of the reservoir (18) end. The reservoir (18) should move into position. 11. Install four screws (17) in position and tighten to snug condition. 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 (2). 13. Install strainer in place on spool valve cartridge (2). 14. Hand screw spool valve assembly (2) in endhead (10) cavity and tighten to a maximum of 35 ft-lb for die cast metal. 15. Install solenoid coil (3) on spool valve assembly (2), and tighten nut to a maximum of 5 ft-lb. Connect wires to terminals on coil (3). 16. Install check valve (4) (27,28,29,30) if removed.

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and

relief

valve

239

F-code

Section

PS M6.2 Lift Pump Assembly Version no

C-code

6140

T-code

001

5. Installation 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. WARNING Be extremely careful when working with solvent. Even a small explosion or fire could cause injury or death. WARNING Compressed air used for cleaning MUST be reduced to less than 30 psi. and then only with effective chip-guarding and personal protective equipment. 2. Install 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 wirings also 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 and connect battery to truck. 8. Operate the lift/lower button to remove air from hydraulic hose and check operation of the whole hydraulic system.

240

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F-code

PS Version no

Section

C-code

M6.2 6140 Lift Pump Assembly T-code

001

WARNING DO NOT use your hands to check for hydraulic leakage. Use a piece of cardboard or paper to search for leaks. Escaping fluid under pressure can penetrate the skin causing serious injury. Relieve pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Keep hands and body away from pinholes and nozzles which eject fluids under high pressure. 9. After running the hydraulic system, check and fill the hydraulic reservoir with more clean oil. 10. Close access door.

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241

F-code

Section

PS M6.2 Lift Pump Assembly Version no

C-code

6140

T-code

001

6. Adjustments

1 2

4 5

POS. NO

DESCRIPTION

POS. NO

DESCRIPTION

Motor

Breather

Solenoid valve

Reservoir

Relief valve cap

6.1. Relief valve (Refer to figure on p age233) Remove hex cap (30) on relief valve. If relief valve is causing the low pressure condition, the pressure can be increased by screwing in the adjusting screw (29), recycling the pump and noting pressure gauge reading. Be sure the final adjustment on the screw is at least 1/2 turn from bottoming position. If the trouble is not remedied by the relief valve adjustment, remove adjustment screw (29), spring (28), and ball (27). Valve seat should be clean and not scored. Replace spring and ball in cavity. Insert 1/4 in. drive pin punch down through spring coils and hold ball against valve seat. Tap gently on drive pin punch with ball peen hammer to seat the ball. Reassemble the relief valve parts. Adjust relief valve and recycle the pump per above. 242

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F-code

PS Version no

Section

C-code

M6.2 6140 Lift Pump Assembly T-code

001

Do not operate motor/pump at relief valve setting any longer than is necessary (NO LONGER THAN 10 SECONDS AT ANY ONE PERIOD).

