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Front Cover

Master Service Manual CRX30/35/40/50

Electric Stand-up Counter Balanced Lift Truck Effective Serial Number CRX**3315001 - up

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

Warning DO NOT operate this equipment unless all

factory installed guards and shields are properly secured in place.

Part no: 313706-000

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Date: 11/24/03

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Prime-Mover CRX30/35/40/50 Service Manual

How to Use This Manual

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How to Use This Manual

Prime-Mover CRX30/35/40/50 Service Manual

Map of the Manual

Map of the Manual How To Use This Manual

Map of the Manual

Safety

Systems Overview

Manual Design

Abbreviations & Symbols Vehicle Specifications

Table of Contents Planned Maintenance

Troubleshooting

Messages, Codes And Tests

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Component Procedures

Alphabetical List of Component Procedures

Go to Chart MAP2

Component Location Photos

Prime-Mover CRX30/35/40/50 Service Manual

How to Use This Manual Map of the Manual

MAP2: Map of the Manual (Continued)

Theory of Operation

Appendix

Index

Lubrication Equivalency Chart

Torque Charts

Decimal Equivalent Chart

Standard/Metric Conversions

Electrical and Hydraulic Schematics

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How to Use This Manual

Prime-Mover CRX30/35/40/50 Service Manual

Manual Design

Manual Design This manual is designed with the following objectives in mind:

To find a component procedure, you may use one of three methods:

• Provide technical coverage for expected levels of user expertise.

•

Look up the component name in the List of Component Procedures.

• Anticipate your needs and reduce your decisions regarding maintenance.

•

Find the component in the Component Locator Photos.

• Reduce page flipping through a “one-stop shopping” approach.

•

Look up the component name in the Index.

The two-line running page header at the top of each page tells you: • Name of the manual (Prime-Mover CRX30/35/40/50 Service Manual) • Current Chapter Title (for example; How to Use This Manual) • Current topic (for example; Manual Design) This manual consists of the following sections: • How to Use This Manual explains the format and design of the manual as well as abbreviations and symbols used within the manual. • Safety explains warning and caution notes, general safety rules and safety rules for batteries, static, jacking, and welding. • Systems Overview includes lift truck specifications and theory of operation information. • Planned Maintenance outlines the recommended schedule of preventive services to keep your lift truck working most efficiently. • Troubleshooting is designed to take you from a symptom to a specific sequence of tests in order to isolate a failing component. • Messages, Codes, and Tests lists the electrical fault codes and procedures for running firmware electrical tests. • Component Procedures gives step-by-step procedures for testing, removal, installation, and adjustment of individual truck components. Components are grouped by truck system.

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• Theory of Operation explains signal flow within the hydraulic and electrical schematics for various conditions of lift truck operation. • Appendix contains reference information such as torque values, lubricants, standard/metric conversions, and electrical and hydraulic schematics. • Index lists subjects alphabetically.

Prime-Mover CRX30/35/40/50 Service Manual

How to Use This Manual Abbreviations & Symbols

Abbreviations & Symbols These abbreviations, acronyms, and symbols are used in this manual. Term/Symbol

Definition

A approx amp aux AWG

ampere approximately ampere or amplifier auxiliary American Wire Gauge

BDI BSOC BWI

Battery Discharge Indicator battery state-of-charge Brush Wear Indicator

CAN cm COP

Controller Area Network centimeter Computer Operating Program

dia. DGND DVM

diameter Digital Ground Digital Volt Meter

UL Electric Truck Type Certification Rating where

electrical equipment is completely enclosed

EPO ESD

Emergency Power Off Electrostatic Discharge

ft.

foot

gal. gm Gnd

gallon or gallons gram ground

HD Ht. in.

hours on deadman height inch, inches

kg km/h kPa

kilogram(s) kilometers per hour kilo Pascal

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Term/Symbol

Definition

lb. LED LPC

pound, pounds Light Emitting Diode Lift Power Control

mA max min mm mph

milliampere maximum minute or minimum millimeter miles per hour

NV Nm

non-volatile newton meter

OACH ODI OSHA oz.

Overall Collapsed Height Operator Display Interface Occupational Safety and Health Association ounce

PC psi PWM P/N

personal computer pounds per square inch pulse width modulation part number

RAM ROM Regen

random access memory read only memory regenerative braking

SAE SG SOL spec STR

Society of Automotive Engineers Specific Gravity solenoid specification Steer Contactor

TPC

Traction Power Control

Underwriter’s Laboratories

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How to Use This Manual Abbreviations & Symbols Term/Symbol

Definition

V VDC

volt volts direct current

wrt w/ w/o

with respect to with without

@ ™ © ® + – ± ° °F °C < > % =

at trademark copyright registered plus or positive minus or negative plus or minus degrees degrees Fahrenheit degrees Celsius less than greater than percent equals

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Prime-Mover CRX30/35/40/50 Service Manual

1: How To Use This Manual

How To Use This Manual

Table of Contents

How to Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Map of the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Manual Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Abbreviations & Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 General Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Battery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Static Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Jacking Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Welding Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Systems Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Lift Truck Dimensions and Specifications . . . . . . . . . . . . . . . . . . . . . . . . 3-2 General System Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Configure Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Maintenance Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Software Configuration/PC Loader Program . . . . . . . . . . . . . . . . . . . . . 3-15

Planned Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Maintenance Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 How to Use This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Power Amplifier Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Electrical Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

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Prime-Mover CRX30/35/40/50 Service Manual

Troubleshooting Wiring Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 Hydraulic Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . 5-25

Messages, Codes, and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 List of Codes and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Message and Code Summary Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Messages and Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Analog Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-85 Input Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-91 Output Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-123

Component Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Component Locator Photos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Covers and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13 Steering and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23 Drive and Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-45 Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-81 Hydraulic Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-125 Mast, Chain, Hose, Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-147

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Traction System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 Travel Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 Hydraulic Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20 Sideshift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-34 Sense Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-36

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How To Use This Manual

Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Lubrication Equivalency Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2 Torque Chart - Standard (Ferrous) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4 Torque Chart - Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5 Torque Chart - Standard (Brass) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6 Decimal Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7 Standard/Metric Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9 Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-11

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1

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Prime-Mover CRX30/35/40/50 Service Manual

Safety

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Safety

Prime-Mover CRX30/35/40/50 Service Manual

Definitions

Definitions Throughout this manual, you will see two kinds of safety reminders:

! WARNING Warning means a potentially hazardous situation exists which, if not avoided, could result in death or serious injury.

! CAUTION Caution means a potentially hazardous situation exists which, if not avoided, may result in minor or moderate injury or in damage to the truck or nearby objects.

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Prime-Mover CRX30/35/40/50 Service Manual

Safety General Safety

General Safety

Do not operate or work on this truck unless you have reviewed the Operator’s Manual (Publication No. 313704-000) and are trained, qualified, and authorized to do so.

8B15004D.EPS

Know the truck’s controls and what they do.

7J27009S.EPS

Do not operate this truck if it is in need of repair or if it is in any way unsafe.

7J27010S.EPS

Operate this truck only from the operator’s compartment.

7J27011S.EPS

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Safety

Prime-Mover CRX30/35/40/50 Service Manual

General Safety

Before working on this truck, always turn the key switch to OFF and disconnect the truck’s battery connector (unless this manual tells you otherwise).

7J27012S.EPS

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

JEWELRY.EPS

Follow the scheduled lubrication, maintenance, and inspection steps.

SCHEDMNT.EPS

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

8B15008D.EPS

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Prime-Mover CRX30/35/40/50 Service Manual

Safety General Safety

Do not use an open flame near the truck.

7J27013S.EPS

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

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

SPILLS.EPS

Use and park this truck indoors. Do not operate outdoors (except for dock or ramp operation, if permitted).

7J27014S.EPS

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Safety

Prime-Mover CRX30/35/40/50 Service Manual

General Safety

Do not wash this truck with a hose. Do not steam clean inside compartments.

Do not add to or modify this truck without written approval from Prime Mover. Refer to the Standards Compliance section of the Operator’s Manual (Publication No. 313704-000).

7J27015S.EPS

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Prime-Mover CRX30/35/40/50 Service Manual

Safety Battery Safety

Battery Safety Before working on or near a battery, review the general safety rules. Always follow these safety rules. See the battery manufacturer’s instruction manual for specific instructions on battery maintenance. The instructions found there take precedence over the instructions found in this truck manual.

Size and Type When you install a battery in this truck, make sure that it is the correct size and voltage.

! WARNING Do not install a battery that weighs less than the recommended minimum weight. This could affect the truck’s stability. This illustration of the truck’s specification plate gives you important information about the battery used in this truck. The following list explains the numbered items in the figure:

1. Maximum allowable weight of battery (pounds/kilograms) 2. Minimum allowable weight of battery (pounds/kilograms) 3. Truck voltage 4. Maximum rating of battery (amp-hours) 5. Truck weight without battery (pounds/kilograms) 2

6. Type of battery to be used (UL classification)

412-645.eps

Figure 2-1:

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Typical Truck Spec Plate

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Safety

Prime-Mover CRX30/35/40/50 Service Manual

Size and Type

! WARNING As a battery is being charged, an explosive gas mixture forms within and around each cell. If the area is not properly ventilated, this explosive gas can remain in or around the battery for several hours after charging. Be sure there are no open flames or sparks in the charging area. An open flame or spark can ignite this gas, resulting in serious damage or injury.

! CAUTION Battery electrolyte is a solution of sulfuric acid and water. Battery acid causes burns. Should any electrolyte come in contact with your clothing or skin, flush the area immediately with cold water. Should the solution get on your face or in your eyes, flush the area with cold water and get medical help immediately.

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

25L6S016.EPS

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

04G6S059.EPS

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Safety Size and Type

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

23L6S012.EPS

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

04G6S058.EPS

Disconnect the battery from the truck at the battery connector, after turning the key switch OFF. Do not break live circuits at the battery terminals. A spark often occurs at the point where a live circuit is broken. 7J27012S.EPS

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

04G6S057.EPS

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Safety

Prime-Mover CRX30/35/40/50 Service Manual

Size and Type

Keep batteries clean. Corrosion causes shorts to the frame.

Keep plugs, terminals, cables, and receptacles in good condition to avoid shorts and sparks.

8D14127S.TIF

Keep filler plugs firmly in place at all times except when the electrolyte level is checked, when water is added to the cells, or when the specific gravity is checked. Make certain that the vent holes in the filler plugs are open to allow the gas to escape from the cells. 09G6S047.TIF

Do not allow cleaning solution, dirt, or any foreign matter to enter the cells.

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Safety Size and Type

Make sure that the battery you are installing in this truck is the correct size. A smaller or lighter weight battery could seriously affect truck stability. See the truck’s specification plate for more information.

7J27016S.EPS

Never plug a battery charger into the truck’s battery connector. Plug the battery charger only into the battery connector from the battery.

7J27017S.EPS

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

25L6S014.EPS

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Safety

Prime-Mover CRX30/35/40/50 Service Manual

Static Precautions

Static Precautions Electronic circuit boards and devices used on this Prime-Mover lift truck can be damaged by the discharge of static electricity, called electrostatic discharge (ESD). Static charges can accumulate from normal operation of the lift truck as well as movement or contact between non-conductive materials (plastic bags, synthetic clothing, synthetic soles on shoes, styrofoam coffee cups). Accumulated static can be discharged through human skin to a circuit board or component by touching the parts. Static discharge is also possible through the air, when a charged object is placed close to another surface at a different electrical potential. Static discharge can occur without seeing or feeling it. Whenever working on or near static-sensitive electronics, always use static discharge precautions. 1. Place a static discharge wrist strap around your wrist. Connect the ground lead to the wrist strap connector. The wrist strap should be equipped with a 1 megohm resistor to protect against shock hazard. 2. Connect the ground plug to the ESD ground jack on the lift truck. The ESD ground jack is located on the tractor frame near the steer tiller. If you cannot use the ground jack, connect the ground clamp to an unpainted, grounded surface on the lift truck frame. 3. Handle circuit boards by edges only. Avoid touching edge connectors. 4. If you will be removing or installing static-sensitive components, place them on a properly grounded static mat. 5. To transport static sensitive components, including failed components being returned, place the components in an antistatic bag or box (available from your Dealer). The wrist strap and associated accessories should be tested monthly to verify they are working properly. A defective static discharge wrist band will not alert you that it is bad.

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8D14130S.TIF

Figure 2-2:

Anti-Static Ground Jack

Prime-Mover CRX30/35/40/50 Service Manual

Safety Static Precautions

MAT2.TIF

Figure 2-3:

Anti-Static Kit (P/N 148115) with Wrist Strap and Mat

Figure 2-3 shows the components of the Prime-Mover antistatic field service kit, Part Number (P/N) 148115. The kit includes a wrist strap, ground cord, and static-dissipative work surface (mat). Follow the instructions packaged with the kit. Wrist straps are available in quantities of 25, as P/N 313666-468.

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Safety

Prime-Mover CRX30/35/40/50 Service Manual

Jacking Safety

Jacking Safety Sometimes you may need to jack the truck off the floor to perform maintenance procedures. When doing so, observe the proper safety precautions: 1. Lower the carriage and forks completely to the floor. Remove any load. 2. Place all controls in neutral. 3. Block the wheels to reduce the risk of movement of the vehicle. 4. Disconnect battery connector. 5. Place the jack under the designated jacking points. See Figures 2-4 and 2-5.

! WARNING Use extreme care whenever the truck is jacked up. Never block the truck between the telescopic and the floor. Keep hands and feet clear from vehicle while jacking the truck. After the truck is jacked, place solid blocks beneath it to support it. DO NOT rely on the jack alone to support the truck.

8D14044S.TIF

Figure 2-4:

Jacking Drive Wheel

Figure 2-5:

Jacking Tractor

6. To jack the drive wheel: Place the jack in the designated jacking position. See Figure 2-4. Jack the truck up just high enough to raise the drive wheel off the floor. Place a block under the frame as shown. 7. To jack the tractor: Place the jack in the designated jacking position near the steerable wheel. See Figure 2-5. Jack the truck so that the steerable wheel is off the floor no more than 1 in. (25.4 mm). Block under the frame as shown. NOTE: After working on vehicle, test all controls and functions to verify correct operation. 8D14047S.TIF

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Safety Towing

Towing To safely tow this lift truck: 1. Lower the carriage and remove any load from the forks. 2. Turn the key switch OFF and disconnect the battery connector. 3. Install the brake release bolts. 4. Using a suitable towing vehicle, lift the truck until the steer tire is no more than 1 in. (25.4 mm) off the floor. 5. Tow the truck slowly in the tractor-first direction.

! WARNING When towing is complete, make sure to remove the brake release bolts. Failure to do so could cause serious injury.

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Safety

Prime-Mover CRX30/35/40/50 Service Manual

Welding Safety

Welding Safety ! CAUTION Flame cutting or welding on painted surfaces may produce potentially harmful fumes, smoke, and vapors. Prior to performing flame cutting or welding operations, it is recommended that the coating be removed in the vicinity where the operation(s) will be performed. Coating removal may be by mechanical methods, chemical methods, or a combination of methods. Perform flame cutting and/or welding operations in well ventilated areas. Use local exhaust if necessary.

Before working on this truck, make sure that: • Fire protection equipment is nearby. • You know where the nearest eyewash station is.

! CAUTION Disconnect the battery before you attempt to inspect, service, or repair the lift truck. 04G6S059.EPS

• Check for shorts to frame as described on page 5-14. If any shorts are detected, remove them before you proceed with the welding operation. • Clean the area to be welded. • Remove Interface Card, Translator Card, and power amplifiers from the lift truck. • Protect all truck components from heat, weld spatter, and debris. • Attach the ground cable as close to the weld area as possible. • Do not perform any welding operations near the electrical components. • Remove battery from truck if welding must be done near the battery compartment.

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7j27012.eps

Prime-Mover CRX30/35/40/50 Service Manual

Systems Overview

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Systems Overview

Prime-Mover CRX30/35/40/50 Service Manual

Lift Truck Dimensions and Specifications

Lift Truck Dimensions and Specifications This lift truck is rated for performance by load center and load weight. Review the specification plate located in the battery compartment for detailed load capacity and load center information.

Prime-Mover model designation

Nominal battery voltage

Serial Number

Approx. weight of lift truck minus battery, load, and operator

Min. battery weight for this lift truck

Max. battery weight for this lift truck

Maximum load capacity for this lift truck

Battery weight must be between the min. and max. weight 412-645.wmf

Figure 3-1:

Lift Truck Specification Plate

For basic dimensions, see Table 3-1, Lift Truck Dimensions and Specifications on page 3-3.

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Systems Overview Lift Truck Dimensions and Specifications

Table 3-1: Lift Truck Dimensions and Specifications

Category

Max Load @ 24 in. (610 mm) Load Center

Model CRX30

CRX35

CRX40

CRX50

3000 lb. (1361 kg)

3500 lb. (1588 kg)

4000 lb. (1814 kg)

5000 lb. (2268 kg)

Overall Collapsed Height* (OACH)

83 - 107 in. (2108 - 2716 mm)

Elevated Height*

127 to 258 in. (3226 to 6553 mm)

123 to 251 in. (3124 to 6375 mm)

Extended Height w/Load Backrest*

175 to 306 in. (4445 to 7772 mm)

175 to 299 in. (4445 to 7594 mm)

Truck Wheelbase

50.3 in. (1280 mm)

53.1 in. (1349 mm)

55.6 in. (1412 mm)

Truck Head Length w/o Sideshift*

68.5 in. (1740 mm)

71.2 in. (1808 mm)

73.7 in. (1872 mm)

Truck Head Length w/Sideshift

70.9 in. (1801 mm)

73.6 in. (1869 mm)

76.1 in. (1933 mm)

Battery Compartment

39.6 x 18.5 x 32.3 in. (1007 x 470 x 820 mm)

39.6 x 21.25 x 32.3 in. (1007 x 540 x 820 mm)

39.6 x 23.75 x 32.3 in. (1007 x 603 x 820 mm)

Battery Voltage Minimum Battery Weight

36V 2300 lb. (1044 kg)

2600 lb. (1180 kg)

2700 lb. (1226 kg)

*Specifications will vary according to mast type

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Systems Overview

Prime-Mover CRX30/35/40/50 Service Manual

General System Data

General System Data Modes of Operation

Maintenance Mode

There are four different modes of operation for this lift truck:

This mode lets you test a circuit in the lift truck while the lift truck is stationary.

• Performance Selection Mode • Configure Mode

You cannot operate the lift truck while it is in Maintenance Mode.

• Maintenance Mode

! WARNING

• Learn Mode To select a mode, enter the correct password (see page 3-5 for instructions on entering a password).

Before placing the lift truck in Maintenance Mode:

Performance Selection Mode

1. Jack the lift truck so that the drive tires are off the floor.

Entering Performance Selection Mode will allow the operator or supervisor to choose between four different performance modes. Each performance mode can be configured and stored for use in different types of applications. Use the MODE button on the operator display to view the mode being used. Pressing the MODE button will cycle through all four performance modes. Configurable settings in Performance Selection Mode include maximum forward and reverse speeds, acceleration strength and coast distances. To configure each mode individually, use the operator display to enter Configure Mode and select Mode #1, Mode #2, Mode #3, or Mode #4.

Configure Mode Entering the Configuration Password lets you access the lift truck’s Configure Mode. This mode lets you enter the lift truck’s software and change the lift truck’s performance limits. Use the Configure Mode Chart on page 3-6 to see which items you can change and the selections that are available.

2. Make sure the controls are in neutral. 3. Make sure the lift truck is blocked to keep it from moving. 4. Lower the forks all the way to the floor. See Maintenance Mode on page 3-11.

Learn Mode You can select Learn Mode after entering Maintenance Mode. Learn Mode lets you re-calibrate the lift truck’s control handle. You would enter Learn Mode and perform the instructions that are shown on the operator display if you replace any of these components: • Interface Card • Control Handle • Firmware NOTE: The lift truck automatically asks the operator to perform Learn on initial power-up. It does not need to be run again.

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Prime-Mover CRX30/35/40/50 Service Manual

Systems Overview Passwords

Passwords There are two levels of passwords that you might use on this lift truck. The Configuration Password allows you to enter most of the items in Configure Mode.

NOTE: If you push and hold the button, you will scroll very quickly. 10. Stop pressing the button when the letter or number you want appears in the space. 11. Move to the next space you want to change by:

The Maintenance Password lets you enter Maintenance Mode.

•

pressing the ENTER button to move the active space to the right.

Entering a Password

•

holding down the ENTER button and pressing the DOWN button to move the active space to the left.

1. The operator display will show CRX30 or similar message depending on the truck model. NOTE: If you are trying to access Maintenance Mode or Configure Mode after the lift truck has shown an error code on its operator display, simply press the ENTER button. 2. Press the ENTER button.

12. Repeat steps 8, 9, and 10 to change the letter or number in this space. Repeat steps 7, 8, 9, and 10 to enter the rest of the password. 13. When the operator display shows the correct password, press the ENTER button. 14. If the password was correct, you are now in the lift truck’s Maintenance Mode.

3. The operator display will show 8 blank spaces. 4. Enter the password as follows: NOTE: The default Maintenance Password is “PM2______”. The default Configuration Password is “PM1______”. 5. To illustrate this procedure, assume you will be entering the default Maintenance Password (“PM2_____"). 6. Look at the operator display. The blinking space is the active space. 7. To move the active space to the right, press the ENTER button. To move the active space to the left, hold down the ENTER button and press the DOWN button. 8. When the space you want to change is active, stop pressing the button. 9. Press the UP button. You will scroll up through the numbers (0, 1, 2, 3 — 7, 8, 9) and letters (a, b, c, — x, y, z). If you press the DOWN button, you will scroll down through the letters (z, y, x, — c, b, a) and numbers (9, 8, 7 — 2, 1, 0).

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Systems Overview

Prime-Mover CRX30/35/40/50 Service Manual

Configure Mode

Configure Mode Configuration Mode Menu NOTE: @ Indicates Factory Default; * Indicates Optional Item Item

Values

Description

Save? Yes Save? No

Exit Configuration Mode Save changes and leave Configuration Mode Abandon changes and leave Configuration Mode

Yes No

Restore Factory Defaults Restore to Factory Defaults Do not restore Factory Defaults

@ Operator Super.

Select Mode Access Mode Selection Accessible by Operator Mode Selection Accessible Only by Supervisor

Quit

Default

Modes

Mode #1

Configure Performance Mode #1. See Mode #1 Menu on page 3-9.

Mode #2

Configure Performance Mode #2. See Mode #2 Menu on page 3-9.

Mode #3

Configure Performance Mode #3. See Mode #3 Menu on page 3-10.

Mode #4

Configure Performance Mode #4. See Mode #4 Menu on page 3-10.

BDI 20%)

@ 20%

PM2_____

Enter new Maintenance Password Default Maintenance Password = "PM2_____"

PM1_____

Enter New Configuration Password Default Configure Password = “PM1______“ Quit @ English French Spanish

Select Language for Messages Quit Language Selection Menu Select English Select French Select Spanish

Quit @ English Metric

Units of Measurement (For Display Messages) Quit Selection Menu English Metric

English

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Set BDI Lift Cutout Point 0% to 50% (1% increments)

Prime-Mover CRX30/35/40/50 Service Manual

Systems Overview Configure Mode

Configuration Mode Menu NOTE: @ Indicates Factory Default; * Indicates Optional Item Item

Values Clock

Set Date and Time Quit

Quit

24 Hour? Y 24 Hour? N

Select 12 or 24 Hour Clock

DayLtS? Y DayLtS? N

Daylight Savings Time?

Set Time

Set Time: 10:41PM = 10:41 PM or 2241 = 10:41 PM (24 Hour Clock)

08/20/98

Set Date: Month/Day/Year

Quit @ Brake Drive Lift Steer 200 Hours FS

Select Hourmeter for Scheduled Maintenance Quit Scheduled Maintenance Menu Select Deadman Brake Hourmeter Select Drive System Hourmeter Select Lift Motor Hourmeter Select Steer Motor Hourmeter Select Interval For Service Reminder 20 to 500 Hours in 20 Hour Increments

SchMaint

Reset Lift Cutout Message Only Disable BWI-Trac Half Speed @ Icon BWI-Lift No Lift @ Icon Sideshift*

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Description

On Off

Defaults (hours) = Hourmeter Brake Drive Lift Steer Reset Clock

E Label 200 350 250 500

EE Label 200 150 100 200

Turn OFF Scheduled Maintenance Brush Wear Indicator Action Mode Half Top Travel Speed After 200 Additional Traction Miles or Illuminated Icon ONLY Brush Wear Indicator Action Mode Lift Motor Inoperative After 10 Additional Lift Hours or Illuminated Icon ONLY Select Sideshift (Low Speed Attachment) Turn Sideshift On Turn Sideshift Off

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Systems Overview

Prime-Mover CRX30/35/40/50 Service Manual

Configure Mode Configuration Mode Menu NOTE: @ Indicates Factory Default; * Indicates Optional Item Item Travel Alarm*

SpdLimit*

Values

Description

Forks Tractor @ Both None

Select Alarm To Sound For Travel Forks-First Direction Of Travel Tractor-First Direction Of Travel Both Directions Of Travel Neither Direction of Travel Set the Height Limit Switch Speed

@ 3.0 MPH 2.0 to 6.0 MPH 3.0 to 10.0 KPH

LftLimit*

Weight*

Attch#1*

Attch#2*

3-8

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0.2 MPH Increments 0.2 KPH Increments (metric)

@ On Off

Set the Lift Limit with Bypass Switch Turn On Switch Function Turn Off Switch Function

On Off Learn

Select Weight Sensor Turn On Weight Sensor Turn Off Weight Sensor Learn Weight Sensor

Type? Clamp Other None Quit

Select Optional Hydraulic Attachment #1 Select Attachment Type Clamp Attachment Another Type of Attachment No Attachment Quit

On Off

Select Optional Hydraulic Attachment #2 Turn Attachment #2 On Turn Attachment #2 Off

Prime-Mover CRX30/35/40/50 Service Manual

Systems Overview Configuring Modes 1-4

Configuring Modes 1-4 Mode #1 Menu NOTE: @ Indicates Factory Default; * Indicates Optional Item Item

Values Quit

Description Quit Mode #1

@ 7.0 MPH 2.0 to 7.0 3.0 to 11.0

Set Maximum Forward Speed 0.2 MPH Increments 0.2 KPH Increments (metric)

2.0 to 7.0 3.0 to 11.0

Set Maximum Reverse Speed 0.2 MPH Increments 0.2 KPH Increments (metric)

@ 7.0 MPH

Set Acceleration Strength

Medium Soft Medium @ Hard

Set Coast Distance

Long Short @ Medium Long

Mode #2 Menu NOTE: @ Indicates Factory Default; * Indicates Optional Item Item

Values Quit

Description Quit Mode #2

@ 7.0 MPH 2.0 to 7.0 3.0 to 11.0

Set Maximum Forward Speed 0.2 MPH Increments 0.2 KPH Increments (metric)

2.0 to 7.0 3.0 to 11.0

Set Maximum Reverse Speed 0.2 MPH Increments 0.2 KPH Increments (metric)

@ 7.0 MPH

Set Acceleration Strength

Medium Soft @ Medium Hard

Set Coast Distance

Long Short Medium @ Long

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3-9

Systems Overview

Prime-Mover CRX30/35/40/50 Service Manual

Configuring Modes 1-4

Mode #3 Menu NOTE: @ Indicates Factory Default; * Indicates Optional Item Item

Values Quit

Description Quit Mode #3

@ 6.5 MPH 2.0 to 7.0 3.0 to 11.0

Set Maximum Forward Speed 0.2 MPH Increments 0.2 KPH Increments (metric)

2.0 to 7.0 3.0 to 11.0

Set Maximum Reverse Speed 0.2 MPH Increments 0.2 KPH Increments (metric)

@ 6.5 MPH

Set Acceleration Strength

Medium Soft @ Medium Hard

Set Coast Distance

Long Short Medium @ Long

Mode #4 Menu NOTE: @ Indicates Factory Default; * Indicates Optional Item Item

Values Quit

Description Quit Mode #4

@ 6.0 MPH 2.0 to 7.0 3.0 to 11.0

Set Maximum Forward Speed 0.2 MPH Increments 0.2 KPH Increments (metric)

2.0 to 7.0 3.0 to 11.0

Set Maximum Reverse Speed 0.2 MPH Increments 0.2 KPH Increments (metric)

@ 6.0 MPH

Set Acceleration Strength

Medium @ Soft Medium Hard

Set Coast Distance

Long Short Medium @ Long

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Prime-Mover CRX30/35/40/50 Service Manual

Systems Overview Maintenance Mode

Maintenance Mode Maintenance Mode Menu NOTE: @ Indicates Factory Default; * Indicates Optional Item Item

Values

Quit

Exit Maintenance Mode

Learn Quit Controls Weight D Input

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Description

Learn the Control Handle Quit Learn Mode Learn Controls: Return Control to Neutral, Press Enter Learn the Weight Sensor Digital Inputs

Quit DI

Quit Digital Inputs

I00

Deadman Switch

I01

EPO Switch

I02*

High Speed Limit Switch

I03

Tilt Up Switch

I04

Tilt Down Switch

I05

Sideshift Right Switch

I06

Sideshift Left Switch

I07*

Lift Limit Mast Switch

I08

Steer Position Sensor

I09*

Attachment Spool Valve Switch

I10

Horn Switch

I11

FU1 Steering Fuse

I12

FU3 Lift Fuse

I13

Traction Motor #1 (Left) Brush Wear Indicator (Both)

I14

Traction Motor #2 (Right) Brush Wear Indicator (upper)

I15

Traction Motor #2 (Right) Brush Wear Indicator (lower)

I16

Lift Motor Brush Wear Indicator (upper)

I17

Lift Motor Brush Wear Indicator (lower)

I18

Traction Motor #1 (left) Speed Sensor

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Systems Overview

Prime-Mover CRX30/35/40/50 Service Manual

Maintenance Mode Maintenance Mode Menu NOTE: @ Indicates Factory Default; * Indicates Optional Item

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I19

Traction Motor #2 (right) Speed Sensor

I20

Traction Motor #1 (left) Thermostat

I21

Traction Motor #2 (right) Thermostat

I22

Lift Motor Thermostat

I23

Lift Switch

I24

Lower Switch

I25*

Tilt Limit Switch

I26*

Tilt Limit Switch

I27

TPC_L Signal

I28

TPC_R Signal

I29

Left Power Amp Switch Inputs

I30

Right Power Amp Switch Inputs

Prime-Mover CRX30/35/40/50 Service Manual

Systems Overview Maintenance Mode

Maintenance Mode Menu NOTE: @ Indicates Factory Default; * Indicates Optional Item Output

Return

Digital Outputs Ready?

Jack Drive Wheels Off Floor

Quit DO

Quit Digital Outputs

O01

Toggle the Load Hold (SOL1) Solenoid

O02*

Toggle the Sideshift (SOL2) Solenoid

O04

Toggle the Tilt (SOL4) Solenoid

O05*

Toggle the Aux PSI Select (SOL 5) Solenoid

O06

Toggle the Auxiliary Direction A (SOL 6) Solenoid

O07

Toggle the Equalization (SOL 7) Solenoid

O08

Toggle the Auxiliary Direction B (SOL 8) Solenoid

O09*

Toggle the High Flow Auxiliary (SOL 9) Solenoid

O10*

Toggle the High Flow Attachment 1 (SOL 10) Solenoid

O11*

Toggle the High Flow Attachment 2 (SOL 11) Solenoid

O12

Toggle the TPC Contactor

O13

Toggle the LPC Contactor

O14

Toggle the STR Contactor

O15

Toggle the AUX Contactor

O16

Ramp Command to Traction Power Amplifier #1 (left)

O17

Ramp Command to Traction Power Amplifier #2 (right)

O18

Toggle Traction Motor Brake #1 (left)

O19

Toggle Traction Motor Brake #2 (right)

O20

Ramp the Frequency to the Operator Display Alarm

O21

Toggle the Horn

O22*

Toggle the Travel Alarm

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Systems Overview

Prime-Mover CRX30/35/40/50 Service Manual

Maintenance Mode Maintenance Mode Menu NOTE: @ Indicates Factory Default; * Indicates Optional Item A Input

# of Errors Logged

TT:Versn

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Analog Inputs Quit AI

Quit Analog Inputs

A05

Throttle Potentiometer Voltage

A06

Battery Discharge Indicator Voltage

A07

Power Supply +12VDC

A08

FU3 Lift Fuse Voltage

A09*

Weight Sensor Voltage

0-16 Quit Enter Clear TT:XX.X

Error Codes Logged System Will Store Up To 16 Error Codes Exit Error Log Menu Press to Scroll Through Logged Error Codes Firmware Version Number

Prime-Mover CRX30/35/40/50 Service Manual

Systems Overview Software Configuration/PC Loader Program

Software Configuration/PC Loader Program

To Install from Windows95:

Overview

2. At the prompt, type a:\install and use your mouse to click on the OK button. If your 3.5 in. disk drive has not been designated as “a”, you will need to substitute the proper drive letter in its place.

The PC Loader Program allows you to update software, set factory defaults, and configure options on your Prime-Mover lift truck. • Flash Memory Program • Blank Primary Memory • Set Factory Defaults • Options

Requirements PC Loader can be installed on an IBM-compatible PC. The PC communicates with the truck through a 9-pin serial cable (P/N 313666-458).

! WARNING We recommend using the surge protector (P/N 313666-459) to protect your PC from possible electrostatic discharge or voltage surges.

Install PC Loader

1. Use your mouse to click on the START button located in the lower left corner of your screen. Then, use your arrow to click on RUN.

3. The program will automatically install onto your PC’s hard drive.

To Install from Windows version 3.1: 1. Locate the Program Manager icon on the main desktop screen and open it by double-clicking on it with your mouse. 2. Locate the menu bar at the top of the screen. Click on FILE. 3. From the FILE menu screen, select RUN by double-clicking on it with your mouse button. 4. At the prompt, type a:\install and use your mouse to click on the OK button. If your 3.5 in. disk drive has not been designated as “a”, you will need to substitute the proper drive letter in its place. 5. The program will automatically install onto your PC’s hard drive.

NOTE: This program can be installed and accessed using either DOS or Windows application.

To Install from DOS: 1. Place the disk in your floppy drive. 2. Type a:\install at the DOS prompt. If your 3.5 in. disk drive has not been designated as “a”, you will need to substitute the proper drive letter in its place. 3. The program will automatically install onto your PC’s hard drive.

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Systems Overview

Prime-Mover CRX30/35/40/50 Service Manual

Connect PC To Lift Truck

Connect PC To Lift Truck 1. Turn truck key switch OFF. 2. Connect the surge protector to the COMM 1 or COMM 2 port of your computer. NOTE: On most PC’s and laptop PC’s, the COMM 1 or COMM 2 port is located on the rear of the unit and is a 9-pin “male” connection. 3. Connect the 9-pin serial cable to the surge protector. 4. Connect the cable to JC1 on the Interface Card mounted on the left side of the tractor frame.

Starting PC Loader NOTE: PC Loader can be started from either DOS or a Windows application.

To Start PC Loader from DOS: 1. Make sure you are in the main directory on your hard drive. Your DOS prompt should be C:\> If you are not in the main directory, type cd\ at the prompt and press ENTER. This should return you to the main directory. 2. Type C:\pmover\loadlite\loadlite.bat at the DOS prompt. 3. The Main Menu screen should appear on your PC’s screen. Select the feature you want to use from the Main Menu. See Figure 3-2.

To Start PC Loader from Windows95: 1. After starting Windows, use your mouse to click on the START button located in the lower left corner of your screen. Then, use your arrow to click on RUN. 2. At the prompt, type C:\pmover\loadlite\loadlite.bat and use your mouse to click on the OK button. 3. The main menu screen should appear on your PC screen. See Figure 3-2.

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To Start PC Loader from Windows version 3.1: 1. Locate the Program Manager icon on the main desktop screen and open it by double-clicking on it with your mouse. 2. Locate the menu bar at the top of the screen. Click on FILE. 3. From the FILE menu screen, select RUN by double-clicking on it with your mouse button. 4. At the prompt, type C:\pmover\loadlite\loadlite.bat and use your mouse to click on the OK button. 5. The Main Menu screen should appear on your PC screen. See Figure 3-2.

Prime-Mover CRX30/35/40/50 Service Manual

Systems Overview Troubleshooting

Figure 3-2:

opening.tif

Main Menu Screen In PC Loader

Troubleshooting At Start-Up If PC Loader cannot read the truck software when you start PC Loader, you will see the communication error screen in Figure 3-3.

Figure 3-3:

1. Check the following:

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comm.tif

Communication Error Screen, At Start-Up

•

Cable connection between the truck and the PC

•

Correct communication port selected (1 or 2)

•

Truck key switch is ON

2. Cycle key switch OFF and ON. 3. Restart PC Loader.

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Systems Overview Troubleshooting

During Regular Use If you see the screen in Figure 3-4 while you are using PC Loader, communication with the truck software was lost.

Figure 3-4:

Communication Error Screen, During Regular Use

Check the following: • Cable connection between the truck and the PC • Truck key switch is ON NOTE: If you see the message in Figure 3-5, the truck’s firmware must be updated.

Figure 3-5:

Dealer Mismatch Screen

To clear the screen, perform the following: 1. Close and restart PC Loader. 2. Update the truck software. See Flash Memory Program on page 3-19. 3. If you see the message in Figure 3-5 at any time after you update the software, call your authorized Prime-Mover Dealer.

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Prime-Mover CRX30/35/40/50 Service Manual

Systems Overview Flash Memory Program

Flash Memory Program The flash memory program allows you to: • Identify current version of software on your truck • Update current version of software with a newer version 1. Type F at the main menu prompt. See Figure 3-6.

Figure 3-6:

Main Menu Screen

Opening.tif

2. Type the number of the software version you want to load on the truck at the flash programming prompt. See Figure 3-7. NOTE: To exit this menu, select A to abort. This will return you to the main menu. 3. After the Flash Memory Program has been installed, select X to terminate PC Loader. Turn the key switch OFF and wait 5 seconds. Then, turn the key switch back ON to complete the software loading process.

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3-19

Systems Overview

Prime-Mover CRX30/35/40/50 Service Manual

Blank Primary Memory

Figure 3-7:

Flash Programming Screen

Blank Primary Memory The Blank Primary Memory feature allows you to clear the memory in a truck so the Operator Display can be used in another truck. NOTE: The primary memory of this truck is located on the Operator Display. 1. Type B at main menu prompt. See Figure 3-8.

Figure 3-8:

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Main Menu Screen

Flash.tif

Prime-Mover CRX30/35/40/50 Service Manual

Systems Overview Blank Primary Memory

2. After selecting this feature, the Blank Primary Memory screen appears. See Figure 3-9.

Figure 3-9:

Clear Primary Memory Caution Screen

clearcau.tif

3. If you type N, the action is cancelled. If you type Y, the memory is cleared. The truck will then automatically restart and a new prompt appears on your screen. See Figure 3-10.

! CAUTION Before removing the Operator Display, be sure you do not cycle the power OFF/ON. Doing so will rewrite the memory of the truck.

Figure 3-10: Blank Primary Memory Screen

clear2.tif

4. Turn the truck OFF. It is now safe to remove the Operator Display from the lift truck.

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3-21

Systems Overview Set Factory Defaults

Set Factory Defaults The “Set Factory Defaults” feature allows you to configure the truck to the original factory settings. 1. Type S at the Main Menu prompt. See Figure 3-11.

Figure 3-11: Main Menu Screen

2. The program will ask you to verify your decision to restore the factory defaults. Enter Y if you want to restore the settings. Enter N if you want to exit to the Main Menu screen. See Figure 3-12.

Figure 3-12: Factory Default Settings Screen

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Prime-Mover CRX30/35/40/50 Service Manual

Systems Overview Options

Options The Options feature allows you to: • Enable and disable options on the truck like sideshift, attachments, electric key, etc. • Check the software version on the truck • Check the serial number of the truck • Check the manufacture date of the truck • Check the model type of the truck 1. Type O at the Main Menu prompt. See Figure 3-13.

Figure 3-13: Main Menu Screen

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opening.tif

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Systems Overview

Prime-Mover CRX30/35/40/50 Service Manual

Options 2. The Options Menu screen shows you the available options which can be enabled/disabled on the truck. See Figure 3-14.

Figure 3-14: Options Menu Screen

3. Use the UP or DOWN arrows to move through the options items. See Figure 3-14. 4. To change an option setting: a. Type Y or N to change the highlighted option. See Figure 3-14. b. When you finish changing the options, type X to exit. NOTE: The option settings for “EE Truck,” “French” and “Spanish” are for information only. They cannot be configured and appear as grey letters. c. The program will then ask you to verify the settings which you have chosen. A message, “Write This Data to the Vehicle?”, will appear at the bottom of your screen. Type Y to configure the truck or N to exit. d. After changing the option settings, the Main Menu appears.

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options.tif

Prime-Mover CRX30/35/40/50 Service Manual

Planned Maintenance

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4-1

Planned Maintenance Maintenance Guidelines

Maintenance Guidelines A planned maintenance program is recommended to enable: • Maximum truck performance • Maximum truck life • Reduction of costly down time • Avoidance of unnecessary repairs Planned maintenance includes: • Lubrication • Cleaning • Inspection • Service The planned maintenance guidelines fall into two categories: • Moderate usage • Severe usage: •

More than 1500 hours of operation per year

•

Extreme environment conditions, such as a bumpy or abrasive floor, constant exposure to air saturated with dirt or metallic particles, or an “EE” label

Perform all of the scheduled checks and maintenance during the suggested intervals. The time intervals given in this guide are based on normal operating conditions. When operating under abnormal or severe conditions, perform these services more often as required to keep the unit in good operating condition. See “Lubrication Equivalency Chart” on page A-2. This provides information on lubrication specifications. Refer to the manufacturer’s supplements for components not listed on the following pages.