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

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243

F-code

Section

PS M6.2 Lift Pump Assembly Version no

C-code

6140

T-code

001

244

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F-code

Section

C-code

PS M6.3 6140 Prime-Trak Hydraulic Pump Version no

T-code

000

CMX

Prime-Trak Hydraulic Pump

15 1

13 3

5 6

8 9 10

23 22

POS. NO

Return

DESCRIPTION

POS. NO

DESCRIPTION

POS. NO

DESCRIPTION

Pump assembly

Plug

Cable

Cap, relief valve

Valve, N/O solenoid

Switch

O ring

Coil

Solenoid

Screw, adjusting valve

Screw, flat head

Wire

Spring

Bracket, mounting

Screw, socket head

Ball

Spacer

Lockwasher

Seal, oil

Coupler

Pin, dowel

Ball

Motor assembly

Adapter, pump

Spring

Boot

Screw, socket head

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245

F-code

Section

C-code

PS M6.3 6140 Prime-Trak Hydraulic Pump Version no

T-code

000

CMX

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. 1. Park the truck on a level surface and make sure parking brake is applied. 2. Lower lifting frame to release pressure in hydraulic system. 3. Disconnect battery from unit to prevent accidental operation. 4. Open access door fully and remove lower cover to gain access to the Prime-Trak pump and motor assembly. 5. Remove hydraulic line from Prime-Trak pump assembly and cap ends to prevent contaminants from entering the hydraulic system. 6. Disconnect electrical power cables from solenoid (21) control wiring. 7. Remove two cap screws from under the PrimeTrak pump and motor assembly, and remove Prime-Trak pump and motor assembly from truck. 8. Thoroughly clean exterior of Prime-Trak pump and motor assembly before disassembly can begin. WARNING Be extremely careful when working with solvent. Even a small explosion or fire could cause injury or death. WARNING Compressed air used for cleaning MUST be reduced to less than 30 psi. and then only with effective chip-guarding and personal protective equipment.

246

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F-code

Section

C-code

PS M6.3 6140 Prime-Trak Hydraulic Pump Version no

T-code

000

CMX

2. Disassembly NOTE! CLEANLINESS! Perform procedures in a clean environment. Make sure all parts are cleaned before disassembly and kept clean during assembly. 1. Before disassembly, clean exterior of the PrimeTrak pump and motor assembly in a cleaning solvent to remove all contamination. WARNING Be extremely careful when working with solvent. Even a small explosion or fire could cause injury or death. WARNING Compressed air used for cleaning MUST be reduced to less than 30 psi. and then only with effective chip-guarding and personal protective equipment. 2. Remove two screws (13) holding pump to endhead (14) and remove pump off. 3. Disconnect wires from terminals on pump coil (12). 4. Remove nut securing coil (12) and remove coil (12) from valve assembly (11). Remove valve assembly (11) from endhead (14). 5. Scribe a line on both endhead (14) and base of pump motor (15,17) to aid when reassembling. Pump motor (17) can be removed by removing two screws (23) on top of pump motor (17). These screws (23) secure pump motor (17) to endhead (14) and spacer (15).

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247

F-code

Section

C-code

PS M6.3 6140 Prime-Trak Hydraulic Pump Version no

T-code

000

CMX

3. Inspection 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. WARNING Be extremely careful when working with solvent. Even a small explosion or fire could cause injury or death. WARNING Compressed air used for cleaning MUST be reduced to less than 30 psi. and then only with effective chip-guarding and personal protective equipment. 2. Inspect all parts for excessive wear or scoring. If heavy scoring is found replace part. 3. Inspect inlet strainer on valve assembly (11) for clogging or excessive wear. Wash in solvent and air dry from inside out. 4. Clean and inspect valve cavity to be sure it is free of all foreign matter. Inspect solenoid operated valve strainer. CAUTION DO NOT bend or apply pressure to center stud or hold cartridge body any place but on flat sides of sub-assembly. 5. Inspect hydraulic hose and replace if worn.

248

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F-code

Section

C-code

PS M6.3 6140 Prime-Trak Hydraulic Pump Version no

T-code

000

CMX

4. Assembly 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. WARNING Be extremely careful when working with solvent. Even a small explosion or fire could cause injury or death. WARNING Compressed air used for cleaning MUST be reduced to less than 30 psi. and then only with effective chip-guarding and personal protective equipment. 2. Install Prime-Trak pump motor (17) by aligning scribe marks that were made earlier and secure with screws (23), if pump motor was removed. 3. Connect power cables from pump motor (17) to pump main solenoid (21) if this solenoid (21) was replaced. 4. Install coupler (16) on Prime-Trak pump motor (17) drive shaft. 5. Align splines on Prime-Trak pump (1) shaft to splines on Prime-Trak motor coupler (16). Gently push Prime-Trak pump (1) shaft in coupler (16) and align Prime-Trak pump (1) mounting holes in endhead (14). When Prime-Trak pump (1) is flush with endhead (14), install two screws (27) and tighten to 10-12 ft-lb. CAUTION DO NOT bend or apply pressure to center stud or hold cartridge body any place but on flat sides of sub-assembly.