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Prime-Mover CRX30/35/40/50 Service Manual

Planned Maintenance Operator’s Daily Checklist

Operator’s Daily Checklist CRX30/35/40/50 Operator’s Daily Checklist Visual Inspection/Key Turned OFF Component

What to Check

Mark

BATTERY Battery Battery Gates

Fully charged/correct water level/correct voltage, no leakage, proper installation Proper installation

BRAKE Deadman Pedal

Pedal moves freely, no binding Deadman brake functions properly (travel circuit disabled)

CONTROLS Function Controls Emergency Power Off

Move smoothly without binding, return to neutral when released Emergency disconnect functions properly

GENERAL Guards/Covers Decals Leakage

Guards and covers installed and secure Replace warning decals that are illegible or damaged. Check floor under truck for any accumulation of fluid indicating a possible leak

LIFT/LOWER SYSTEM Cables/Hoses Hydraulic Reservoir

No damage to chains or hoses Check hydraulic fluid level in hydraulic reservoir

TIRES Tires

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No gouges, chunking, or flat spots No bond failures Adequate tread (if applicable)

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Planned Maintenance

Prime-Mover CRX30/35/40/50 Service Manual

Operator’s Daily Checklist

CRX30/35/40/50 Operator’s Daily Checklist Operational Inspection/Key Turned ON Component

What to Check

HORN Sounds when button is depressed STEERING Smooth steering, without binding or excess play DIRECTIONAL/SPEED CONTROL Moves smoothly without binding Returns to neutral when released Controls speed and direction properly Plugging functions properly Speed limits function properly LIFT/LOWER SYSTEM Lift/lower controls move smoothly and return to neutral when released All controls perform their functions as indicated OPERATOR DISPLAY Displays correct information and is easily readable BRAKES Pedal moves freely without binding Lift truck stops in specified distance Deadman brake functions properly (travel circuits disabled) EMERGENCY POWER OFF BUTTON Shuts down travel and lift functions when depressed SAFETY All warning and working lights (optional) are functional All limit switches function properly Travel alarm (optional) functions Check condition of static straps (beneath tractor)

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Mark

Prime-Mover CRX30/35/40/50 Service Manual

Planned Maintenance Moderate and Severe Usage: 90-Day Inspection

Moderate and Severe Usage: 90-Day Inspection Component

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What To Do

Refer to

Drive Unit

Change the fluid in the drive unit. Refer to the “Recommended Oils by Temperature Chart” to assure the proper type of fluid for your application.

page 7-46

Mounting Hardware

Check torque of mounting hardware for major truck components (lift motor and pump, aux. motor and pump, brake assembly, drive motor and drive unit, hydraulic manifolds, and mast-to-drive unit mounting bolts). Tighten or replace any loose, broken, or missing hardware. Check the torque of the overhead guard mounting bolts.

page A-4

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Planned Maintenance

Prime-Mover CRX30/35/40/50 Service Manual

Moderate Usage: Every 6 Months or 500 hours; Severe Usage: Every 3 Months or 250 Hours

Moderate Usage: Every 6 Months or 500 hours; Severe Usage: Every 3 Months or 250 Hours (whichever comes first) Component

What To Do

Refer to

Check the weight stamped on the battery in the truck against the minimum and maximum allowable weights on the specification tag for the truck. Report any trucks that are running with batteries under the minimum, or over the maximum allowable weight. Make sure the battery has no more than 0.5 in. (13 mm) free play in any direction.

page 5-14

Inspect all battery connectors and leads for damage and cuts in protective coatings. Check for voltage and shorts to frame.

page 7-91

Battery Gates

Make sure the battery gates are in place and not damaged.

page 7-93

Brakes/Brake Pads

In the tractor-first direction, check brakes for proper operation. Visually inspect the friction disc and plates with the brakes released. Minimum thickness of the friction disc is 0.207 in. (5.3 mm). The air gap between the armature disc and the brake coil must be 0.012 to 0.018 in. (0.305 to 0.457 mm). Failure to keep the brake shimmed will cause premature wear on the friction disc and plates and excessive motor heat.

page 7-76

Electrical Cables

Inspect all cables for nicks or cuts. Replace any cable that is damaged or shows signs of excessive heat. Inspect over-the-mast cables for proper tension. Make sure over-the-mast pulleys spin freely and show no signs or wear.

Control Handle Functions

Operate the lift/lower function. Verify the response is smooth and controllable. Operate the travel function. Verify that the full range of acceleration is smooth and responsive. Make sure that plugging/Regen is functioning properly. Look for any play in the center position of the lift or travel. Operate the Tilt, Sideshift and Optional attachment switches. Verify they operate the function smoothly and do not stick. Enter the maintenance mode and test the travel potentiometer, Test A05. Make sure the potentiometer voltage is stable with no voltage fluctuations in the neutral position. If the voltage fluctuates by more than 0.2V in 10 seconds, replace the potentiometer to avoid unscheduled down time. Run the potentiometer all the way up and down the scale to verify smooth voltage changes.

Battery

Battery Connector

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page 7-91

page 5-14

page 7-37

Prime-Mover CRX30/35/40/50 Service Manual

Planned Maintenance Moderate Usage: Every 6 Months or 500 hours;

Component

What To Do

Refer to

Deadman Pedal

The Deadman Pedal must operate smoothly with no binding. Check proper activation and deactivation of the deadman switch under the pedal.

page 7-43

Horn

Make sure the horn sounds loudly when activated.

page 7-101

Hydraulic Hoses

Inspect all hydraulic hoses for leaks, nicks, cuts, chafing and bulges. Replace bad hoses as soon as possible. Inspect all fittings for leaks. Repair any leaks immediately. Inspect over-the-mast hoses for proper tension. Make sure over-the-mast pulleys spin freely and show no signs of wear.

Hydraulic Reservoir

Check for proper fluid level and the proper fluid for the working environment.

Optional Lights

Make sure all lights function and mountings are secure.

Overhead Guard

Look for any physical damage to the guard. If the overhead guard is structurally damaged, replace the guard.

page 7-20

Switches

Check mast and optional switches for proper operation (if used).

page 7-122

Chassis and Mast

Inspect the mast pivot and telescopic bearings and rollers for damage or wear. Inspect the outside of the main frame for wear, especially if the truck is used in drive-in racks.

page 7-148

Contactors

Inspect contact tips for burnt or pitted surfaces. Failure to replace the tips may cause surfaces to weld together, causing unscheduled down time. Check the plunger for smooth operation with no binding. If binding occurs, the truck may exhibit intermittent fault codes.

page 7-84

Drain Holes

Make sure the drain holes are not blocked by any debris.

page 7-126

(beneath deadman pedal and in battery compartment)

Drive Unit

Check for proper fluid level in the drive unit. If the fluid level is low, investigate for leaks and determine causes.

Forks

Inspect forks for modifications, bends, cracks or wear. Check for welding arcs and signs of excessive heat.

page 7-46

NOTE: If any of the imperfections above are found, replace the fork immediately. Hardware (bolts, nuts, and screws)

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Check the tightness of wire and cable connections. This can be done by physically trying to move the connection with your hand.

page A-4 (Torque Chart)

4-7

Planned Maintenance

Prime-Mover CRX30/35/40/50 Service Manual

Moderate Usage: Every 6 Months or 500 hours; Severe Usage: Every 3 Months or 250 Hours Component

What To Do

Refer to

Lift Chains

Check for proper adjustment of the chains. Lubricate as required. Inspect the chains for excessive stretch or wear.

page 7-153

Motors

Visually inspect brushes for excessive heat (discoloration of the pigtails). If excessive heat is evident, inspect the armature circuit for loose connections. Find the shortest brush in the holder. Remove the brush and check the overall dimension. Inspect the brush for even wear over the full surface of the brush. If the brush is not contacting the complete surface, replace the brushes. Inspect the brush rigging for damage or loose brush holders. Ensure that the connections on the brush leads are tight. Check brush spring tension. Blow out the inside of the motor with compressed air. Check the cable lugs to make sure they are tight to the terminal studs. Both the inside and outside nut should be torqued to the values listed on page A-4. Replace any cable that shows signs of excessive heat.

page 7-102

Wheel and Tires

Inspect all wheels and tires for chunking, bond failure, and excessive or uneven wear. Replace any tire exhibiting any of these symptoms. Check caster wheel bearing for binding or excessive play. Inspect drive and caster axle for excessive play.

page 7-27

Steerable Wheel Assembly

Inspect the caster wheel axle and bearings for excessive wear. Inspect the steer chain for proper adjustment. Flex of the chain should be approximately 1/8 in. (3.175 mm).

page 7-31

Lift, Side Shift and Tilt Cylinders

Inspect the condition of the rams for leaking seals, scored pistons and secure mounting. Check the lift cylinders for any load drift. Use the following specifications and observe the drift over a 10-minute period:

page 7-142

• CRX30: 3.0 in. (76 mm) drift with 3000 lb. load • CRX35: 3.5 in. (89 mm) drift with 3500 lb. load • CRX40: 4 in. (102 mm) drift with 4000 lb. load • CRX50: 5 in. (127 mm) drift with 5000 lb. load

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page 7-102

page 7-105 page 7-102

Prime-Mover CRX30/35/40/50 Service Manual

Planned Maintenance Moderate Usage: Every 6 Months or 500 hours;

Component

What To Do

Refer to

Shorts and Voltage Leaks to Frame

Using a non-flammable cleaner, clean any dirt and oil buildup inside the tractor compartments. This will reduce the chance of intermittent error codes caused by shorts between maintenance intervals. It will also extend the life of cables and harnesses.

page 5-14

NOTE: Do not use any cleaners or solvents inside motors. Unplug the battery and check for voltage leaks to frame. If voltage exists, the battery must be cleaned. If cleaning does not remove the voltage to frame, the battery must be serviced by an authorized battery technician. Run the ground tests as outlined on page 5-14.

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Sideshift Carriage

Ensure the cap screws that secure the lower mounting hooks to the carriage bar are tight.

Warning Decals

Replace any warning decals that have become unreadable or are damaged.

4-9

Planned Maintenance

Prime-Mover CRX30/35/40/50 Service Manual

Moderate and Severe Usage: Annually or 1500 hours (whichever comes first)

Moderate and Severe Usage: Annually or 1500 hours (whichever comes first) Component

What To Do

Refer to

Hydraulic Reservoir

Change the fluid in the main hydraulic reservoir and install a new fluid filter. Refer to Lubrication Equivalency Chart on page A-2 to assure proper type of fluid for your application.

page 7-126

Pump Couplings

Remove, clean, inspect and repack.

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Prime-Mover CRX30/35/40/50 Service Manual

Planned Maintenance Battery Maintenance

Battery Maintenance Charging - General This section gives you only general battery information. For exact battery charging and maintenance information, read the Battery Instruction Manual and the Battery Charger Instruction Manual.

Inspection Before installing the battery in the truck, inspect the battery for: • Cleanliness • Missing vent caps • Broken or damaged posts • A cracked or damaged case • Corrosion of metal parts • Wetness on the top or sides of the battery case

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4-11

Planned Maintenance

Prime-Mover CRX30/35/40/50 Service Manual

Inspection

This page intentionally left blank.

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Prime-Mover CRX30/35/40/50 Service Manual

Troubleshooting

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5-1

Troubleshooting How to Use This Chapter

How to Use This Chapter This chapter is designed to help you troubleshoot possible problems that may affect truck performance. • When a particular component has been identified as or suspected to be bad, it is recommended that you troubleshoot the wiring from that component back to the Interface Card. • Conduct any related tests in the truck’s Maintenance Mode to help you make any determinations. • This truck features electronic devices that can help diagnose a situation. There is a bank of LEDs located on the Translator Card assembly that can be used to troubleshoot a condition. • Always take note of any fault codes that appear on the Operator Display. Gather as much information as you can at the time of the Fault Code.

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Prime-Mover CRX30/35/40/50 Service Manual

Troubleshooting Start-up

Start-up Waiting For Precharge Message What is Precharge? Precharge is a method for powering up the traction power amplifiers in a controlled manner. The circuits for doing this are located within the amplifiers themselves. The amplifiers have large banks of capacitors to prevent voltage spikes. When the truck key switch is turned OFF, these capacitors are discharged slowly to near 0V. If the contactor is immediately closed with these capacitors discharged, very high currents would result. This could damage the amplifiers and/or the traction fuse and TPC Contactor. The precharge circuits in the amplifiers will normally begin to charge up these capacitor banks as soon as the truck key switch is closed, and they are normally charged in just a few seconds. You may encounter a “Waiting For Precharge” message during the start-up of this truck. If this occurs, it means that the voltage on the output side of the TPC contactor has not reached at least 31V. This is necessary before the power amplifiers can be started and the truck’s SelfTest can be completed. The “Waiting For Precharge” message occurs for the following reasons: 1. The battery voltage is too low. 2. There is an internal short to ground in one or both of the power amplifiers. 3. There is an internal short to ground in the truck wiring. 4. The precharge circuits in one or both of the amplifiers are bad. 5. The sense line to the TPC is bad. 6. The Interface Card is bad. 7. The key switch has been turned OFF and ON too frequently, resulting in overheating of the precharge circuits and causing precharge to be very slow.

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Troubleshooting 1. Check to see if battery voltage is at least 32V when under no load. 2. Check for precharge with digital voltmeter by measuring the voltage at the output side of the TPC contactor with reference to TP4 (B-). When the key switch is turned ON, the voltage must climb higher than 31V and eventually reach within 1V of battery positive (B+). NOTE: When the key switch is turned OFF, this voltage will slowly drop to 0V. Use Analog Test A08 in Maintenance Mode to view this voltage. 3. If the voltage at the output of the TPC contactor does not reach 31V: a. Verify that power is reaching the amplifiers by checking for B+ at the following points: • JPF5-1 or JPF-2 on the Contactor Fuse Panel • JPX1-1 on the Translator Card • JPX2-1 on the Translator Card • JPX3-10 on the Translator Card • JPTL1-1 on the left power amplifier • JPTL2-1 on the right power amplifier 4. Use the following process of elimination to isolate the problem: a. Turn the key switch OFF and carefully disconnect the B+ power cable to one of the two amplifiers. Recheck to see if precharge will occur. If it will, the amplifier that has been disconnected is bad and must be replaced. NOTE: Disconnect one of the power cables to the amplifiers at the TPC contactor and turn on the truck. Both power cables to the amplifiers should precharge independently. If one does not, then that amplifier is bad. b. Reconnect the first amplifier and disconnect the B+ power cable to the remaining amplifier. If precharge will now occur, then the second amplifier is bad and must be replaced.

5-3

Troubleshooting Waiting For Precharge Message c. Disconnect the B+ power cable from both amplifiers and carefully connect a 5K ohm 1/2 watt resistor across the TPC contactor. If the output side of the TPC contactor will now precharge, then both amplifiers must be replaced. If it will not precharge, then there is a short to ground in the truck’s wiring. 5. If the voltage at the output of the TPC does reach 31V: a. Perform a continuity check from the output side of the TPC contactor to JPC8-8 on the Interface Card and/or measure the voltage at JPC8-8 with respect to B-. If there is no continuity and/or voltage present, repair the truck’s wiring harness. b. Read the voltage at the output of the TPC contactor using the Analog input test A08 in Maintenance Mode. If the voltage read does not correspond with the voltage measured at JPC8-8, replace the Interface Card.

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Prime-Mover CRX30/35/40/50 Service Manual

Troubleshooting Power Amplifier Fault Codes

Power Amplifier Fault Codes The truck will return a fault code to the operator display when an error has been detected in the lift truck. More specifically, the left and right traction power amplifiers may return error codes, 2M and HK, which could indicate a number of possible problems. Use the following procedures to help diagnose and troubleshoot these particular power amplifier codes.

What these error codes mean: Error code “2M” means that a problem has been detected with the Left Traction amplifier, and a code “HK” means that a problem has been detected with the Right Traction amplifier. The Left Traction amplifier is always checked first, so any error condition which affects both amplifiers will result in the display of the “2M” error code.

How these codes are detected: NOTE: TPC_x is a reference to either the right or left power amplifier. Depending on which amplifier you are working on, substitute “L” or “R” for the “x”. Detection of these error codes is centered around the TPC_x signal lines from each of the amplifiers to the Translator Card. These lines are used by the amplifiers to request that the TPC contactor be de-energized. The signal line to the left traction amplifier is named TPC_L and connects to the Translator Card at JPX2-13. The signal line to the right traction amplifier is named TPC_R and connects to the Translator Card at JPX1-13.

2. One or both amplifiers turn off its TPC_x output when the amplifier is supposed to be on. 3. One or both of the TPC_x lines stay on after the amplifiers are told to turn off.

What can cause these error codes: 1. The amplifier has an internal failure. 2. The TPC_x signal line from the amplifier to the Translator Card is open or shorted to battery minus. 3. The KEY output signal line from the Translator to one or both of the amplifiers is open or shorted to battery minus. NOTE: This signal is not connected to the truck key switch. 4. The EPO output signal line from the Translator Card to one or both of the amplifiers is open or shorted to battery minus. NOTE: This signal is not connected to the truck EPO switch. 5. The Translator Card has failed and cannot read these inputs properly. 6. The power cables from the TPC contactor to one or both of the amplifiers is open. 7. The sense line to the TPC contactor output is shorted to battery positive resulting in the truck trying to start the amplifiers when the amplifier capacitor banks are not properly charged. 8. Battery power is not being provided to an amplifier at JPTL1-1 or JPTR1-1, preventing the amplifier from turning on.

A fault code will be detected when any of the following conditions occur: 1. An amplifier refuses to turn on its TPC_x output when the amplifier is told to turn on. NOTE: The amplifiers are told to turn on when both the KEY and EPO signal outputs from the Translator Card are turned on.

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5-5

Troubleshooting

Prime-Mover CRX30/35/40/50 Service Manual

Power Amplifier Start-up Procedure:

Power Amplifier Start-up Procedure: The following is a description of the sequence of events which occurs regarding the power amplifiers when the truck key switch is first turned ON. 1. The truck must complete a series of internal checks before any tests of the power amplifiers are started. 2. Once the internal checks are complete, the voltage at the output side of the TPC contactor must reach at least 32V before the amplifiers can be turned on. This is referred to as “precharging” because the amplifiers have large capacitor banks which must be charged prior to closing the TPC contactor, or they may be damaged. This precharging is done by the amplifiers themselves and starts when the truck key switch is turned ON. If precharging does not happen within 5 seconds, a “Waiting For Precharge” message will be displayed. Note that since both amplifiers are connected in parallel, one amplifier can precharge both amplifier's capacitor banks. See Waiting For Precharge Message on page 5-3. 3. Once precharge occurs, the amplifiers will be run briefly with the TPC contactor open in order to verify that the TPC contactor is not welded: a. First, the amplifiers are activated by turning on the KEY and EPO outputs from the Translator card to the amplifiers. There are LED indicators on the Translator Card which illuminate when these lines are turned on. See Figure 5-2. The amplifiers must respond to this by turning on their respective TPC_x output (TPC_L for left amplifier, TPC_R for right amplifier). NOTE: The KEY output is not connected to the truck key switch in any way, and the EPO output is not connected to the truck EPO in any way. If an amplifier fails to turn on its TPC_x output within 1 second, an error code “2M” and/or “HK” will be displayed on the operator display.

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b. Once both amplifiers have turned on their TPC_x outputs, the DM (deadman) output from the Translator Card will be turned on next. This signal also has an LED indicator. c. Next, one and only one direction command signal line will be turned on for each amplifier. These direction signals each have an LED indicator and are named as follows: • FWD_L - Forward command to the left power amplifier • REV_L - Reverse command to the left power amplifier • FWD_R - Forward command to the right power amplifier • REV_R - Reverse command to the right power amplifier The left forward direction line will always be turned on, but the right amplifier direction line will changed depending on how the steerable wheel is turned: If the wheel is close to straight, the right amplifier will be set to drive reverse. If the wheel is not close to straight, the right amplifier will be set to drive forward. This will cause the drive wheels to always drive against each other during SelfTest. d. Once the direction lines have been set, a small throttle command is sent to each amplifier. The amplifiers must then pull down the TPC contactor output voltage down sufficiently to verify that the TPC contactor is open. If this does not happen, a fault code “44” will be displayed on the operator display. e. The amplifiers are shut down when the TPC contactor output voltage drops down sufficiently or when 0.6 seconds elapses, whichever comes first.

Prime-Mover CRX30/35/40/50 Service Manual

Troubleshooting Troubleshooting Procedure:

4. Once the TPC contactor welded test is complete, the truck must log on to each of the amplifiers using the communication lines TXD_L, RXD_L, TXD_R, and RXD_R. The TXD lines are transmit lines from the Translator Card, and the RXD lines are receive lines to the Translator Card. Logging on involves sending several bytes of data to each amp on the TXD lines, followed by having each of these bytes echoed back to the Translator Card on the RXD lines. A failure during this procedure will produce a “5F” and/or “5G” error code to be displayed on the operator display. The procedure for restarting the amplifiers after they have been shutdown is similar in that many of the same steps are taken (in the following sequence). When the Deadman pedal is depressed: 1. Precharge must have occurred or a “Waiting For Precharge” message will be displayed. 2. The KEY and EPO outputs are turned on. 3. The power amplifiers must turn on their TPC_x outputs, 4. The Deadman output will be turned on, 5. When the control handle is moved, the appropriate direction lines will be turned on. 6. The throttle commands will be sent to the amplifiers. NOTE: This sequence of events can be observed by watching the LED indicators on the Translator Card.

Troubleshooting Procedure: 1. Verify that the Translator Card can read the TPC_x inputs properly: a. Enter Maintenance Mode and select either Test I27 for the left amplifier or I28 for the right amplifier TPC_x input test. b. Disconnect the harness to the power amp at JPX1 for the left amplifier or JPX2 for the right amplifier. The TPC_x input test must indicate OFF. If not, replace the Translator Card.

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c. Carefully connect pin 13 of connector PX1 or PX2 on the Translator Card to battery negative using a jumper clip. The TPC_x input test must now indicate ON. If not, replace the Translator Card. Remove the jumper clip. d. Reconnect the harness to the power amp and verify that the TPC_x input test indicates OFF (Note that the KEY and EPO outputs from the Translator should be off when in the TPC_x Maintenance Mode tests). If not, there is a problem in the harness to the amplifier and/or the amplifier itself. 2. Verify the harness to the power amp: a. Check for continuity of the TPC_x line to the affected amplifier per the truck schematic. b. Disconnect the connector JPTL1 for the left amplifier or JPTR1 for the right amplifier, and verify that the TPC_x input test indicates OFF. If not, the harness has a short to battery minus. 3. Test the amplifier TPC_x output driver: a. Disconnect the connector JPX1 for the left amplifier or JPX2 for the right amplifier. This will shut down the power amplifier. b. Measure the resistance from JX1-13 and/or JX2-13 to battery minus. This resistance must be greater than 20K ohms. If not, the amplifier has failed. 4. Monitor the operation of the TPC_x line: a. Measure the voltage on the TPC_x line to the affected amplifier using a Digital Volt Meter (DVM) referenced to battery minus: • When the KEY and EPO signal lines are off, the TPC_x line must be at least 8V with respect to battery minus. If not, replace the amplifier. • When the KEY and EPO signal lines are on, the TPC_x line must be no more than 2V with respect to battery minus. If not, replace the amplifier.

5-7

Troubleshooting

Prime-Mover CRX30/35/40/50 Service Manual

Electrical Troubleshooting Guidelines

Electrical Troubleshooting Guidelines Many problems are caused by a faulty or dirty battery. Make sure the battery is clean. See Battery Exterior Cleaning on page 7-93.

! WARNING Jack and block the lift truck so that the drive tires are off the floor whenever a troubleshooting procedure requires turning key switch S1 ON.

! CAUTION Unless otherwise directed, disconnect the battery connector when you check electrical circuits or components with an ohmmeter. Electrical current can damage the ohmmeter. • Save time and trouble by looking for simple causes first. • For information on electrical connector location and function, see Table 5-1, Electrical Connector Locator Chart on page 5-9. • Use a DVM such as a Fluke meter for all measurements. Analog meters can give inaccurate readings and load down sensitive electronic circuits enough to cause failure. Make sure meter cables are connected to the proper meter jacks and that proper function and scale are selected. • Printed circuit boards have been conformal coated. You may need to clean test points in order to obtain accurate readings. • When measuring voltage, connect the positive meter lead to the connector or probe point marked (+) in the test. Connect the negative meter lead to the connector or probe point marked (-).

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• Whenever measuring resistance, turn the key switch OFF and disconnect the battery connector. Battery current can damage an ohmmeter.

Prime-Mover CRX30/35/40/50 Service Manual

Troubleshooting Electrical Connector Locator Chart

Electrical Connector Locator Chart Terminology Pin Identifier Lines (color added for clarity)

The term “connector JPx” means a mated connector consisting of two connector halves. One half contains male connectors, or pins (P); the other half contains female connectors, or jacks (J). When you disconnect a mated JP connector, you will have two connector halves. The individual connector halves are designated by “Jx” and “Px.” If you cannot locate a connector designated “Jx” or “Px,” look for “JPx,” and vice versa. Molex connectors have ridges on the sides to help locate pin number 1. Molex female sockets have a single ridge on the short side at pin number 1. Male plugs have 1, 2, and 3 raised ridges on the long side at pin numbers 1, 2, and 3. See Figure 5-1.

Jack

Pins 8C04013S.TIF

Figure 5-1:

Molex Jack and Pin Connector

Refer to Table 5-1, Electrical Connector Locator Chart to locate electrical connectors on the lift truck. NOTE: Some connector names may apply to more than one connector.

Table 5-1: Electrical Connector Locator Chart

Connector

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Function or Routing

Location

JPA1

Attachment Card connector to Interface Card

Attachment Card

JPA2

Attachment Card connector to solenoids

Attachment Card

JPA3

Attachment Card connector to control switches

Attachment Card

JPA4

In-line connector for high speed attachment clamp switch

Near high speed auxiliary spool valve

JPB+

(+) Battery connector

Battery

JPB-

(-) Battery connector

Battery

JPB2

Right Brake connector

Right brake

JPB3

Left Brake connector

Left brake

JPD1

Operator display connector

Operator Display

JPD2

Operator display connector to overlay

Operator Display

JPC1

Interface Card connector to loader module

Interface Card

JPC2

NOT USED

JPC3

NOT USED

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Troubleshooting

Prime-Mover CRX30/35/40/50 Service Manual

Electrical Connector Locator Chart Table 5-1: Electrical Connector Locator Chart

Connector

Function or Routing

Location

JPC4

Interface Card connector to traction Translator Card

Interface Card

JPC5

Interface Card connector to operator display

Interface Card

JPC6

Interface Card connector to multi-function control handle

Interface Card

JPC7

Interface Card connector to deadman switch and steer position sensor

Interface Card

JPC8

Interface Card connector to contactor fuse panel and horn

Interface Card

JPC9

Interface Card connector to hydraulic manifold

Interface Card

JPC10

Interface Card connector to brakes and motor sensors

Interface Card

JPC11

Interface Card connector to weight sensor (optional)

Interface Card

JPC12

Interface Card connector to lift limit and speed limit switches

Interface Card

JPF1

Fuse/Relay card connector to B(+), B(-)

Fuse/Relay Card

JPF2

Fuse/Relay Card connector to Interface Card

Fuse/Relay Card

JPF3

Fuse/Relay Card connector to key switch (S1) and EPO switch

Fuse/Relay Card

JPF4

Fuse/Relay Card connector to Attachment Card

Fuse/Relay Card

JPF5

Fuse/Relay Card connector to Translator Card

Fuse/Relay Card

JPH1

Sideshift connector to Interface Card

SOL2

JPH2

Over-The-Mast Cable connector, Tractor Side

Over-The-Mast Cable

JPH3

Multi-Function Control Handle connector

Control Handle

JPTL1

Left traction power amplifier connector

Left Traction Power Amplifier

JPTR1

Right traction power amplifier connector

Right Traction Power Amplifier

JPS1

Lift/Lower control switch connector

Lift/Lower Switch

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Prime-Mover CRX30/35/40/50 Service Manual

Troubleshooting Electrical Connector Locator Chart

Table 5-1: Electrical Connector Locator Chart

Connector

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Function or Routing

Location

JPS2

Steer position sensor connector to Interface Card

Steer Position Sensor

JPS3

Left traction motor speed sensor connector to Interface Card

Left Traction Motor Speed Sensor

JPS4

Right traction motor speed sensor connector to Interface Card

Right Traction Motor Speed Sensor

JPS5

High speed limit switch connector to Interface Card

High Speed Limit Switch

JPS6

Lift limit switch connector to Interface Card

Lift Limit Switch

JPS7

NOT USED

JPS8

Lift motor brush wear indicator and temp sensor connector to Interface Card

Lift Motor Brush Wear Indicator and Temperature Sensors

JPS11

Left traction motor brush wear indicator and temperature sensor connector to Interface Card

Left Traction Motor Brush Wear Indicator and Temperature Sensor

JPS12

Right traction motor brush wear indicator and temperature sensor connector to Interface Card

Right Traction Motor Brush Wear Indicator and Temperature Sensor

JPWL1

Right working light connector

Right Working Light

JPWL2

Left working light connector

Left Working Light

JPWL3

Reverse working light connector

Reverse Working Light

JPWL4

Interconnection to JPWL2

JPWL5

Interconnection to JPWL1

JP3

Strobe lights connection

Strobe Light

JP48

Over-the-mast cable connection

Over-The-Mast Cable

JPX1

Right Traction Motor connection to Translator Card

Translator Card

JPX2

Left Traction Motor connection to Translator Card

Translator Card

JPX3

Translator Card Connection to Interface Card

Translator Card

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Troubleshooting

Prime-Mover CRX30/35/40/50 Service Manual

Translator Card LEDs

Translator Card LEDs There is a bank of 10 LEDs mounted on the Translator Card. These LEDs can be used to determine if there is continuity in circuitry and communication between specific truck components, the Translator Card itself, and the Interface Card.

READY LED COMM LED

If the COMM LED is not illuminated, communication from the Interface Card to the Translator Card has been interrupted.

HBEAT LED The HBEAT LED is a status indicator for the microprocessor on the Translator Card. When the HBEAT LED is illuminated, the Translator Card microprocessor is functioning properly. If the HBEAT LED is not illuminated, the microprocessor on the Translator Card has failed. In effect, the Translator Card is “dead”.

HBEAT LED EPO LED DM LED FWDL LED REVL LED FWDR LED REVR LED KEY LED

Figure 5-2:

Translator Card LEDs

READY LED When the READY LED is illuminated, the Translator Card is exchanging/outputting data with the Interface Card. An illuminated or “on” condition indicates that this function is performing properly and the card is “ready” to function. If the READY LED is not illuminated or “off,” the communication from the Translator to the Interface Card has been interrupted.

COMM LED The COMM LED refers to the communication from the Interface Card to the Translator Card. The Translator Card is receiving a heartbeat signal from the Interface Card. When the COMM LED is illuminated, a connection has been established with the Interface Card and that communication is functioning properly.

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EPO LED The EPO LED is a generated output signal to the traction power amplifiers. The amplifiers in this lift truck are sent a signal from the Translator Card which simulates a signal that would be generated from an actual switch. Since the amplifiers are not connected directly to the EPO switch, the translator card makes them “think” that they are. If the EPO LED is illuminated, the EPO circuit is closed and the truck is functional. If the EPO LED is not illuminated, the EPO button has been depressed, opening the circuit and cutting power to the truck. If the EPO LED is not illuminated, the KEY LED should not be illuminated as well. NOTE: TPC contactor must close to illuminate the LED.

DM LED The DM LED is an indication of an output signal to the power amplifiers. Since the deadman switch is not directly connected, the Translator Card generates an output signal to the amplifiers to make them “think” that they are connected. When the DM LED is illuminated, the Translator Card is sending a signal to the amplifiers that the deadman switch has been depressed. If the DM LED is not illuminated, the Translator Card is sending a signal that the deadman switch is not depressed.

Prime-Mover CRX30/35/40/50 Service Manual

Troubleshooting Translator Card LEDs

FWDL LED The FWDL LED is an indication of an output signal to the left traction power amplifier. When forward travel is requested, the Translator Card sends an output signal to the left traction power amplifier. If the FWDL LED is illuminated, the Translator Card is sending an output signal to the left traction power amplifier indicating that forward travel has been requested. If the FWDL LED is not illuminated, the Translator Card is not sending an output signal to the left traction power amplifier.

The FWDR LED and the REVR LED should never be illuminated at the same time.

REVR LED The REVR LED is an indication of an output signal to the right traction power amplifier. When reverse travel is requested, the Translator Card sends an output signal to the right traction power amplifier. If the REVR LED is illuminated, the Translator Card is sending an output signal to the right traction power amplifier indicating that forward travel has been requested.

The FWDL LED and the REVL LED should never be illuminated at the same time.

If the REVR LED is not illuminated, the Translator Card is not sending an output signal to the right traction power amplifier.

REVL LED

The REVR LED and the FWDR LED should never be illuminated at the same time.

The REVL LED is an indication of an output signal to the left traction power amplifier. When reverse travel is requested, the Translator Card sends an output signal to the left traction power amplifier. If the REVL LED is illuminated, the Translator Card is sending an output signal to the left traction power amplifier indicating that reverse travel has been requested. If the REVL LED is not illuminated, the Translator Card is not sending an output signal to the left traction power amplifier. The REVL LED and the FWDL LED should never be illuminated at the same time.

FWDR LED

KEY LED The KEY LED is a generated output signal to the traction power amplifiers. The amplifiers in this lift truck are sent a signal from the Translator Card which simulates a signal that would be generated from an actual switch. Since the amplifiers are not connected directly to the key switch, the Translator Card makes them “think” that they are. If the KEY LED is illuminated, the key switch circuit (S1) circuit is closed and the truck is functioning. If the KEY LED is illuminated, the key switch is OFF. If the KEY LED is not illuminated, the EPO LED should be off as well.

The FWDR LED is an indication of an output signal to the right traction power amplifier. When forward travel is requested, the Translator Card sends an output signal to the right traction power amplifier. If the FWDR LED is illuminated, the Translator Card is sending an output signal to the left traction power amplifier indicating that forward travel has been requested. If the FWDR LED is not illuminated, the Translator Card is not sending an output signal to the right traction power amplifier.

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5-13

Troubleshooting

Prime-Mover CRX30/35/40/50 Service Manual

Shorts to Frame Test

To test for shorts to frame:

“Shorts to frame” is an industry term for unintentional current leakage paths between normally isolated electrical circuits and their metal enclosures.

1. Turn the key switch OFF and disconnect the battery connector.

Shorts to frame may be metallic connections, such as a wire conductor contacting metal through worn insulation. More often, shorts to frame are resistive “leakage” paths caused by contamination and/or moisture. These leakage paths can result in unwanted electrical noise on the metallic lift truck structure, and may result in improper operation. Shorts to frame can be caused by: • Accumulation of dirt • Battery electrolyte leakage • Motor brush dust • Motor brush leads touching the housing • Breakdown in insulation • Bare wires • Pinched wiring harness • Improper mounting of circuit cards Shorts to frame can occur at numerous locations on a lift truck, including: • Batteries • Motors • Cables, wiring, and harnesses • Heat sinks • Bus bars • Solenoids • Contactors • Terminal strips • Switches • Power panel insulation • Circuit card mounts

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

Prime-Mover CRX30/35/40/50 Service Manual

Troubleshooting Shorts to Frame Test

a. To identify the cause of the short to frame, disconnect circuit components until the low resistance condition disappears. Do not reconnect components one at a time, but leave them disconnected until the low resistance reading disappears. Prevent disconnected terminals or connectors from touching lift truck frame or other conductive surfaces. b. The most likely areas to check are:

components one at a time, but leave them disconnected until the leakage current reads less than 0.001A (1mA). Prevent disconnected terminals or connectors from touching lift truck frame or other conductive surfaces. b. The most likely areas to check are: • Motors • Heat sinks • Power cables

• Motors

• Power circuit components

• Heat sinks

• Control circuit components

• Power cables

c. Repair or replace the component(s) causing the leakage current. Repeat step 6.

• Power circuit components • Control circuit components c. Repair or replace the component causing the low resistance condition, Then repeat Step 4. d. Reconnect all other components previously disconnected, one at a time, measuring resistance between steps. If a reading is less than 1000 ohms when reconnecting a component, that component or its wiring is bad; repair or replace as appropriate. e. When, after all components are reconnected, you get readings greater than 1000 ohms, continue with the next step.

d. Reconnect all other components previously disconnected, measuring current between steps. If a reading is more than 0.001A (1mA) when reconnecting a component, that component or its wiring is bad. Repair/replace as appropriate. 7. When, after all components are reconnected, you get a reading less than 0.001A (1mA) there is no short to frame condition with the lift truck or the battery. If you previously removed the battery from the lift truck, re-install the battery.

5. Reconnect the battery connector to the lift truck and turn the key switch ON. If the battery was previously removed, make sure the battery case does not touch the lift truck frame. 6. Use a DVM on the current function to measure leakage current to the lift truck frame from B+, B-, and all fuses and motor terminals. Begin measuring at the highest ampere scale and work toward the lowest. If the current is less than 0.001 ampere (1mA), go to step 7. If the current is more than 0.001A (1mA), continue this step below. a. To identify the cause of the short to frame, disconnect circuit components until the leakage current reads less than 0.001A (1mA). Do not reconnect

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5-15

Troubleshooting

Prime-Mover CRX30/35/40/50 Service Manual

Shorts to Frame Test

Turn the key switch OFF and disconnect the battery connector.

With battery connector disconnected, measure leakage current from battery case to battery B+ and to battery B-.

Connect a 12V test light from battery case to battery B+, then from case to battery B-.

Is leakage current > 0.001 A?

Start at highest current setting of meter, then work down.

Yes

Is the test light on, even momentarily?

Is leakage current < 0.0002 A?

Yes

Install another battery.

Remove battery from truck. A serious problem exists with the battery. DO NOT continue until this condition is corrected, or meter damage may result.

Yes

Go to Chart STF-2

STF_1.WMF

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Prime-Mover CRX30/35/40/50 Service Manual

Troubleshooting Shorts to Frame Test

STF-2

With battery connector disconnected (or disconnnected/removed), measure resistance from truck frame to truck B+, to truck B(NOT battery B+/B-), & to all fuses & motors.

Is resistance LESS than 1000 ohms?

Do NOT continue until resistance measures > 1000 ohms, or meter damage could result.

Disconnect a circuit component and measure current again. (Do not reconnect previously disconnected components.)

Reconnect the battery connector. Turn key switch ON.

Yes

Disconnect a circuit component and measure resistance again. (Do not reconnect previously disconnected components.)

Measure leakage current to truck frame from B+, B-, all fuses and motors.

Is current LESS than 0.001A (1 mA)?

Yes

Is resistance MORE than 1000 ohms?

Yes

Repair or replace the component last disconnected. Reconnect all components one at a time, measuring resistance between steps.

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Is current LESS than 0.001A (1 mA)?

Repair or replace the component last disconnected. Reconnect all components one at a time, measuring current between steps.

Yes

Truck has no shorts to frame. Reinstall battery if previously removed.

5-17

Troubleshooting Troubleshooting Wiring Problems

Troubleshooting Wiring Problems Visually inspect all wiring and electrical components for: • Loose connections or connectors • Loose or broken terminals • Damaged terminals, blocks, or strips • Exposed wire at terminations • Abrasions, scrapes, nicks in the wire, damage from overheating or burns, or other general insulation damage • Broken wiring and shorted conditions (especially those that are close to metal edges or surfaces) During troubleshooting and repairs, it is sometimes necessary to unmate a connector, move a harness, cut a cable tie, or remove the wire from a bracket. Note the location of the wire and all protective or securing attachments before moving the harness. After repair, return or replace all protective and/or securing hardware to its original condition. Protective materials are necessary to provide reliable performance of the interconnect system. Examine and maintain any added materials used to dress or protect the wire. This includes spiral wrap, brackets, cable ties, fasteners, flexible conduit and so on. Do not attach tie wraps so tight that they pinch cable harnesses. Avoid tie wrapping to hydraulic hoses, which expand with pressure, causing extra pinching of tie wrapped electrical cables. Use a digital ohmmeter to check for wiring continuity. For general instructions on repairing wiring problems, see “Wiring, General” on page 7-97. The illustrations on the following pages show defects to look for when inspecting wires and crimped connections.

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Prime-Mover CRX30/35/40/50 Service Manual

Troubleshooting Troubleshooting Wiring Problems

Acceptable

Not Acceptable

• Wire intact

1. Broken strands

• Clean cut

2. Insulation not cut straight

• No insulation damage

3. Nicks in insulation or wires

• No nicks or broken strands

STRANDA.BMP STRANDNA.BMP MULTWA.BMP MULTWINA.BMP

Figure 5-3:

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Stranded and Solid Wire Defects

5-19

Troubleshooting

Prime-Mover CRX30/35/40/50 Service Manual

Troubleshooting Wiring Problems

Acceptable

Not Acceptable

• No damage to braid, insulation, or conductor

1. Insulation damaged or not cut straight

• Center lead worked out through hole in braid made by parting strands

3. Braid damaged when stripping insulation

• If braid unused, braid trimmed flush to outside insulation

2. Braid cut from exit hole 4. Conductor nicked or cut 5. Braid unused, braid extends beyond insulation 6. Conductor frayed, missing strands MWCUTIA.BMP MWCUTINA.BMP MWCUTBA.BMP MWCUTBNA.BMP MWCUTEA.BMP MWCUTENA.BMP

Figure 5-4:

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Shielded Cable Defects

Prime-Mover CRX30/35/40/50 Service Manual

Troubleshooting Troubleshooting Wiring Problems

Acceptable

Not Acceptable 1

• Insulation intact, square cut and clean

1. Insulation damaged or not cut straight

• Accurate stripping length

2. Insulation strip not uniform

• No damage, compression marks, splits or stress marks in insulation

3. Insulation compressed, split or plier marks evident

• Clean strip with no damage

4. Insulation blistered or not cleanly stripped 5. Wires twisted or kinked, stress marks evident WIABRAA.BMP WIABRANA.BMP WICOMPA.BMP WICOMPNA.BMP WIBLISA.BMP WIBLISNA.BMP

Figure 5-5:

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Shielded Cable Stripping Defects

5-21

Troubleshooting

Prime-Mover CRX30/35/40/50 Service Manual

Troubleshooting Wiring Problems

Acceptable

Wire strands extended from terminal barrel a minimum of 0.03 in. (0.76 mm) but not in contact area. 2 Not Acceptable

1. Wire strands not extending from terminal 2. Wire strands in contact area

CRMPEXT.BMP CRMPVISI.BMP

Figure 5-6:

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Crimped Connector Defects

Prime-Mover CRX30/35/40/50 Service Manual

Troubleshooting Troubleshooting Wiring Problems

Acceptable

Not Acceptable 1

• Wire bottomed in pin, visible in inspection hole

1. Wire not bottomed in pin 2

• No strip gap

2. Excessive strip gap CRMPVIST.BMP CRMPINA.BMP CRMPINNA.BMP CRMPSTA.BMP CRMPJNA.GMP

Figure 5-7:

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Pin Connector and Pin/Socket Defects

5-23

Troubleshooting

Prime-Mover CRX30/35/40/50 Service Manual

Motor Overheating

Motor Overheating Motor overheating can be due to any one of the causes listed below.

Ventilation Make sure that the ventilating holes or slots in the motor housing are not obstructed. Also make sure that the ventilation slots in the lift truck covers are free of obstructions.

Dirt See Motor Cleaning on page 7-102.

Bad Bearings To check a motor for bad bearings: 1. Remove the motor from the lift truck. 2. Remove the brushes from the motor. 3. Rotate the motor’s armature shaft by hand. It should rotate smoothly without any binding. If there is any binding, the motor’s bearings are probably bad and you should replace the motor assembly. 4. Check for end play on the armature shaft. There should be no noticeable end play.

Low Battery Voltage Check battery voltage. If it is too low, replace or recharge the battery.