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249

F-code

Section

C-code

PS M6.3 6140 Prime-Trak Hydraulic Pump Version no

T-code

000

CMX

6. Apply a small amount of clean hydraulic oil to the O ring and backup ring and install on spool valve cartridge (11). 7. Install strainer in place on spool valve cartridge (11). 8. Hand screw spool valve assembly (11) in PrimeTrak pump (1) cavity and tighten to a maximum of 35 ft-lb for die cast metal. 9. Install coil (12) on spool valve assembly (11), and tighten nut to a maximum of 5 ft-lb. Connect wires to terminals on coil (11). 10. Install check valve (8,9,10) and relief valve (2,3,4,5,6) if removed.

250

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F-code

Section

C-code

PS M6.3 6140 Prime-Trak Hydraulic Pump Version no

T-code

000

CMX

5. Installation 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. WARNING Be extremely careful when working with solvent. Even a small explosion or fire could cause injury or death. WARNING Compressed air used for cleaning MUST be reduced to less than 30 psi. and then only with effective chip-guarding and personal protective equipment. 2. Install Prime-Trak pump and motor assembly back in truck and secure with two cap screws to frame of truck. 3. Properly connect all electrical power cables noting their position recorded earlier. 4. Properly connect all solenoid control wirings also noting their positions recorded earlier. 5. Uncap and connect hydraulic hose to pump. 6. Fill lift pump hydraulic reservoir with new clean oil. 7. Connect battery to truck. 8. Operate the system to remove air from hydraulic hose and check operation of the whole hydraulic system.

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251

F-code

Section

C-code

PS M6.3 6140 Prime-Trak Hydraulic Pump Version no

T-code

000

CMX

252

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1997-09-24

F-code

Section

C-code

S7.0

7310 Lift Cylinder

Version no

000

T-code

RMX,HMX,CMX

Lift Cylinder 1

3 3 4 4

POS. NO

DESCRIPTION

POS. NO

Cylinder assembly

Seal, rod

Body, cylinder

Wiper, rod

Ring, retainer

Fitting, grease

Rod, cylinder

DESCRIPTION

The lift cylinders are the positive displacement type, meaning there are NO seals on the lower end of the cylinder rod. NOTE! CLEANLINESS! Perform procedures in a clean environment. Make sure all parts are cleaned before disassembly and kept clean during assembly.

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253

F-code

Section

C-code

PS S7.0 Lift Cylinder

7310

Version no

T-code

000

RMX,HMX,CMX

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. Park the truck on a level surface and make sure parking brake is applied. 2. Raise and block lifting frame of truck to prevent lifting frame from tipping when the lift cylinder is removed. Release pressure in cylinder by activating lowering valve. 3. Drain hydraulic oil from lift pump reservoir. 4. Disconnect and remove battery from unit to prevent accidental operation. 5. Open access door fully. 6. Remove hydraulic line from lift pump assembly and cap ends to prevent contaminants from entering the hydraulic system. Cylinder Assembly

7. Remove cap screw (16) and securing upper link mounting pin (22). Remove upper link pin (22). 8. Drive roll pin (30) from the lifting frame pivot pin and remove pivot pin (1).

101 102

8. Remove one shoulder bolt (102) and one flat washer (101) from the cylinder rod. Remove lift cylinder assembly from truck. Remove upper links (23,26) and shims (25) from cylinder assembly. 10. Thoroughly clean exterior of cylinder. Remove hydraulic hose from lift cylinder and cap ends. WARNING Be extremely careful when working with solvent. Even a small explosion or fire could cause injury or death. WARNING Compressed air used for cleaning MUST be reduced to less than 30 psi. and then only with effective chip-guarding and personal protective equipment.

254

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F-code

Section

C-code

S7.0

7310 Lift Cylinder

Version no

000

T-code

RMX,HMX,CMX

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

Inlet Port

1. Before disassembly, clean exterior of the cylinder in a cleaning solvent to remove all contamination. WARNING Be extremely careful when working with solvent. Even a small explosion or fire could cause injury or death. WARNING Compressed air used for cleaning MUST be reduced to less than 30 psi. and then only with effective chip-guarding and personal protective equipment. 2. Be sure all hydraulic fluid has been removed from the cylinder. Stroking the piston rod will help force the fluid out.

1 2

3. Put the base end of the cylinder assembly (1) in a vise equipped with soft jaws. 4. Push cylinder rod (4) in until end of cylinder rod (4) and retainer ring (3) can be viewed through cylinder body (2) inlet port.