Heavy Loads Do not try to lift loads that are beyond the lift truck’s capacity. Heavy loads may cause the lift truck to become unstable. (See the specification plate on the lift truck for maximum allowable loads.)

Open or Short Circuit in Motor See Electric Motor Tests on page 7-108.

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! CAUTION Do not breathe any fumes from a motor that has been severely overheated. Burning insulation can create noxious fumes. Before trying to find the cause of the problem: • Disconnect all power to the motor. • Let the motor cool. • Thoroughly ventilate the area to clear away any fumes.

Prime-Mover CRX30/35/40/50 Service Manual

Troubleshooting Hydraulic Troubleshooting Guidelines

Hydraulic Troubleshooting Guidelines ! CAUTION Use extreme care when blocking the forks or mast for any reason. Never remove a block when it is supporting the forks or mast. Lower the forks fully and tilt the mast forward. When you check voltage at solenoids, make sure hydraulic lines and components are fully installed. Whenever possible, keep the key switch OFF and the battery connector disconnected.

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Troubleshooting

Prime-Mover CRX30/35/40/50 Service Manual

Hydraulic Troubleshooting Guidelines

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Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests

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6-1

Messages, Codes, and Tests

Prime-Mover CRX30/35/40/50 Service Manual

List of Codes and Tests

List of Codes and Tests Codes Code 10 - Power ON; SelfTest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Code 1H - Traction Power Amp #1 Overheated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 Code 1L - Interface Card Detected EPO Switch Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 Code 1T - Battery Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15 Code 28 - Excessive Acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16 Code 29 - No Movement When Travel Requested . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 Code 2A - Traction Motor #1 (left) Overheated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 Code 2F - Regen Circuit #1 Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19 Code 2H - Speed Feedback Circuit #1 Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 Code 2M - Traction Power Amp #1 (left) Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21 Code 2N - Brush Wear Indicator, Motor #1 (left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22 Code 42 - LPC Contactor Closed When Commanded Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23 Code 43 - LPC Contactor Open When Commanded Closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24 Code 44 - TPC Contactor Closed When Commanded Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25 Code 45 - TPC Contactor Open When Commanded Closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26 Code 4B - STR Contactor Closed When Commanded Open. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28 Code 4C - STR Contactor Open When Commanded Closed. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29 Code 5F - No Comm. From Traction Power Amp #2 (right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30 Code 5G - No Comm. From Traction Power Amp #1 (left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31 Code 5H - No Communication From Translator Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32 Code 5K - SPI Communication Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33 Code 6D - Pressure Sensor Out-Of-Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34 Code 6F - Lift Motor Overheated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35 Code 6U - Lift Motor Brush Wear Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36 Code 80 - Throttle Controller Reading Out-Of-Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37 Code A0 - Incorrect Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38 Code AG - Operator Display Comm. Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39 Code AH - Bad Operator Display Checksum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40 Code AJ - Defective ROM Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41 Code AK - Defective RAM Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42 Code AL - Defective Battery Backed RAM Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43 Code EC - Operating System Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44 Code F4 - System Card COP Time-Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45 Code F5 - Bad Op Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46 Code F6 - Device Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47 Code F8 - COP Not Enabled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48 Code FG - +12 Volt Power Supply Out-Of-Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49 Code FH - Battery Voltage Out-Of-Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50 Code G2 - No Steer Position Reference Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-51 Code G7 - No Steer Sensor Signal Input While Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52 Code H6 - Traction Motor #2 (right) Overheated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-53 Code H9 - Regen Circuit #2 Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54 Code HB - Speed Feedback Circuit #2 Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55 Code HE - Brush Wear Indicator, Motor #2 (right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-56 Code HF - Traction Power Amp #2 (right) Overheated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-57 Code HK - Traction Power Amp #2 (right) Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-58 Code L1 - Forward Direction Switch Closed at Power-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-59 Code L2 - Reverse Direction Switch Closed at Power-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-60

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Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests List of Codes and Tests

Code L3 - Throttle Command With Deadman Input Not Selected . . . . . . . . . . . . . . . . . . . . . . . 6-61 Code L4 - Throttle Command With No Direction Selected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62 Code L5 - Throttle Command Too High at Start-up (>4.2V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-63 Code L6 - Throttle Command Too Low At Start-up (<3.0V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64 Code L7 - Both Forward And Reverse Direction Selected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-65 Code L8 - Deadman Input On At Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-66 Code L9 - Precharge Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-67 Code LA - Overvoltage During Regen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-68 Code LB - Low Battery Voltage Detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-69 Code LC - Internal Fault, Power Amplifier #1 (left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-70 Code R1 - Forward Direction Switch Closed at Power-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-71 Code R2 - Reverse Direction Switch Closed at Power-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-72 Code R3 - Throttle Command With Deadman Input Not Selected . . . . . . . . . . . . . . . . . . . . . . . 6-73 Code R4 - Throttle Command With No Direction Selected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-74 Code R5 - Throttle Command Too High at Start-up (>4.2V). . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-75 Code R6 - Throttle Command Too Low At Start-up (<3.0V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-76 Code R7 - Both Forward And Reverse Direction Selected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-77 Code R8 - Deadman Input On At Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-78 Code R9 - Precharge Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-79 Code RA - Overvoltage During Regen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-80 Code RB - Low Battery Voltage Detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-81 Code RC - Internal Fault, Power Amplifier #2 (right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-82 Code RR - Battery Disconnected During Regen/Plugging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-83 Code “Waiting for Precharge” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-84

Analog Tests Test A05 - Throttle Potentiometer Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test A06 - Battery Discharge Indicator Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test A07 - Power Supply +12VDC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test A08 - FU2 Traction Fuse Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test A09 - Weight Sensor Voltage (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-86 6-87 6-88 6-89 6-90

Input Tests Test I00 - Deadman Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-92 Test I01 - EPO Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-93 Test I02 - High Speed Limit Switch (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-94 Test I03 - Tilt Up Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-95 Test I04 - Tilt Down Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-96 Test I05 - Sideshift Right Switch (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-97 Test I06 - Sideshift Left Switch (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-98 Test I07 - Lift Limit Mast Switch (optional) Switch 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-99 Test I08 - Steer Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-100 Test I09 - Spool Valve Switch (S17) (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-101 Test I10 - Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-102 Test I11 - FU1 Steering Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-103 Test I12 - FU3 Lift Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-104 Test I13 - Traction Motor #1 (left) Brush Wear Indicator (both) . . . . . . . . . . . . . . . . . . . . . . . 6-105 Test I14 - Traction Motor #2 (right) Brush Wear Indicator (upper) . . . . . . . . . . . . . . . . . . . . . 6-106 Test I15 - Traction Motor #2 (right) Brush Wear Indicator (lower) . . . . . . . . . . . . . . . . . . . . . 6-107 Test I16 - Lift Motor Brush Wear Indicator (upper) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-108

Return

6-3

Messages, Codes, and Tests

Prime-Mover CRX30/35/40/50 Service Manual

List of Codes and Tests Test I17 - Lift Motor Brush Wear Indicator (lower) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test I18 - Traction Motor #1 (left) Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test I19 - Traction Motor #2 (right) Speed Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test I20 - Traction Motor #1 (left) Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test I21 - Traction Motor #2 (right) Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test I22 - Lift Motor Thermostat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test I23 - Lift Switch (S13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test I24 - Lower Switch (S14) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test I25 - Attachment Spool Valve Switch (S17) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test I26 - Tilt Limit Switch (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test I27 - TPC_L Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test I28 - TPC_R Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test I29 - Left Power Amplifier Switch Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test I30 - Right Power Amplifier Switch Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-109 6-110 6-111 6-112 6-113 6-114 6-115 6-116 6-117 6-118 6-119 6-120 6-121 6-122

Output Tests Test O01 - Toggle the Load Hold (SOL1) Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test O02 - Toggle the Sideshift (SOL2) Solenoid (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . Test O04 - Toggle the Tilt (SOL4) Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test O05 - Toggle the Aux PSI Select (SOL5) Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test O06 - Toggle the Auxiliary Direction A Solenoid (SOL6) . . . . . . . . . . . . . . . . . . . . . . . . . Test O07 - Toggle the Equalization (SOL7) Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test O08 - Toggle the Auxiliary Direction B (SOL8) Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . Test O09 - Toggle the High Flow Auxiliary (SOL9) Solenoid (Optional). . . . . . . . . . . . . . . . . . Test O10 - Toggle the High Flow Attachment 1 (SOL10) Solenoid (Optional) . . . . . . . . . . . . . Test O11 - Toggle the High Flow Attachment 2 (SOL11) Solenoid (Optional) . . . . . . . . . . . . . Test O12 - Toggle the TPC Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test O13 - Toggle the LPC Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test O14 - Toggle the STR Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test O15 - Toggle the AUX Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test O16 - Ramp Command to Traction Power Amp #1 (left). . . . . . . . . . . . . . . . . . . . . . . . . Test O17 - Ramp the #2 (right) Traction Power Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . Test O18 - Toggle Traction Motor Brake #1 (left). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test O19 - Toggle Traction Motor Brake #2 (right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test O20 - Ramp the Frequency to the Operator Display Alarm . . . . . . . . . . . . . . . . . . . . . . Test O21 - Toggle the Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test O22 - Toggle the Travel Alarm (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-4

Return

6-124 6-125 6-126 6-127 6-128 6-129 6-130 6-131 6-132 6-133 6-134 6-135 6-136 6-137 6-138 6-140 6-142 6-143 6-144 6-145 6-146

Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Message and Code Summary Tables

6: Messages, Codes, and Tests

Message and Code Summary Tables The following tables summarize informational, performance limiting, and fault codes. NOTE: The following “Effect” designations are used throughout these tables: “Effect” Designations 0 0 mph speed limit (coasts) H Load Handler Shutdown 1 1 mph speed limit (coasts) I Informational Acquire speed, configurable Lift system shutdown A from 1.0 mph to max. L speed Hard Plug until <1 mph then Main lift system shutdown B M dump brake Traction system derating 2nd stage lift pump D N (Configure) inhibited Decelerate to config. speed Speed limit E NI (0 or 1.5 mph) Decelerate to 0 speed Minimum Power (Traction F P System) G Guidance Disabled Q Maximum weight assumed

R Top Speed Minus 2 mph S Steer system shutdown Traction system shutdown T w/o applying brake W X Y Z

Lowering system shutdown Total shutdown Total shutdown w/o applying brake Height detection shutdown

2.5 2.5 mph speed limit

Informational/Performance Limiting Fault Codes Code

Condition

Effect

Power on SelfTest Traction power amp #1 overheated Emergency power off switch detected down Lift cutout point configured for Battery State-of-Charge (BSOC) has been reached

1H 1L

Return

Traction Lift Brushes Transistor Wrench Temp Motor Motor Icon Icon Icon Icon Icon Icon On On On On On On On/ On On Blink

Blink

6-5

Messages, Codes, and Tests

Prime-Mover CRX30/35/40/50 Service Manual

Message and Code Summary Tables .

Traction System Fault Codes (Apply to Left Traction Motor and Power Amp #1) Code

Condition

Effect

Excessive acceleration No movement detected when travel is requested Traction Motor #1 overheated Regen Circuit Failure Failure detected in speed feedback circuit #1 Brush Wear Indicator, Motor #1 Traction Power Amplifier #1 Fault

29 2A 2F 2H 2N 2M

Traction Lift Brushes Transistor Wrench Temp Motor Motor Icon Icon Icon Icon Icon Icon Blink

Blink

2.5

On/ Blink On

Blink Blink

I/2.5

Blink On

Blink

Contactor Fault Codes Code

6-6

Return

Condition P (or LPC) contactor detected closed when commanded open P (or LPC) contactor detected open when commanded closed PC (or TPC) contactor detected closed when commanded open PC (or TPC) contactor detected closed when commanded open Steer contactor detected closed when commanded open Steer contactor detected open when commanded closed

Effect

Traction Lift Brushes Transistor Wrench Temp Motor Motor Icon Icon Icon Icon Icon Icon

Blink

Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Message and Code Summary Tables

Communications Fault Codes Code

5G 5H 5K

Condition

Effect

No communications from traction power amp #2 (right) No communications from traction power amp #1 (left) No communications from translator card SPI communication timeout

Traction Lift Brushes Transistor Wrench Temp Motor Motor Icon Icon Icon Icon Icon Icon

Blink

Lift System Fault Codes Code 6D 6F 6U

Condition

Effect

Pressure sensor out-of-range Lift motor overheated

Traction Lift Brushes Transistor Wrench Temp Motor Motor Icon Icon Icon Icon Icon Icon

Brush wear indicator, lift motor

Blink

I/L

On/ Blink On

Blink

Operator’s Controls Fault Codes

Return

Code

Condition

Effect

Traction throttle reading out-of-range

Traction Lift Brushes Transistor Wrench Temp Motor Motor Icon Icon Icon Icon Icon Icon On

Blink

6-7

Messages, Codes, and Tests

Prime-Mover CRX30/35/40/50 Service Manual

Message and Code Summary Tables .

System Fault Codes Code A0 AG AH AJ AK AL

Condition

Effect

Incorrect software for proper vehicle operation Communications to operator display failed Bad operator display checksum Bad ROM checksum Bad RAM checksum Bad NV RAM checksum

Traction Lift Brushes Transistor Wrench Temp Motor Motor Icon Icon Icon Icon Icon Icon

Blink

2.5

Blink

2.5

Blink

Y Y Y

On On On

Blink Blink Blink

MTX Fault Codes Code EC

Condition

Effect

Operating system error

Traction Lift Brushes Transistor Wrench Temp Motor Motor Icon Icon Icon Icon Icon Icon On Blink

Function Controller Fault Codes Code

Condition

Effect

F4 F5 F6 F8

System card COP timeout Bad Op code Device reset System card COP timeout +12V Power supply out-of-range Battery voltage out-of-range

Y Y Y Y

FG FH

Traction Lift Brushes Transistor Wrench Temp Motor Motor Icon Icon Icon Icon Icon Icon On Blink On Blink On Blink On Blink

Blink Blink

Steering Fault Codes Code G2 G7

6-8

Return

Condition No steer position reference input Steer encoder-drive wheel speed mismatch

Effect

Traction Lift Brushes Transistor Wrench Temp Motor Motor Icon Icon Icon Icon Icon Icon

2.5

Blink

2.5

Blink

Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Message and Code Summary Tables

Traction System Fault Codes (Apply to Motor #2 (right) and Power Amp #2) Code H6 H9 HB HE HF HK

Condition

Effect

Traction motor #2 2.5 overheated Regen circuit #2 failure T Motor #2 velocity feedback P error Brush wear indicator, I/2.5 motor #2 Power amp #2 overheated I Traction power amplifier #2 fault

Traction Lift Brushes Transistor Wrench Temp Motor Motor Icon Icon Icon Icon Icon Icon On/ On Blink On On Blink Blink On

Blink

On/ Blink Blink

Left Power Amp Fault Codes Code L1 L2 L3 L4 L5 L6 L7 L8 L9 LA LB LC

Return

Condition Forward direction switch closed at power-up Reverse direction closed at power-up Throttle command with deadman input not selected Throttle command with no direction selected Throttle command too high at start-up (>4.2V) Throttle command too low at start-up (<3.0V) Both forward and reverse direction selected Deadman input on at start-up Precharge failure Overvoltage during regen Low battery voltage detected General fault, power amplifier #1

Effect

Traction Lift Brushes Transistor Wrench Temp Motor Motor Icon Icon Icon Icon Icon Icon

T T

On On

6-9

Messages, Codes, and Tests

Prime-Mover CRX30/35/40/50 Service Manual

Message and Code Summary Tables .

Right Side Power Amp Fault Codes Code R1 R2 R3 R4 R5 R6 R7 R8 R9 RA RB RC RR

6-10

Return

Effect

Traction Lift Brushes Transistor Wrench Temp Motor Motor Icon Icon Icon Icon Icon Icon

T T

On On

Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Messages and Codes

Messages and Codes

Return

6-11

Messages, Codes, and Tests

Prime-Mover CRX30/35/40/50 Service Manual

Messages and Codes

Code 10

- Power ON; SelfTest

Code Title

Power ON; SelfTest

Reason

During power-up, the truck will run through SelfTest to check internal circuits. After SelfTest is complete, all systems should be functional.

System Response Alarm Sounds

Operator Display

SelfTest

Travel PC Contactor

Energized

Lift PC Contactor

Energized

Performance Limits

6-12

Return

Travel System

Operational

Lift/Lower System

Operational

Attachments

Operational

How To Clear

This is a status indication only; there is no need to clear.

Tests to Run

None

Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Messages and Codes

Code 1H

- Traction Power Amp #1 Overheated

Code Title

Traction Power Amplifier #1 Overheated

Reason

The traction power amplifier #1 has overheated.

System Response Alarm Sounds

Yes

Operator Display

Code 1H. Overheated, Allow Time to Cool.

Travel PC Contactor

Energized

Lift PC Contactor

Energized

Performance Limits

Return

Travel System

2.5 mph speed limit

Lift/Lower System

Operational

Attachments

Operational

How To Clear

Allow time for power amplifier to cool. Self-resetting.

Tests to Run

O14 - Ramp Command to Traction Power Amp #1

6-13

Messages, Codes, and Tests

Prime-Mover CRX30/35/40/50 Service Manual

Messages and Codes

Code 1L

- Interface Card Detected EPO Switch Down

Code Title

The Interface Card Detected The Emergency Power Off Switch As Down

Reason

The emergency power off switch has been depressed.

System Response Alarm Sounds

Yes

Operator Display

Code 1L. Lift Emergency Stop Button.

Travel PC Contactor

De-energized

Lift PC Contactor

De-energized

Performance Limits

6-14

Return

Travel System

Shutdown

Lift/Lower System

Shutdown

Attachments

Shutdown

How To Clear

Turn key switch OFF, lift emergency off button, then turn key switch ON to resume operation.

Tests to Run

I01 - Emergency Power Off Switch

Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Messages and Codes

Code 1T

- Battery Low

Code Title

Battery Low

Reason

Lift cutout point configured for BSOC has been reached.

System Response Alarm Sounds

Yes

Operator Display

Code 1T. Battery Low, No Lift.

Travel PC Contactor

Energized

Lift PC Contactor

De-energized

Performance Limits

Return

Travel System

Operational

Lift/Lower System

No lift

Attachments

Operational

How To Clear

Change battery. Self resetting.

Tests to Run

A06 - Battery Discharge Indicator Voltage

6-15

Messages, Codes, and Tests

Prime-Mover CRX30/35/40/50 Service Manual

Messages and Codes

Code 28

- Excessive Acceleration

Code Title

Excessive Acceleration

Reason

Excessive acceleration detected.

System Response Alarm Sounds

Yes

Operator Display

Code 28. Speed limited.

Travel PC Contactor

Energized

Lift PC Contactor

Energized

Performance Limits

6-16

Return

Travel System

Speed limited

Lift/Lower System

Operational

Attachments

Operational

How To Clear

Cycle the deadman switch.

Tests to Run

I18 - Traction Motor #1 Speed Sensor

Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Messages and Codes

Code 29

- No Movement When Travel Requested

Code Title

No Movement Detected When Travel Is Requested This code is detected if the following four conditions occur at the same time for more than two seconds: • Speed request from throttle is greater than 25%.

Reason

• Velocity from the left motor speed sensor is zero. • The ramp command to the left power amplifier is greater than 50%. • No current limit detected from power amplifier #1.

System Response Alarm Sounds

Yes

Operator Display

Code 29. Speed limited.

Travel PC Contactor

Energized

Lift PC Contactor

Energized

Performance Limits

Return

Travel System

Speed limited

Lift/Lower System

Operational

Attachments

Operational

How To Clear

Cycle the deadman switch.

Tests to Run

I18 - Traction Motor #1 (left) Speed Sensor O16 - Ramp Command to Traction Power Amp #1 (left)

6-17

Messages, Codes, and Tests

Prime-Mover CRX30/35/40/50 Service Manual

Messages and Codes

Code 2A

- Traction Motor #1 (left) Overheated

Code Title

Traction Motor #1 (left) Overheated

Reason

The Interface Card has detected the left traction motor has overheated.

System Response Alarm Sounds

Yes

Operator Display

Code 2A. Overheated, Allow Time to Cool.

Travel PC Contactor

Energized

Lift PC Contactor

Energized

Performance Limits

6-18

Return

Travel System

2.5 mph speed limit

Lift/Lower System

Operational

Attachments

Operational

How To Clear

Allow time for the motor to cool. Self resetting.

Tests to Run

I20 - Traction Motor #1 (left) Thermostat I21 - Traction Motor #2 (right) Thermostat

Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Messages and Codes

Code 2F

- Regen Circuit #1 Failure

Code Title

Failure Detected in Regen Circuit #1

Reason

A fault has been detected in the regen circuit by the left traction power amplifier.

System Response Alarm Sounds

Yes

Operator Display

Code 2F. Not Slowing.

Travel PC Contactor

De-energized

Lift PC Contactor

Energized

Performance Limits

Return

Travel System

Shutdown

Lift/Lower System

Operational

Attachments

Operational

How To Clear

Cycle the deadman switch.

Tests to Run

O16 - Ramp Command to Traction Power Amp #1 (left)

6-19

Messages, Codes, and Tests

Prime-Mover CRX30/35/40/50 Service Manual

Messages and Codes

Code 2H

- Speed Feedback Circuit #1 Failure

Code Title

Failure Detected In Speed Feedback Circuit #1

Reason

The speed feedback circuit is not communicating, inoperative, or not installed in the truck.

System Response Alarm Sounds

Yes

Operator Display

Code 2H. Speed limited.

Travel PC Contactor

Energized

Lift PC Contactor

Energized

Performance Limits

6-20

Return

Travel System

Speed limited

Lift/Lower System

Operational

Attachments

Operational

How To Clear

Cycle the deadman switch.