5. Insert a screwdriver in inlet cylinder body (2) port, taking care not to harm port threads, and slide retainer ring (3) in deep groove in rod (4).

6. Remove rod (4) from cylinder body (2). 7. Remove rod wiper (6) and rod seal (5) from inside cylinder body (2). 5

8. It is not necessary to inspect rod wiper (6), rod seal (5), or retainer ring (3). These parts are replaced as new in the seal kit available for this cylinder.

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255

F-code

Section

C-code

PS S7.0 Lift Cylinder

7310

Version no

T-code

000

RMX,HMX,CMX

1 2

2. Inspect cylinder body (2) for excessive wear or scoring. If heavy scoring is found replace entire cylinder assembly (1). 3. Inspect cylinder rod (4) for nicks, scratches, or scoring. If heavy scoring is found replace cylinder rod (4). 4. Inspect hydraulic hose and replace if worn.

5 6

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F-code

Section

C-code

S7.0

7310 Lift Cylinder

Version no

000

T-code

RMX,HMX,CMX

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

Inlet Port

1. All parts should be cleaned and dried thoroughly. Metal parts should be lightly oiled prior to reassembly. WARNING Be extremely careful when working with solvent. Even a small explosion or fire could cause injury or death. WARNING Compressed air used for cleaning MUST be reduced to less than 30 psi. and then only with effective chip-guarding and personal protective equipment. 2. Install new rod seal (5) in cylinder body (2). Install new rod wiper (6) with lips facing inward to bottom of cylinder body (2).

1 2

3. Place new retainer ring (3) in groove of cylinder rod (4).

Return

4. Oil outside of cylinder rod (4) and carefully insert in cylinder body (2).

5. Push cylinder rod (4) in cylinder body (2) until retainer ring (3) and cylinder rod (4) can be viewed through inlet port.

6. Using a screwdriver through cylinder body (2) inlet port, taking care not to harm port threads, slide retainer ring (3) in small groove. Rotate cylinder rod (4) and make sure retainer ring (3) is in the small groove all the way around cylinder rod (4).

7. Extend cylinder rod (4) to the fully out position to make sure retainer ring (3) is locked in place.

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257

F-code

Section

C-code

PS S7.0 Lift Cylinder

7310

Version no

T-code

000

RMX,HMX,CMX

5. Installation 1. In order to prevent air from filling the cylinder assembly it is recommended that the cylinder rod is fully retracted. 2. Install shims (25) and upper links (23,26) on cylinder assembly. 3. Slide lifting frame pivot pin (1) through lifting frame and upper links (23,26) and secure with a roll pin (30). 4. Install pivot pin (22) in carrier frame and upper links (23,26) and secure with cap screw (16). 5. Install one shoulder bolt (102) and one flat washer (101) though carrier frame and in cylinder rod. 6. Uncap and connect hydraulic hose to cylinder assembly and lift pump. 7. Install and connect battery to truck. Cylinder Assembly

8. Lift truck and remove all blocking. 9. Operate the truck’s hydraulic system and check operation of system as a whole looking for leaks and tight places on the lifting linkage.

101 102

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F-code

Section

C-code

S7.1 7310 Prime-Trak Cylinders

Version no

T-code

000

CMX

Prime-Trak Cylinders 1 2

Inlet Port

POS. NO

DESCRIPTION

POS. NO

DESCRIPTION

Wiper, rod

Ring, retainer

Seal, rod

Tube, cylinder with switch plate

Rod, cylinder

Tube, cylinder NO switch plate

The Prime-Trak cylinders are the positive displacement type, meaning there are NO seals on the lower end of the cylinder rod. NOTE! CLEANLINESS! Perform procedures in a clean environment. Make sure all parts are cleaned before disassembly and kept clean during assembly.

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259

F-code

Section

C-code

PS S7.1 Prime-Trak Cylinders Version no

T-code

000

CMX

7310

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. Park the truck on a level surface and make sure parking brake is applied.