Tests to Run

I18 - Traction Motor #1 (left) Speed Sensor A07 - Power Supply +12VDC

Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Messages and Codes

Code 2M

- Traction Power Amp #1 (left) Fault

Code Title

Traction Power Amplifier #1 (left) Fault

Reason

A fault has been detected by the left traction power amplifier. TPC_L line at incorrect state.

System Response Alarm Sounds

Yes

Operator Display

Code 2M. Traction Shutdown.

Travel PC Contactor

De-energized

Lift PC Contactor

Energized

Performance Limits Travel System

Shutdown

Lift/Lower System

Operational

Attachments

Operational

How To Clear

Cycle the deadman switch.

Tests to Run

O16 - Ramp Command to Traction Power Amp #1 (left) O17 - Ramp Command to Traction Power Amp #2 (right) I27 - TPC_L Signal I28 - TPC_R Signal

Corrective Action: Reference “Power Amplifier Fault Codes” on page 5-5.

Return

6-21

Messages, Codes, and Tests

Prime-Mover CRX30/35/40/50 Service Manual

Messages and Codes

Code 2N

- Brush Wear Indicator, Motor #1 (left)

Code Title

Brush Wear Indicator, Motor #1 (left)

Reason

The switch on traction motor #1 (left) brush wear indicator is closed indicating service is required.

System Response Alarm Sounds

Yes

Operator Display

Code 2N. Schedule Service.

Travel PC Contactor

Energized

Lift PC Contactor

Energized

Performance Limits

6-22

Return

Travel System

2.5 mph speed limit

Lift/Lower System

Operational

Attachments

Operational

How To Clear

Replace brushes. Self resetting.

Tests to Run

I13 - Traction Motor #1 (left) Brush Wear Indicator (both)

Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Messages and Codes

Code 42

- LPC Contactor Closed When Commanded Open

Code Title

P (or LPC) Contactor Detected Closed When Commanded Open

Reason

A voltage is detected after the pump contactor when it was commanded open.

System Response Alarm Sounds

Yes

Operator Display

Code 42. Lift Shutdown.

Travel PC Contactor

Energized

Lift PC Contactor

De-energized

Performance Limits

Return

Travel System

Operational

Lift/Lower System

Shutdown

Attachments

Shutdown

How To Clear

Cycle the key switch OFF/ON.

Tests to Run

O13 - Toggle the LPC Contactor

6-23

Messages, Codes, and Tests

Prime-Mover CRX30/35/40/50 Service Manual

Messages and Codes

Code 43

- LPC Contactor Open When Commanded Closed

Code Title

P (or LPC) Contactor Detected Open When Commanded Closed

Reason

The correct voltage was not detected after the pump contactor when it was commanded closed.

System Response Alarm Sounds

Yes

Operator Display

Code 43. Lift Shutdown.

Travel PC Contactor

Energized

Lift PC Contactor

De-energized

Performance Limits

6-24

Return

Travel System

Operational

Lift/Lower System

Lift Shutdown

Attachments

Shutdown

How To Clear

Cycle the deadman switch.

Tests to Run

O13 - Toggle the LPC Contactor

Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Messages and Codes

Code 44

- TPC Contactor Closed When Commanded Open

Code Title

PC (or TPC) Contactor Detected Closed When Commanded Open

Reason

A voltage is detected after the traction contactor when it was commanded open.

System Response Alarm Sounds

Yes

Operator Display

Code 44. Drive Shutdown.

Travel PC Contactor

De-energized

Lift PC Contactor

Energized

Performance Limits

Return

Travel System

Shutdown

Lift/Lower System

Operational

Attachments

Operational

How To Clear

Cycle the key switch OFF/ON.

Tests to Run

O12 - Toggle the TPC Contactor

6-25

Messages, Codes, and Tests

Prime-Mover CRX30/35/40/50 Service Manual

Messages and Codes

Code 45

- TPC Contactor Open When Commanded Closed

Code Title

PC (or TPC) Contactor Detected Open When Commanded Closed

Reason

The correct voltage was not detected after the traction contactor when it was commanded closed.

System Response Alarm Sounds

Yes

Operator Display

Code 45. Drive Shutdown.

Travel PC Contactor

De-energized

Lift PC Contactor

Energized

Performance Limits Travel System

Shutdown

Lift/Lower System

Operational

Attachments

Operational

How To Clear

Cycle the deadman switch.

Tests to Run

O12 - Toggle the TPC Contactor

NOTE: The following description of fault code 45 applies to trucks using software version VM 1.7. A Code 45 means that the TPC contactor and/or fuse FU2 is detected open when commanded closed. A code 45 is detected when; • the voltage at the output side of the TPC contactor drops below 20V and the battery voltage is greater than 22V when the contactor is supposed to be closed • the voltage at the output side of the TPC contactor is 3 or more volts above the battery voltage and the battery voltage is greater than 30V when the contactor is supposed to be closed • the voltage at the output side of the TPC contactor drops below 20V when the power amplifiers are first turned on or when they are being restarted from idle.

6-26

Return

NOTE: The TPC contactor is supposed to be open when this happens.

What Causes a Code 45: The following list should help you identify possible error code sources should you encounter a Code 45. • The TPC contactor may have failed open. • Fuse FU2 may have failed open. • The Translator Card has failed so that the amplifiers will not turn off when the TPC contactor is opened. • The Interface Card has failed so that it cannot properly read the voltages at the TPC contactor.

Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Messages and Codes

Corrective Action: It is important to determine what conditions existed when this code occurred. 1. Did the code occur during Regen/plugging? •

Check the battery condition.

•

Check Fuse FU2 for continuity.

•

Check operation of the TPC contactor to verify that it remained closed until the error code was displayed.

NOTE: The TPC contactor will be opened when the error is detected. 2. Did the error code occur while the truck was standing idle? •

Check the LEDs on the Translator Card to verify that the amplifiers are being told to turn off. After 30 seconds of inactivity, the TPC contactor should open. At the same time, the KEY, EPO, DM, FWD_L, REV_L, FWD_R, and REV_R LEDs on the Translator Card should all turn off. If the LEDs do not turn off, the Translator Card is bad.

•

Check the voltage at the output side of the TPC contactor. It should be approx. B+. If not, one or more of the power amplifiers may be bad. Turn the key switch OFF and disconnect both amplifiers from the TPC contactor and place the disconnected leads so that they will not touch anything. Turn the truck ON and measure voltage at the disconnected leads. They should both be within 2V of B+. Turn the key switch OFF and time how long it takes for the voltage at each lead to drop to 5V. It must take at least 5 seconds for this to occur.

3. Did the code occur when the deadman pedal was depressed after the amplifiers were idle for a significant time period?

Return

•

Check the operation of the TPC contactor to verify that it closed.

•

Check Fuse FU2 for continuity.

6-27

Messages, Codes, and Tests

Prime-Mover CRX30/35/40/50 Service Manual

Messages and Codes

Code 4B

- STR Contactor Closed When Commanded Open

Code Title

Steer Contactor Detected Closed When Commanded Open

Reason

A voltage is detected after the steer contactor when it was commanded open.

System Response Alarm Sounds

Yes

Operator Display

Code 4B. Schedule Service.

Travel PC Contactor

Energized

Lift PC Contactor

Energized

Performance Limits

6-28

Return

Travel System

Operational

Lift/Lower System

Operational

Attachments

Operational

How To Clear

Self resetting.

Tests to Run

I11 - FU1 Steering Fuse O14 - Toggle the STR Contactor

Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Messages and Codes

Code 4C

- STR Contactor Open When Commanded Closed

Code Title

Steer Contactor Detected Open When Commanded Closed

Reason

The correct voltage was not detected after the steer contactor when it was commanded closed.

System Response Alarm Sounds

Yes

Operator Display

Code 4C. Drive Shutdown.

Travel PC Contactor

De-energized

Lift PC Contactor

Energized

Performance Limits

Return

Travel System

Shutdown

Lift/Lower System

Operational

Attachments

Operational

How To Clear

Self resetting.

Tests to Run

I11 - FU1 Steering Fuse O14 - Toggle the STR Contactor

6-29

Messages, Codes, and Tests

Prime-Mover CRX30/35/40/50 Service Manual

Messages and Codes

Code 5F

- No Comm. From Traction Power Amp #2 (right)

Code Title

No Communication Received From Traction Power Amplifier #2 (right)

Reason

The communication bus signal from traction power amplifier #2 (right) is missing or incorrect.

System Response Alarm Sounds

Yes

Operator Display

Code 5F. Drive Shutdown.

Travel PC Contactor

De-energized

Lift PC Contactor

Energized

Performance Limits Travel System

Shutdown

Lift/Lower System

Operational

Attachments

Operational

How To Clear

Cycle the deadman switch.

Tests to Run

None

Corrective Action: 1. Turn the key switch OFF and disconnect the battery. 2. Check the wiring from the Translator Card to power amplifier #1 and power amplifier #2. Then, check the wiring from the Translator Card to the Interface Card. Repair as necessary. 3. Swap traction power amplifier #1 and #2. If the code changes, replace the bad power amplifier. 4. Replace the Translator Card. 5. If no wiring faults are found, replace the Interface Card.

6-30

Return

Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Messages and Codes

Code 5G

- No Comm. From Traction Power Amp #1 (left)

Code Title

No Communications Received From Traction Power Amplifier #1 (left)

Reason

The communication bus signal from traction power amplifier #1 (left) is missing or incorrect.

System Response Alarm Sounds

Yes

Operator Display

Code 5G. Drive Shutdown.

Travel PC Contactor

De-energized

Lift PC Contactor

Energized

Performance Limits Travel System

Shutdown

Lift/Lower System

Operational

Attachments

Operational

How To Clear

Cycle the deadman switch.

Tests to Run

None

Corrective Action: 1. Turn the key switch OFF and disconnect the battery. 2. Check the wiring from the Translator Card to the Interface Card. Then, check the wiring from the Translator Card to power amplifier #1 and power amplifier #2. 3. Swap traction power amplifier #1 and #2. If the code changes, replace the power amplifier. 4. Replace the Translator Card, 5. If no wiring faults are found, replace the Interface Card.

Return

6-31

Messages, Codes, and Tests

Prime-Mover CRX30/35/40/50 Service Manual

Messages and Codes

Code 5H

- No Communication From Translator Card

Code Title

No Communication From Translator Card

Reason

The communication signal from the Translator Card is missing or incorrect.

System Response Alarm Sounds

Yes

Operator Display

Code 5H. Drive Shutdown.

Travel PC Contactor

De-energized

Lift PC Contactor

Energized

Performance Limits Travel System

Shutdown

Lift/Lower System

Operational

Attachments

Operational

How To Clear

Cycle the deadman switch.

Tests to Run

None

Corrective Action: Check the wiring from the Translator Card to the Interface Card. Repair or replace as necessary.

6-32

Return

Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Messages and Codes

Code 5K

- SPI Communication Timeout

Code Title

SPI Communication Timeout

Reason

A fault has been detected by the right traction power amplifier.

System Response Alarm Sounds

Yes

Operator Display

Code 5K. Shutdown.

Travel PC Contactor

De-energized

Lift PC Contactor

De-energized

Performance Limits

Return

Travel System

Shutdown

Lift/Lower System

Shutdown

Attachments

Shutdown

How To Clear

Cycle the deadman switch.

Tests to Run

None

6-33

Messages, Codes, and Tests

Prime-Mover CRX30/35/40/50 Service Manual

Messages and Codes

Code 6D

- Pressure Sensor Out-Of-Range

Code Title

Pressure Sensor Out-Of-Range

Reason

The pressure sensor out-of-range.

System Response Alarm Sounds

Yes

Operator Display

Code 6D. Aux Shutdown.

Travel PC Contactor

Energized

Lift PC Contactor

Energized

Performance Limits

6-34

Return

Travel System

Operational

Lift/Lower System

Operational

Attachments

Shutdown

How To Clear

Cycle the key switch OFF/ON.

Tests to Run

A07 - Power Supply +12 VDC A09 - Weight Sensor Voltage

Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Messages and Codes

Code 6F

- Lift Motor Overheated

Code Title

Lift Motor Overheated

Reason

The Interface Card has detected that the lift motor has overheated.

System Response Alarm Sounds

Yes

Operator Display

Code 6F. Lift Shutdown.

Travel PC Contactor

Energized

Lift PC Contactor

De-energized

Performance Limits

Return

Travel System

Operational

Lift/Lower System

Lift system shutdown, Lower only

Attachments

Shutdown

How To Clear

Allow time to cool. Self resetting.

Tests to Run

I22 - Lift Motor Thermostat

6-35

Messages, Codes, and Tests

Prime-Mover CRX30/35/40/50 Service Manual

Messages and Codes

Code 6U

- Lift Motor Brush Wear Indicator

Code Title

Brush Wear Indicator, Lift Motor

Reason

The switch on the lift motor brush wear indicator is closed, indicating service is required.

System Response Alarm Sounds

Yes

Operator Display

Code 6U. Schedule Service.

Travel PC Contactor

Energized

Lift PC Contactor

De-energized

Performance Limits

6-36

Return

Travel System

Operational

Lift/Lower System

Shutdown

Attachments

Operational

How To Clear

Self resetting.

Tests to Run

I16 - Lift Motor Brush Wear Indicator (upper) I17 - Lift Motor Brush Wear Indicator (lower)

Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Messages and Codes

Code 80

- Throttle Controller Reading Out-Of-Range

Code Title

Traction Throttle Reading Out-Of-Range

Reason

Throttle potentiometer voltage is out-of-range. Results in total shutdown without applying the brake.

System Response Alarm Sounds

Yes

Operator Display

Code 80. Drive Shutdown.

Travel PC Contactor

De-energized

Lift PC Contactor

Energized

Performance Limits

Return

Travel System

Shutdown

Lift/Lower System

Operational

Attachments

Operational

How To Clear

The control potentiometer needs to be returned to within its limits. Self resetting.

Tests to Run

A05 - Throttle Potentiometer Voltage A07 - Power Supply +12 VDC

6-37

Messages, Codes, and Tests

Prime-Mover CRX30/35/40/50 Service Manual

Messages and Codes

Code A0

- Incorrect Software

Code Title

Incorrect Software For Proper Vehicle Operation

Reason

Software has been detected that is not correct for this vehicle.

System Response Alarm Sounds

Yes

Operator Display

Code A0. Shutdown.

Travel PC Contactor

De-energized

Lift PC Contactor

De-energized

Performance Limits Travel System

Shutdown

Lift/Lower System

Shutdown

Attachments

Shutdown

How To Clear

Cycle the key switch OFF/ON.

Tests to Run

None

Corrective Action: 1. Check the Firmware version by using the operator display. If the display shows 0.0 or the incorrect version, obtain new Firmware from Prime-Mover. 2. If the proper Firmware version appears on the operator display, replace the Interface Card.

6-38

Return

Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Messages and Codes

Code AG

- Operator Display Comm. Failure

Code Title

Communications To/From Operator’s Display Failed

Reason

Serial communications from the operator display has failed or is incorrect.

System Response Alarm Sounds

Yes

Operator Display

Code AG. Speed limited.

Travel PC Contactor

Energized

Lift PC Contactor

Energized

Performance Limits Travel System

2.5 mph speed limit

Lift/Lower System

Operational

Attachments

Operational

How To Clear

Self resetting.

Tests to Run

None

Corrective Action: 1. Check the continuity of the cable from the Interface Card (JC5) to the operator display (JD1). Repair or replace as necessary. 2. The operator display may be bad. 3. The Interface Card may be bad.

Return

6-39

Messages, Codes, and Tests

Prime-Mover CRX30/35/40/50 Service Manual

Messages and Codes

Code AH

- Bad Operator Display Checksum

Code Title

Bad Operator Display Checksum

Reason

The software checksum in the display does not match the one in the Interface Card.

System Response Alarm Sounds

Yes

Operator Display

Code AH. Speed limited.

Travel PC Contactor

Energized

Lift PC Contactor

Energized

Performance Limits Travel System

2.5 mph speed limit

Lift/Lower System

Operational

Attachments

Operational

How To Clear

Self resetting.

Tests to Run

None

Corrective Action: 1. Check the Firmware version by using the operator display. If the display shows 0.0 or an incorrect version, obtain new Firmware from Prime-Mover. 2. If the proper firmware version appears on the operator display, replace the operator display. 3. The Interface Card may be bad.

6-40

Return

Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Messages and Codes

Code AJ

- Defective ROM Memory

Code Title

Bad ROM Checksum

Reason

The ROM memory test during start-up has failed.

System Response Alarm Sounds

Yes

Operator Display

Code AJ. ROM check failure.

Travel PC Contactor

De-energized

Lift PC Contactor

De-energized

Performance Limits Travel System

Shutdown

Lift/Lower System

Shutdown

Attachments

Shutdown

How To Clear

Cycle the key switch OFF/ON.

Tests to Run

A07 - Power Supply +12 VDC

Corrective Action: If the power supply voltage is correct, replace the Interface Card.

Return

6-41

Messages, Codes, and Tests

Prime-Mover CRX30/35/40/50 Service Manual

Messages and Codes

Code AK

- Defective RAM Memory

Code Title

Bad RAM Checksum

Reason

The RAM memory test during start-up has failed.

System Response Alarm Sounds

Yes

Operator Display

Code AK. RAM check failure.

Travel PC Contactor

De-energized

Lift PC Contactor

De-energized

Performance Limits Travel System

Shutdown

Lift/Lower System

Shutdown

Attachments

Shutdown

How To Clear

Cycle the key switch OFF/ON.

Tests to Run

A07 - Power Supply +12 VDC

Corrective Action: If the power supply voltage is correct, replace the Interface Card.

6-42

Return

Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Messages and Codes

Code AL

- Defective Battery Backed RAM Memory

Code Title

Bad Non-Volatile RAM Checksum

Reason

The Non-Volatile (NV) RAM memory test during start-up has failed.

System Response Alarm Sounds

Yes

Operator Display

Code AL. NV RAM check failure.

Travel PC Contactor

De-energized

Lift PC Contactor

De-energized

Performance Limits Travel System

Shutdown

Lift/Lower System

Shutdown

Attachments

Shutdown

How To Clear

Cycle the key switch OFF/ON.

Tests to Run

None

Corrective Action: Replace the Interface Card.

Return

6-43

Messages, Codes, and Tests

Prime-Mover CRX30/35/40/50 Service Manual

Messages and Codes

Code EC

- Operating System Error

Code Title

Operating System Error

Reason

A fault has been detected in the operating system.

System Response Alarm Sounds

Yes

Operator Display

Code EC. Shutdown.

Travel PC Contactor

De-energized

Lift PC Contactor

De-energized

Performance Limits Travel System

Shutdown

Lift/Lower System

Shutdown

Attachments

Shutdown

How To Clear

Cycle the key switch OFF/ON.

Tests to Run

None

Corrective Action: Replace the Interface Card.

6-44

Return

Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Messages and Codes

Code F4

- System Card COP Time-Out

Code Title

System Card COP Time-out

Reason

The COP circuit has timed out before a reset was generated.

System Response Alarm Sounds

Yes

Operator Display

Code F4. Shutdown.

Travel PC Contactor

De-energized

Lift PC Contactor

De-energized

Performance Limits Travel System

Shutdown

Lift/Lower System

Shutdown

Attachments

Shutdown

How To Clear

Cycle the key switch OFF/ON.

Tests to Run

None

Corrective Action: Replace the Interface Card.

Return

6-45

Messages, Codes, and Tests

Prime-Mover CRX30/35/40/50 Service Manual

Messages and Codes

Code F5

- Bad Op Code

Code Title

Invalid Op Code

Reason

Bad code was detected during SelfTest. Results in total shutdown without applying the brake.

System Response Alarm Sounds

Yes

Operator Display

Code F5. Shutdown.

Travel PC Contactor

De-energized

Lift PC Contactor

De-energized

Performance Limits Travel System

Shutdown

Lift/Lower System

Shutdown

Attachments

Shutdown

How To Clear

Cycle the key switch OFF/ON.

Tests to Run

None

Corrective Action: Replace the Interface Card.

6-46

Return

Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Messages and Codes

Code F6

- Device Reset

Code Title

Device Reset

Reason

An Interface Card reset has occurred.

System Response Alarm Sounds

Yes

Operator Display

Code F6. Shutdown.

Travel PC Contactor

De-energized

Lift PC Contactor

De-energized

Performance Limits Travel System

Shutdown

Lift/Lower System

Shutdown

Attachments

Shutdown

How To Clear

Cycle the key switch OFF/ON.

Tests to Run

A07 - Power Supply +12VDC

Corrective Action: If the power supply test shows the correct voltage, replace the Interface Card.

Return

6-47

Messages, Codes, and Tests

Prime-Mover CRX30/35/40/50 Service Manual

Messages and Codes

Code F8

- COP Not Enabled

Code Title

System Card COP Time-0ut

Reason

Interface Card COP not enabled.

System Response Alarm Sounds

Yes

Operator Display

Code F8. Shutdown.

Travel PC Contactor

De-energized

Lift PC Contactor

De-energized

Performance Limits Travel System

Shutdown

Lift/Lower System

Shutdown

Attachments

Shutdown

How To Clear

Cycle the key switch OFF/ON.

Tests to Run

None

Corrective Action: Replace the Interface Card.

6-48

Return

Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Messages and Codes

Code FG

- +12 Volt Power Supply Out-Of-Range

Code Title

+12 Volt Power Supply Out-Of-Range

Reason

The +12V power supply voltage is out-of-range.

System Response Alarm Sounds

Yes

Operator Display

Code FG. Shutdown.

Travel PC Contactor

De-energized

Lift PC Contactor

De-energized

Performance Limits

Return

Travel System

Shutdown

Lift/Lower System

Shutdown

Attachments

Shutdown

How To Clear

Cycle the key switch OFF/ON.

Tests to Run

A07 - Power Supply +12VDC

6-49

Messages, Codes, and Tests

Prime-Mover CRX30/35/40/50 Service Manual

Messages and Codes

Code FH

- Battery Voltage Out-Of-Range

Code Title

Battery Voltage Out-Of-Range

Reason

Battery voltage was detected out-of-range.

System Response Alarm Sounds

Yes

Operator Display

Code FH. Check Battery.

Travel PC Contactor

De-energized

Lift PC Contactor

De-energized

Performance Limits

6-50

Return

Travel System

Shutdown

Lift/Lower System

Shutdown

Attachments

Shutdown

How To Clear

Cycle the key switch OFF/ON.

Tests to Run

A06 - Battery Discharge Indicator Voltage

Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Messages and Codes

Code G2

- No Steer Position Reference Input

Code Title

No Steer Position Reference Input

Reason

No steer position reference input was detected.

System Response Alarm Sounds

Yes

Operator Display

Code G2. Speed limited.

Travel PC Contactor

Energized

Lift PC Contactor

Energized

Performance Limits

Return

Travel System

2.5 mph speed limit

Lift/Lower System

Operational

Attachments

Operational

How To Clear

Cycle the deadman switch.

Tests to Run

I08 - Steer Position Sensor

6-51

Messages, Codes, and Tests

Prime-Mover CRX30/35/40/50 Service Manual

Messages and Codes

Code G7

- No Steer Sensor Signal Input While Driving

Code Title

No Steer Sensor Signal Input While Driving

Reason

No pulses are being sent from the steer position sensor to the Interface Card when there are large differences in the traction motor speeds.

System Response Alarm Sounds

Yes

Operator Display

Code G3. Speed limited.

Travel PC Contactor

Energized

Lift PC Contactor

Energized

Performance Limits

6-52

Return

Travel System

2.5 mph speed limit

Lift/Lower System

Operational

Attachments

Operational

How To Clear

Cycle the deadman switch.

Tests to Run

I08 - Steer Position Sensor I18 - Traction Motor #1 (left) Speed Sensor I19 - Traction Motor #2 (right) Speed Sensor

Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Messages and Codes

Code H6

- Traction Motor #2 (right) Overheated

Code Title

Traction Motor #2 (right) Overheated

Reason

The Interface Card has detected that the right traction motor has overheated.

System Response Alarm Sounds

Yes

Operator Display

Code H6. Overheated, Allow time to cool.

Travel PC Contactor

Energized

Lift PC Contactor

Energized

Performance Limits

Return

Travel System

2.5 mph speed limit

Lift/Lower System

Operational

Attachments

Operational

How To Clear

Allow time to cool. Self resetting.

Tests to Run

I21 - Traction Motor #2 (right) Thermostat I20 - Traction Motor #1 (left) Thermostat

6-53

Messages, Codes, and Tests

Prime-Mover CRX30/35/40/50 Service Manual

Messages and Codes

Code H9

- Regen Circuit #2 Failure

Code Title

Regen Circuit #2 Failure

Reason

A failure has been detected in regen circuit #2.

System Response Alarm Sounds

Yes

Operator Display

Code H9. Drive Shutdown.

Travel PC Contactor

De-energized

Lift PC Contactor

Energized

Performance Limits

6-54

Return

Travel System

Shutdown

Lift/Lower System

Operational

Attachments

Operational

How To Clear

Cycle the key switch ON/OFF.

Tests to Run

O17 - Ramp Command to Traction Power Amp #2 (Right)

Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Messages and Codes

Code HB

- Speed Feedback Circuit #2 Failure

Code Title

Failure Detected In Speed Feedback Circuit #2

Reason

The speed feedback circuit is not communicating, is inoperative, or not installed in the truck.

System Response Alarm Sounds

Yes

Operator Display

Code HB. Speed limited.

Travel PC Contactor

Energized

Lift PC Contactor

Energized

Performance Limits

Return

Travel System

Speed limited

Lift/Lower System

Operational

Attachments

Operational

How To Clear

Cycle the deadman switch.

Tests to Run

I19 - Traction Motor #2 (right) Speed Sensor A07 - Power Supply +12 VDC

6-55

Messages, Codes, and Tests

Prime-Mover CRX30/35/40/50 Service Manual

Messages and Codes

Code HE

- Brush Wear Indicator, Motor #2 (right)

Code Title

Brush Wear Indicator, Traction Motor #2 (right)

Reason

The switch on traction motor #2 (right) brush wear indicator is closed indicating service is required.

System Response Alarm Sounds

Yes

Operator Display

Code HE. Schedule Service.

Travel PC Contactor

Energized

Lift PC Contactor

Energized

Performance Limits

6-56

Return

Travel System

2.5 mph speed limit

Lift/Lower System

Operational

Attachments

Operational

How To Clear

Replace brushes. Self resetting.

Tests to Run

I14 - Traction Motor #2 Brush Wear Indicator (upper) I15 - Traction Motor #2 Brush Wear Indicator (lower)

Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Messages and Codes

Code HF

- Traction Power Amp #2 (right) Overheated

Code Title

Traction Power Amplifier #2 (right) Overheated

Reason

The temperature reading from power amplifier #2 indicates overheating.

System Response Alarm Sounds

Yes

Operator Display

Code HF. Speed limited.

Travel PC Contactor

Energized

Lift PC Contactor

Energized

Performance Limits

Return

Travel System

2.5 mph speed limit

Lift/Lower System

Operational

Attachments

Operational

How To Clear

Allow time for the power amplifier to cool. Self resetting.

Tests to Run

None

6-57

Messages, Codes, and Tests

Prime-Mover CRX30/35/40/50 Service Manual

Messages and Codes

Code HK

- Traction Power Amp #2 (right) Fault

Code Title

Traction Power Amplifier #2 (right) Fault

Reason

A fault has been detected by the power amplifier.

System Response Alarm Sounds

Yes

Operator Display

Code HK. Traction Shutdown.

Travel PC Contactor

De-energized

Lift PC Contactor

Energized

Performance Limits Travel System

Shutdown

Lift/Lower System

Operational

Attachments

Operational

How To Clear

Cycle the deadman switch.

Tests to Run

O16 - Ramp Command to Traction Power Amp #1 (left) O17 - Ramp Command to Traction Power Amp #2 (right) I28 - TPC_R Signal I27 - TPC_L Signal

Corrective Action: Reference “Power Amplifier Fault Codes” on page 5-5.

6-58

Return

Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Messages and Codes

Code L1

- Forward Direction Switch Closed at Power-up

Code Title

Forward Direction Switch Closed at Power-up

Reason

The switch for forward direction was detected closed during power-up.

System Response Alarm Sounds

Yes

Operator Display

Code L1. Drive Shutdown.

Travel PC Contactor

De-energized

Lift PC Contactor

Energized

Performance Limits

Return

Travel System

Shutdown

Lift/Lower System

Operational

Attachments

Operational

How To Clear

Cycle the deadman switch.

Tests to Run

I29 - Left Power Amp Switch Inputs

6-59

Messages, Codes, and Tests

Prime-Mover CRX30/35/40/50 Service Manual

Messages and Codes

Code L2

- Reverse Direction Switch Closed at Power-up

Code Title

Reverse Direction Switch Closed at Power-up

Reason

The switch for reverse direction was detected closed during power-up.

System Response Alarm Sounds

Yes

Operator Display

Code L2. Drive Shutdown.

Travel PC Contactor

De-energized

Lift PC Contactor

Energized

Performance Limits

6-60

Return

Travel System

Shutdown

Lift/Lower System

Operational

Attachments

Operational

How To Clear

Cycle the deadman switch.

Tests to Run

I29 - Left Power Amp Switch Inputs

Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Messages and Codes

Code L3

- Throttle Command With Deadman Input Not Selected

Code Title

Throttle Command With Deadman Input Not Selected

Reason

A throttle command was detected without a deadman input.

System Response Alarm Sounds

Yes

Operator Display

Code L3. Drive Shutdown.

Travel PC Contactor

De-energized

Lift PC Contactor

Energized

Performance Limits

Return

Travel System

Shutdown

Lift/Lower System

Operational

Attachments

Operational

How To Clear

Cycle the deadman switch.

Tests to Run

I29 - Left Power Amp Switch Inputs

6-61

Messages, Codes, and Tests

Prime-Mover CRX30/35/40/50 Service Manual

Messages and Codes

Code L4

- Throttle Command With No Direction Selected

Code Title

Throttle Command With No Direction Selected

Reason

A throttle command was detected with no direction selected.

System Response Alarm Sounds

Yes

Operator Display

Code L4. Drive Shutdown.

Travel PC Contactor

De-energized

Lift PC Contactor

Energized

Performance Limits

6-62

Return

Travel System

Shutdown

Lift/Lower System

Operational

Attachments

Operational

How To Clear

Cycle the deadman switch.

Tests to Run

I29 - Left Power Amp Switch Inputs

Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Messages and Codes

Code L5

- Throttle Command Too High at Start-up (>4.2V)

Code Title

Throttle Command Too High At Start-up (>4.2V)

Reason

The throttle command was out-of-range (>4.2V) during start-up.

System Response Alarm Sounds

Yes

Operator Display

Code L5. Drive Shutdown.

Travel PC Contactor

De-energized

Lift PC Contactor

Energized

Performance Limits

Return

Travel System

Shutdown

Lift/Lower System

Operational

Attachments

Operational

How To Clear

Cycle the deadman switch.

Tests to Run

None

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Messages, Codes, and Tests

Prime-Mover CRX30/35/40/50 Service Manual

Messages and Codes

Code L6

- Throttle Command Too Low At Start-up (<3.0V)

Code Title

Throttle Command Too Low At Start-up (<3.0V)

Reason

The throttle command was out-of-range (<3.0V) during start-up.

System Response Alarm Sounds

Yes

Operator Display

Code L6. Drive Shutdown.

Travel PC Contactor

De-energized

Lift PC Contactor

Energized

Performance Limits

6-64

Return

Travel System

Shutdown

Lift/Lower System

Operational

Attachments

Operational

How To Clear

Cycle the deadman switch.

Tests to Run

None

Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Messages and Codes

Code L7

- Both Forward And Reverse Direction Selected

Code Title

Both Forward And Reverse Directions Selected

Reason

Forward and reverse travel has been requested.

System Response Alarm Sounds

Yes

Operator Display

Code L7. Drive Shutdown.

Travel PC Contactor

De-energized

Lift PC Contactor

Energized

Performance Limits

Return

Travel System

Shutdown

Lift/Lower System

Operational

Attachments

Operational

How To Clear

Cycle the deadman switch.

Tests to Run

I29 - Left Power Amp Switch Inputs

6-65

Messages, Codes, and Tests

Prime-Mover CRX30/35/40/50 Service Manual

Messages and Codes

Code L8

- Deadman Input On At Start-up

Code Title

Deadman Input ON At Start-up

Reason

The deadman input was detected ON at start-up.

System Response Alarm Sounds

Yes

Operator Display

Code L8. Drive Shutdown.

Travel PC Contactor

De-energized

Lift PC Contactor

Energized

Performance Limits

6-66

Return

Travel System

Shutdown

Lift/Lower System

Operational

Attachments

Operational

How To Clear

Cycle the deadman switch.

Tests to Run

I29 - Left Power Amp Switch Inputs

Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Messages and Codes

Code L9

- Precharge Failure

Code Title

Precharge Failure

Reason

The power amplifier failed to precharge.

System Response Alarm Sounds

Yes

Operator Display

Code L9. Drive Shutdown.

Travel PC Contactor

De-energized

Lift PC Contactor

Energized

Performance Limits

Return

Travel System

Shutdown

Lift/Lower System

Operational

Attachments

Operational

How To Clear

Cycle the deadman switch.

Tests to Run

None

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Messages, Codes, and Tests

Prime-Mover CRX30/35/40/50 Service Manual

Messages and Codes

Code LA

- Overvoltage During Regen

Code Title

Overvoltage During Regen

Reason

Voltage was detected out-of-range during regen.

System Response Alarm Sounds

Yes

Operator Display

Code LA. Drive Shutdown.

Travel PC Contactor

De-energized

Lift PC Contactor

Energized

Performance Limits

6-68

Return

Travel System

Shutdown

Lift/Lower System

Operational

Attachments

Operational

How To Clear

Cycle the deadman switch.

Tests to Run

Check battery condition and connections.

Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Messages and Codes

Code LB

- Low Battery Voltage Detected

Code Title

Low Battery Voltage Detected

Reason

Low battery voltage has been detected.

System Response Alarm Sounds

Yes

Operator Display

Code LB. Drive Shutdown.

Travel PC Contactor

De-energized

Lift PC Contactor

Energized

Performance Limits

Return

Travel System

Shutdown

Lift/Lower System

Operational

Attachments

Operational

How To Clear

Cycle the deadman switch.

Tests to Run

Check battery condition.

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Messages, Codes, and Tests

Prime-Mover CRX30/35/40/50 Service Manual

Messages and Codes

Code LC

- Internal Fault, Power Amplifier #1 (left)

Code Title

Internal Fault

Reason

A general fault has occurred in power amplifier #1 (left).

System Response Alarm Sounds

Yes

Operator Display

Code LC. Drive Shutdown.

Travel PC Contactor

De-energized

Lift PC Contactor

Energized

Performance Limits

6-70

Return

Travel System

Shutdown

Lift/Lower System

Operational

Attachments

Operational

How To Clear

Cycle the deadman switch.

Tests to Run

O16 - Ramp Command to Traction Power Amp #1 (left) O17 - Ramp Command to Traction Power Amp #2 (right)

Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Messages and Codes

Code R1

- Forward Direction Switch Closed at Power-up

Code Title

Forward Direction Switch Closed at Power-up

Reason

The switch for forward direction was detected closed during power-up.

System Response Alarm Sounds

Yes

Operator Display

Code R1. Drive Shutdown.

Travel PC Contactor

De-energized

Lift PC Contactor

Energized

Performance Limits

Return

Travel System

Shutdown

Lift/Lower System

Operational

Attachments

Operational

How To Clear

Cycle the deadman switch.

Tests to Run

I30 - Right Power Amplifier Switch Inputs

6-71

Messages, Codes, and Tests

Prime-Mover CRX30/35/40/50 Service Manual

Messages and Codes

Code R2

- Reverse Direction Switch Closed at Power-up

Code Title

Reverse Direction Switch Closed at Power-up

Reason

The switch for reverse direction was detected closed during power-up.

System Response Alarm Sounds

Yes

Operator Display

Code R2. Drive Shutdown.

Travel PC Contactor

De-energized

Lift PC Contactor

Energized

Performance Limits

6-72

Return

Travel System

Shutdown

Lift/Lower System

Operational

Attachments

Operational

How To Clear

Cycle the deadman switch.

Tests to Run

I30 - Right Power Amplifier Switch Inputs

Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Messages and Codes

Code R3

- Throttle Command With Deadman Input Not Selected

Code Title

Throttle Command With Deadman Input Not Selected

Reason

A throttle command was detected without a deadman input.

System Response Alarm Sounds

Yes

Operator Display

Code R3. Drive Shutdown.

Travel PC Contactor

De-energized

Lift PC Contactor

Energized

Performance Limits

Return

Travel System

Shutdown

Lift/Lower System

Operational

Attachments

Operational

How To Clear

Cycle the deadman switch.

Tests to Run

I30 - Right Power Amplifier Switch Inputs

6-73

Messages, Codes, and Tests

Prime-Mover CRX30/35/40/50 Service Manual

Messages and Codes

Code R4

- Throttle Command With No Direction Selected

Code Title

Throttle Command With No Direction Selected

Reason

A throttle command was detected with no direction selected.

System Response Alarm Sounds

Yes

Operator Display

Code R4. Drive Shutdown.

Travel PC Contactor

De-energized

Lift PC Contactor

Energized

Performance Limits

6-74

Return

Travel System

Shutdown

Lift/Lower System

Operational

Attachments

Operational

How To Clear

Cycle the deadman switch.

Tests to Run

I30 - Right Power Amplifier Switch Inputs

Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Messages and Codes

Code R5

- Throttle Command Too High at Start-up (>4.2V)

Code Title

Throttle Command Too High At Start-up (>4.2V)

Reason

The throttle command was out-of-range (>4.2V) during start-up.

System Response Alarm Sounds

Yes

Operator Display

Code R5. Drive Shutdown.

Travel PC Contactor

De-energized

Lift PC Contactor

Energized

Performance Limits

Return

Travel System

Shutdown

Lift/Lower System

Operational

Attachments

Operational

How To Clear

Cycle the deadman switch.

Tests to Run

None

6-75

Messages, Codes, and Tests

Prime-Mover CRX30/35/40/50 Service Manual

Messages and Codes

Code R6

- Throttle Command Too Low At Start-up (<3.0V)

Code Title

Throttle Command Too Low At Start-up (<3.0V)

Reason

The throttle command was out-of-range (<3.0V) during start-up.

System Response Alarm Sounds

Yes

Operator Display

Code R6. Drive Shutdown.

Travel PC Contactor

De-energized

Lift PC Contactor

Energized

Performance Limits

6-76

Return

Travel System

Shutdown

Lift/Lower System

Operational

Attachments

Operational

How To Clear

Cycle the deadman switch.

Tests to Run

None

Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Messages and Codes

Code R7

- Both Forward And Reverse Direction Selected

Code Title

Both Forward And Reverse Directions Selected

Reason

Forward and reverse travel has been requested.

System Response Alarm Sounds

Yes

Operator Display

Code R7. Drive Shutdown.

Travel PC Contactor

De-energized

Lift PC Contactor

Energized

Performance Limits

Return

Travel System

Shutdown

Lift/Lower System

Operational

Attachments

Operational

How To Clear

Cycle the deadman switch.

Tests to Run

I30 - Right Power Amplifier Switch Inputs

6-77

Messages, Codes, and Tests

Prime-Mover CRX30/35/40/50 Service Manual

Messages and Codes

Code R8

- Deadman Input On At Start-up

Code Title

Deadman Input ON At Start-up

Reason

The deadman input was detected ON at start-up.

System Response Alarm Sounds

Yes

Operator Display

Code R8. Drive Shutdown.

Travel PC Contactor

De-energized

Lift PC Contactor

Energized

Performance Limits

6-78

Return

Travel System

Shutdown

Lift/Lower System

Operational

Attachments

Operational

How To Clear

Cycle the deadman switch.

Tests to Run

I30 - Right Power Amplifier Switch Inputs

Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Messages and Codes

Code R9

- Precharge Failure

Code Title

Precharge Failure

Reason

The power amplifier failed to precharge.

System Response Alarm Sounds

Yes

Operator Display

Code R9. Drive Shutdown.

Travel PC Contactor

De-energized

Lift PC Contactor

Energized

Performance Limits

Return

Travel System

Shutdown

Lift/Lower System

Operational

Attachments

Operational

How To Clear

Cycle the deadman switch.

Tests to Run

None

6-79

Messages, Codes, and Tests

Prime-Mover CRX30/35/40/50 Service Manual

Messages and Codes

Code RA

- Overvoltage During Regen

Code Title

Overvoltage During Regen

Reason

Voltage was detected out-of-range during Regen.

System Response Alarm Sounds

Yes

Operator Display

Code RA. Drive Shutdown.

Travel PC Contactor

De-energized

Lift PC Contactor

Energized

Performance Limits

6-80

Return

Travel System

Shutdown

Lift/Lower System

Operational

Attachments

Operational

How To Clear

Cycle the deadman switch.

Tests to Run

Check battery condition and connections.

Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Messages and Codes

Code RB

- Low Battery Voltage Detected

Code Title

Low Battery Voltage Detected

Reason

Low battery voltage has been detected.

System Response Alarm Sounds

Yes

Operator Display

Code RB. Drive Shutdown.

Travel PC Contactor

De-energized

Lift PC Contactor

Energized

Performance Limits

Return

Travel System

Shutdown

Lift/Lower System

Operational

Attachments

Operational

How To Clear

Cycle the deadman switch.

Tests to Run

Check battery condition. A06 - Battery Discharge Indicator Voltage

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Messages, Codes, and Tests

Prime-Mover CRX30/35/40/50 Service Manual

Messages and Codes

Code RC

- Internal Fault, Power Amplifier #2 (right)

Code Title

Internal Fault

Reason

A general fault has occurred in power amplifier #2 (right).

System Response Alarm Sounds

Yes

Operator Display

Code RC. Drive Shutdown.

Travel PC Contactor

De-energized

Lift PC Contactor

Energized

Performance Limits

6-82

Return

Travel System

Shutdown

Lift/Lower System

Operational

Attachments

Operational

How To Clear

Cycle the deadman switch.

Tests to Run

O16 - Ramp Command to Traction Power Amp #1 (left) O17 - Ramp Command to Traction Power Amp #2 (right)

Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Messages and Codes

Code RR

- Battery Disconnected During Regen/Plugging

Code Title

Battery Disconnected During Regen/Plugging

Reason

The Battery was disconnected during Regen/plugging. Battery voltage was detected at 45V or higher.

System Response Alarm Sounds

Yes

Operator Display

Code RR. Drive Shutdown.

Travel PC Contactor

De-energized

Lift PC Contactor

Energized

Performance Limits

Return

Travel System

Shutdown

Lift/Lower System

Operational

Attachments

Operational

How To Clear

Cycle the deadman switch.

Tests to Run

Check battery connector. A06 - Battery Discharge Indicator Voltage

6-83

Messages, Codes, and Tests

Prime-Mover CRX30/35/40/50 Service Manual

Messages and Codes

Code “Waiting for Precharge” Code Title

Waiting for Precharge

Reason

The capacitor charge voltage in the power amplifier has not reached a minimum of 32V during start-up.