3 5 4

5 8 3

2. Release pressure in hydraulic system by pressing the lowering button on steering control handle. 3. Raise and block drive end of truck so caster wheels are 2 - 3 in. [50 - 75 mm] off the floor. 4. Disconnect battery from unit to prevent accidental operation. 5. Open access door fully and disconnect negative wire from hydraulic pump(s) solenoid to prevent pump from operating. 6. Loosen nut (13), cap screw (14), and bracket securing Prime-Trak cylinders to carrier frame. 7. Remove hydraulic lines from cylinder assembles (11) and cap ends to prevent contaminants from entering the hydraulic system. 8. Remove cylinder assembly (11) from truck. 9. Before disassembly, thoroughly clean exterior of the cylinders (11) in a cleaning solvent to remove all contamination. WARNING Be extremely careful when working with solvent. Even a small explosion or fire could cause injury or death. WARNING Compressed air used for cleaning MUST be reduced to less than 30 psi. and then only with effective chip-guarding and personal protective equipment.

260

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F-code

Section

C-code

S7.1 7310 Prime-Trak Cylinders

Version no

T-code

000

CMX

1 2

3. Put the base end of the cylinder assembly(s) in a vise equipped with soft jaws.

4. Push cylinder rod (3) in until end of cylinder rod (3) and retainer ring (4) can be viewed through cylinder body (5,6) inlet port.

5. Insert a screwdriver in inlet cylinder body (5,6) port, taking care not to harm port threads, and slide retainer ring (4) in deep groove in rod (3). 5

6. Remove rod (3) from cylinder body (5,6). 7. Remove rod wiper (1) and rod seal (2) from inside cylinder body (5,6). 8. It is not necessary to inspect rod wiper (1), rod seal (2), or retainer ring (4). These parts are replaced as new in the seal kit available for this cylinder.

Inlet Port

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261

F-code

Section

PS S7.1 Prime-Trak Cylinders Version no

T-code

000

CMX

C-code

7310

1 2

3. Inspect cylinder rod (3) for nicks, scratches, or scoring. If heavy scoring is found replace cylinder rod (3).

4. Inspect hydraulic hose and replace if worn.

Inlet Port

262

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Section

C-code

S7.1 7310 Prime-Trak Cylinders

Version no

T-code

000

CMX

1 2

3. Place new retainer ring (4) in groove of cylinder rod (3).

4. Oil outside of cylinder rod (3) and carefully insert in cylinder body (5,6).

5. Push cylinder rod (3) in cylinder body (5,6) until retainer ring (4) and cylinder rod (3) can be viewed through inlet port. 5

7. Extend cylinder rod (3) to the fully out position to make sure retainer ring (4) is locked in place.

Inlet Port

Return

6. Using a screwdriver through cylinder body (5,6) inlet port, taking care not to harm port threads, slide retainer ring (4) in small groove. Rotate cylinder rod (3) and make sure retainer ring (4) is in the small groove all the way around cylinder rod (3).

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263

F-code

Section

C-code

PS S7.1 Prime-Trak Cylinders Version no

T-code

000

CMX

7310

5. Installation 1

1. In order to prevent air from filling the cylinder assembly it is recommended that the cylinder rod is fully retracted.

2. Uncap and connect hydraulic hose to cylinder assembly(s).

3 5 4

4. Lift truck and remove all blocking. 9

5 8 3

3. Install cylinder assembly(s) in it’s proper position with spring (10) located under.

5. Tighten cap screw (14) until it make contact with cylinder assembly (11), then further rotate cap screw (14) four full turns for proper caster adjustment. 6. Tighten nut (13) to secure cap screw (14) from backing off. 7. Adjust Prime-Trak lift limit switch (see Prime-Trak Hydraulic System). 8. Connect battery to truck. 9. Operate the truck’s hydraulic system and check operation of system as a whole looking for leaks and tight places on the lifting linkage. WARNING DO NOT use your hands to check for hydraulic leakage. Use a piece of cardboard or paper to search for leaks. Escaping fluid under pressure can penetrate the skin causing serious injury. Relieve pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Keep hands and body away from pinholes and nozzles which eject fluids under high pressure. 10. Close access door.

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1997-09-24

F-code

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Service Manual

1997-09-24

Section

C-code

S7.1 7310 Prime-Trak Cylinders

Version no

T-code

000

CMX

265

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

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