System Response Alarm Sounds

Operator Display

Waiting for Precharge

Travel PC Contactor

De-energized

Lift PC Contactor

De-energized

Performance Limits

6-84

Return

Travel System

Shutdown

Lift/Lower System

Shutdown

Attachments

Shutdown

How To Clear

Troubleshoot the problem. Cycle the key switch ON/OFF.

Tests to Run

A08 - FU2 Traction Fuse Voltage

Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Analog Tests

6:snMessages, Codes, and Tests

Analog Tests

! WARNING Do not disconnect energized circuits while running the following tests. If the circuits are disconnected while energized, permanent damage to the electrical system could occur.

Return

6-85

Messages, Codes, and Tests

Prime-Mover CRX30/35/40/50 Service Manual

Analog Tests

Test A05 - Throttle Potentiometer Voltage This test measures the voltage from the forward/reverse throttle potentiometer in the control handle.

Related messages, codes, and tests • Code 80 - Traction Throttle Reading Out-of-Range

! WARNING Jack the drive tires off the floor before conducting this test. See Jacking Safety on page 2-14.

! CAUTION The current in the armature should not exceed 50A for more than 10 seconds or 100A for more than 5 seconds without field excitation.

Limits: • The following table displays the voltage range that should be present on the operator display at corresponding control handle positions. Control Handle Position

Voltage Range

Full forks-first

3.0 to 3.9V

Neutral

2.0 to 3.0V

Full tractor-first

1.1 to 2.0V

• When JPC6 is disconnected, 5.0V should be present on the operator display.

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Press Enter to run test: 1. Running Learn for the controls may make the code disappear. 2. Move the control handle into the different positions listed in the table above and check the operator display for the correct voltage. When observing the voltage on the operator display, the values should change smoothly and evenly as the control handle is moved from full forks-first position to full tractor-first position. 3. If the readings on the operator display are outside of the voltage range listed in the table, the test has failed.

Diagnosis and Repair

! CAUTION Observe proper ESD precautions. See Static Precautions on page 2-12. NOTE: If the throttle potentiometer is replaced, Learn will need to be run on the truck for controls. 1. Check connection JPC6. It may be loose or disconnected from the Interface Card. 2. The throttle potentiometer may be bad. Using an ohmmeter, the potentiometer should read approx. 2000 ohms from PC6-15 to PC6-13 when the handle is in the neutral position. 3. The Interface Card may be bad. Replace as necessary.

Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Analog Tests

Test A06 - Battery Discharge Indicator Voltage This test measures the voltage used to calculate the battery state of charge.

Related messages, codes, and tests • Code 1T - Lift Cutout Point Configured For BSOC Has Been Reached.

Press Enter to run test: 1. The battery voltage as shown on the operator display should be 32 to 39VDC. 2. If the numbers displayed are not in this range, the test has failed.

Diagnosis and Repair 1. If the voltage is steady, but out-of-range, check the battery with a voltmeter. The battery may need servicing. 2. The wiring from the key switch may need servicing. Repair or replace as necessary. 3. The key switch may be bad. Replace as necessary. 4. The Interface Card may be bad. Replace as necessary.

Return

6-87

Messages, Codes, and Tests Analog Tests

Test A07 - Power Supply +12VDC This test measures the +12V Power Supply Voltage.

Related messages, codes, and tests • Code FG - +12V Power Supply Out-of-Range.

Limits: • +11 ±0.5V. If the operator display does not read within these limits, the test has failed.

Press Enter to run test: The operator display will show voltage measured.

Diagnosis and Repair

! CAUTION Observe proper ESD precautions. See Static Precautions on page 2-12. 1. Connect the (+) lead of a voltmeter to JPC5-1 and the (-) lead to TP4 (B-). With the key ON, the meter should show approx. 10.5V. If it does not, or the operator display is dark, turn the key switch OFF, disconnect all connectors from the Interface Card except the operator display (JPC5) and B+Key (JPC8). If the display lights up, then one of the disconnected components is dragging the 12V supply down. 2. The cable from the Interface Card to the operator display may be bad. Repair or replace as necessary. 3. The power supply in the Interface Card may be bad. Replace the Interface Card as necessary.

6-88

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Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Analog Tests

Test A08 - FU2 Traction Fuse Voltage This test measures voltage at Fuse FU2.

Related messages, codes, and tests None.

Press Enter to run test: 1. If FU2 is visually good and the TPC contactor is closed then the operator display should read battery voltage when run. 2. If the operator display shows 0V then either the TPC contactor is open or Fuse FU2 is bad. 3. If the operator display shows 0V and the TPC contactor is closed, then Fuse FU2 is bad.

Return

6-89

Messages, Codes, and Tests

Prime-Mover CRX30/35/40/50 Service Manual

Analog Tests

Test A09 - Weight Sensor Voltage (optional) This test measures the voltage from the pressure sensor used for load weight sensing.

Related messages, codes, and tests • Code A07 - Power Supply +12VDC

! CAUTION Use extreme caution when working near the elevated forks.

Limits: • The operator display shows the voltage present with various load weights. Load Weight

Voltage

0 (no load)

5000 lb.

• If the weight sensor is disconnected at the Interface Card, the operator display will show 0V.

Press Enter to run test: The voltage shown on the operator display should increase and decrease linearly as the load weight is either increased or decreased. If it does not, the test has failed.

Diagnosis and Repair

! CAUTION Observe proper ESD precautions. See Static Precautions on page 2-12. 1. Connect a voltmeter to JPC11-3 (+) and JPC11-2 (-). With no weight on the forks, the voltmeter should indicate approx. 1.0V.

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2. As weight is added to the forks, the voltage should increase and the value indicated on the operator display should also increase. If the voltage increases on the voltmeter but not on the Operator Display, replace the Interface Card. 3. If neither the meter nor the display value changes, replace the pressure sensor. 4. If the weight and voltage indicated are both low, the 12V supply to the sensor may be low. Connect a voltmeter to JPC11-4 (+) and JPC11-2 (-). If it is less than 11.5V, troubleshoot using Test A07.

Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Input Tests

6:snMessages, Codes, and Tests

Input Tests

! WARNING Do not disconnect energized circuits while running the following tests. If the circuits are disconnected while energized, permanent damage to the electrical system could occur.

Return

6-91

Messages, Codes, and Tests

Prime-Mover CRX30/35/40/50 Service Manual

Input Tests

Test I00 - Deadman Switch This test is used to observe the ON/OFF signal from the deadman switch.

Related messages, codes, and tests None.

! WARNING

Diagnosis and Repair

! CAUTION Observe proper ESD precautions. See Static Precautions on page 2-12. 1. Verify proper operation of the deadman switch (S2) by removing the pedal assembly.

Do not conduct this test on a ramp.

2. The cable from the Interface Card to the deadman switch (JPC7-S2) may not be working properly. Check it for continuity.

Press Enter to run test:

3. The switch may not be working properly.

The following table indicates the correct message that should appear on the operator display during this test.

4. Carefully jumper pins JPC7-16 and JPC7-5. If the display changes, the switch or circuit is bad. Remove the jumper when the test is complete.

Operator Action

Operator Display Message

Off deadman

OFF

On deadman

If the display does not change when the pedal is depressed, the test has failed.

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5. If the display does not change, replace the Interface Card.

Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Input Tests

Test I01 - EPO Switch

Diagnosis and Repair

This test is to observe the ON/OFF signal from the EPO switch.

Related messages, codes, and tests • Code 1L - Emergency Power Off (EPO) Switch Detected Down.

! CAUTION Observe proper ESD precautions. See Static Precautions on page 2-12. 1. Turn the key switch OFF and disconnect the battery. 2. Check continuity of switch S21.

! CAUTION Opening the EPO switch will open the TPC and LPC contactors. All traction and lift control will cease.

Press Enter to run test: Use the following table as a guideline for this test. EPO Button

Operator Display Message

Switch S21 Position

EPO Switch Resistance

Out

OFF

Up (closed)

<0.5 ohms

Down (open)

Infinite

3. Check continuity of the wiring from S21-2 to JC8-6 and from S21-1 to JC8-11. Repair or replace wiring as necessary. 4. Contactor fuse panel may be bad. Repair or replace as necessary. 5. Interface Card may be bad. Repair or replace as necessary.

If the display does not change when the switch is depressed, the test has failed.

Return

6-93

Messages, Codes, and Tests

Prime-Mover CRX30/35/40/50 Service Manual

Input Tests

Test I02 - High Speed Limit Switch (optional) This test is to observe ON/OFF signal from the high speed limit switch (if installed).

Diagnosis and Repair

! CAUTION Observe proper ESD precautions. See Static Precautions on page 2-12.

Related messages, codes, and tests • Code A07- Power Supply +12VDC

! WARNING

1. Check the mechanical operation of the switch (S11). 2. Check the continuity of the cable from the Interface Card (JC12) to the switch (JS5). Repair or replace as necessary.

Do not attempt high speeds during this test. Speed limiting while elevated may be defeated during this test.

3. Using a voltmeter, measure the 12V supply to the switch (+) JS5-1, (-) JS5-3. If the 12V supply is out-of-range (>11.5V), run the 12V power supply test (Test A07).

! CAUTION

4. Jumper from JS5-2 to JS5-3. If the display changes, replace the switch. If the display does not change, replace the Interface Card.

Use extreme caution when working around an elevated mast.

Press Enter to run test: The following table indicates the correct messages on the operator display for this test.

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Mast Position

Operator Display Message

Lowered

Raised

OFF

Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Input Tests

Test I03 - Tilt Up Switch This test is to observe the ON/OFF signal from the tilt up switch in the control handle.

Related messages, codes, and tests • Test O06 - Toggle the Tilt Solenoid (SOL4)

Press Enter to run test: If the display does not change when the tilt up switch is depressed, the test has failed.

Diagnosis and Repair

! CAUTION Observe proper ESD precautions. See Static Precautions on page 2-12. 1. Carefully jumper from connection JC6-3 to JC6-14 on the Interface Card. If the display changes, the switch or wiring is bad. If the display does not change, replace the Interface Card. 2. Use an ohmmeter to check for continuity at PC6-3 and PC6-14. With the switch closed, the meter should show 0 ohms. With the switch open, the meter should show infinite resistance. If the meter reads out-of-range, repair or replace the switch or wiring as necessary.

Return

6-95

Messages, Codes, and Tests Input Tests

Test I04 - Tilt Down Switch This test is to observe the ON/OFF signal from the tilt down switch in the control handle.

Related messages, codes, and tests • Test O06 - Toggle the Tilt Solenoid (SOL4)

Press Enter to run test: If the display does not change when the tilt down switch is depressed, the test has failed.

Diagnosis and Repair

! CAUTION Observe proper ESD precautions. See Static Precautions on page 2-12. 1. Carefully jumper from connection JC6-4 to JC6-14 on the Interface Card. If the display changes, then the switch or wiring is bad. If the display does not change, replace the Interface Card. 2. Use an ohmmeter to check for continuity at PC6-4 and PC6-14. With the switch closed, the meter should show 0 ohms. With the switch open, the meter should show infinite resistance. If the meter reads out-of-range, repair or replace the switch or wiring as necessary.

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Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Input Tests

Test I05 - Sideshift Right Switch (optional) This test is to observe the ON/OFF signal from the sideshift right switch in the control handle. NOTE: This option must be configured on the truck for this test to work.

Related messages, codes, and tests • O05 - Toggle the Sideshift (SOL2) Solenoid

Press Enter to run test: If the display does not change when the sideshift right switch is depressed, the test has failed.

Diagnosis and Repair

! CAUTION Observe proper ESD precautions. See Static Precautions on page 2-12. 1. Carefully jumper from connection JC6-6 to JC6-14 on the Interface Card. If the display changes, the switch or wiring is bad. If the display does not change, replace the Interface Card. 2. Check for continuity with an ohmmeter at PC6-6 and PC6-14. With the switch closed, the meter should show 0 ohms. With the switch open, the meter should show infinite resistance. If the meter reads out-of-range, repair or replace the switch or wiring as necessary.

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Messages, Codes, and Tests Input Tests

Test I06 - Sideshift Left Switch (optional) This test is to observe the ON/OFF signal from the sideshift left switch in the control handle. NOTE: This option must be configured on the truck for this test to work.

Related messages, codes, and tests • O05 - Toggle the Sideshift (SOL2) Solenoid

Press Enter to run test: If the display does not change when the sideshift left switch is depressed, the test has failed.

Diagnosis and Repair

! CAUTION Observe proper ESD precautions. See Static Precautions on page 2-12. 1. Carefully jumper from connection JC6-5 to JC6-14 on the Interface Card. If the display changes, then the switch or wiring is bad. If the display does not change, replace the Interface Card. 2. Use an ohmmeter to check for continuity at PC6-5 and PC6-14. With the switch closed, the meter should show 0 ohms. With the switch open, the meter should show infinite resistance. If the meter reads out-of-range, repair or replace the switch or wiring as necessary.

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Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Input Tests

Test I07 - Lift Limit Mast Switch (optional) Switch 12 This test is to observe the ON/OFF signal from the lift limit mast switch. NOTE: This option must be configured on the truck for this test to work.

Related messages, codes, and tests None.

! WARNING Lifting should only be done in an area with a ceiling height greater than the truck’s maximum elevated height.

Diagnosis and Repair

! CAUTION Observe proper ESD precautions. See Static Precautions on page 2-12. 1. Using an ohmmeter, check the cable from the Interface Card (JC12) to the lift limit switch (JS6) for continuity. Repair or replace as necessary. 2. Using a voltmeter, check for approx. 11.5V at JPC12-4 (+) and JPC12-2 (-). If approx. 11.5V is not seen, troubleshoot the power supply using Test A07. 3. Carefully connect a jumper from JPC12-5 to JPC12-2. If the display changes, replace the switch. If the display does not change, replace the Interface Card.

! CAUTION Use extreme caution when working around an elevated mast.

Press Enter to run test: The following table indicates the correct messages on the operator display for this test. Mast Position

Operator Display Message

Lowered

Raised

OFF

If the display does not change when the lift limit switch is closed, the test has failed. NOTE: This test will only show on the display if the option is turned ON.

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Messages, Codes, and Tests

Prime-Mover CRX30/35/40/50 Service Manual

Input Tests

Test I08 - Steer Position Sensor This test is to observe the binary signal (BCD) from the steer position sensor.

Related messages, codes, and tests • Code G2 - No Steer Position Reference Input • Code G3 - No Steer Sensor Signal While Driving

! WARNING Jack the steer tire off the floor before conducting this test. See Jacking Safety on page 2-14.

Diagnosis and Repair

! CAUTION Observe proper ESD precautions. See Static Precautions on page 2-12. 1. The cable from the Interface Card to the steer position sensor (JC7 to JS2) may be bad. Check for shorts and continuity. Repair or replace the cable as necessary. 2. To see if the steer position prox switch is working properly, check the switch to make sure it shows no visible signs of damage. Replace any damaged components. 3. Hook the (+) lead of a voltmeter to JPC7-17 and the (-) lead to TP4 (B-). 4. Place a steel object such as a screwdriver over the bottom of the prox switch.

! CAUTION Steer tire rotation is opposite that of the steer tiller.

When the metal object is over the bottom of the prox switch, the voltmeter should read less than 2V.

Press Enter to run test:

When the metal object is taken away from the bottom of the prox switch, the voltmeter should read more than 7V.

Press Enter on the operator display and step on the deadman pedal. As the steer tire rotates, the numbers listed below appear on the display. If they do not change or are erratic, the test has failed. Steer Tire Position (±2°)

Operator Display Message

90° (full clockwise) to 66°

101

65° to 40°

100

39° to 14°

000

13° to -15° (wheels centered)

001

-16° to -45°

011

-46° to -76°

010

-90° (counterclockwise) to -77°

110

Error Condition

111

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If the above two conditions are not met, replace the prox switch. 5. Now connect the (+) lead of the voltmeter to JPC7-18 and repeat step 4. The results should be the same. 6. Now connect the (+) lead of the voltmeter to JPC7-8 and repeat step 4. The results should be the same. 7. If steps 5 and 6 pass, replace the Interface Card.

Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Input Tests

Test I09 - Spool Valve Switch (S17) (optional) This test is to observe the ON/OFF signal from the attachment control lever switch that is mounted on the top of the auxiliary manifold.

Related messages, codes, and tests None.

Press Enter to run test: 1. Use the following table as a guideline. Switch Position

Operator Display Message

Depressed

Released

OFF

2. If the display does not change when the switch is depressed, the test has failed.

Diagnosis and Repair 1. Check to make sure that switch S17 is mechanically functioning. 2. Replace the suspect switch with a new switch and repeat this test. 3. If test fails, troubleshoot wiring.

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Messages, Codes, and Tests

Prime-Mover CRX30/35/40/50 Service Manual

Input Tests

Test I10 - Horn Switch This test is to observe ON/OFF signal from the Horn switch in the operator’s control handle.

Related messages, codes, and tests None.

Press Enter to run test: 1. Use the following table as a guideline. Horn Switch Position

Operator Display Message

Depressed

Released

OFF

2. If the display does not change when the switch is depressed, the test has failed. NOTE: When connecting jumpers, use caution and connect correct pins.

Diagnosis and Repair 1. Check to make sure that switch S3 is mechanically functioning. Replace as necessary or repair wiring. 2. Remove connector JPC6 from the Interface Card. With an ohmmeter, check the continuity from PC6-7 to PC6-14. When the switch is depressed, the ohmmeter should show 0 ohms. When the switch is released, the meter should show infinite resistance. 3. Carefully connect a jumper from JC6-7 to JC6-14. With the jumper installed, the display should indicate ON. With the jumper removed, the display should show OFF. If this is not observed, replace the Interface Card.

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Messages, Codes, and Tests Input Tests

Test I11 - FU1 Steering Fuse This test is to measure the absence or presence of B+ voltage at the load side of the Steer Motor (STR) contactor.

3. FU1 sense may be disconnected or broken. Check continuity from JC8-9 to STR-2 and repair or replace as necessary. 4. The deadman switch may not be working properly. Run test I00.

Related messages, codes, and tests

5. The STR contactor tips may be burned or open.

• Test O02 - Toggle the STR Contactor

6. The Interface Card may be bad. Replace as necessary.

• Code G2 - No Steer Position Reference Input • Test I00 - Deadman Switch

! CAUTION When this test is activated and the deadman pedal is depressed, the steer motor/pump will activate.

Press Enter to run test: NOTE: The deadman pedal must be depressed for this test to function. Use the following table as a guideline. B+ Voltage Status

Operator Display Message

B+ present

B+ absent

OFF

If the display message does not change when the test is activated, the test has failed.

Diagnosis and Repair

! CAUTION Observe proper ESD precautions. See Static Precautions on page 2-12. 1. FU1 may be bad. Remove and test. Replace as necessary. 2. The connections at FU1 may be corroded or loose. Clean and retighten as necessary.

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Messages, Codes, and Tests

Prime-Mover CRX30/35/40/50 Service Manual

Input Tests

Test I12 - FU3 Lift Fuse This test is to measure the absence or presence of B+ voltage at the load side of the lift motor (LPC) contactor.

Diagnosis and Repair

! CAUTION Observe proper ESD precautions. See Static Precautions on page 2-12.

Related messages, codes, and tests • Test O13 - Toggle the LPC Contactor • Test I00 - Deadman Switch

2. The connections at FU3 may be corroded or loose. Clean and retighten as necessary.

! WARNING Jack the drive tires off the floor before conducting this test. See Jacking Safety on page 2-14.

! CAUTION When this test is activated and the deadman pedal is depressed, the Traction motors will activate.

Press Enter to run test: NOTE: The deadman pedal must be depressed for this test to function. Use the following table as a guideline. B+ Voltage Status

Operator Display Message

B+ present

B+ absent

OFF

If the display message does not change when the test is activated, the test has failed.

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1. FU3 may be bad. Remove and test. Replace as necessary.

3. FU3 sense may be disconnected or broken. Check continuity from JC8-8 to TPC-2 and repair or replace as necessary. 4. The deadman switch may not be working properly. Run test I00. 5. The Interface Card may be bad. Replace as necessary.

Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Input Tests

Test I13 - Traction Motor #1 (left) Brush Wear Indicator (both) This test is used to observe the composite signal from the two brush wear indicator switches in traction motor #1 (left).

Related messages, codes, and tests • Code 2N - Brush Wear Indicator, Motor #1

! CAUTION When working around the motors, extreme caution should be taken to prevent small parts from falling into them.

Press Enter to run test: Use the following table as a guideline. Brush Status

Operator Display Message

Worn, needs replacing

OFF

• Model CRX50: When the brush wear indicator touches the brush rigging, the operator display should show ON. • Models CRX30/35/40: When the wire in the brush touches the commutator surface, the operator display should show ON.

Diagnosis and Repair NOTE: If the test will not show ON, go to step 1. If the test will not show OFF and the brushes are OK, go to step 4.

! CAUTION Observe proper ESD precautions. See Static Precautions on page 2-12. 1. Carefully attach a jumper from the brush wear indicator to the brush spring of the motor. If the display shows ON now, clean the brush wear indicator connection. If it does not show ON, go to step 2. 2. Depending on which brushes are worn, attach the jumper from JPS11-2 or JPS11-4 to the brush spring. If it shows ON now, repair or replace the wiring. If it does not show ON, go to step 3. 3. Depending on which brushes are worn, attach the jumper from JPC10-8 or JPC10-9 to the brush spring. If the display shows ON, repair or replace the wiring. If it does not show ON with the jumper in place and the connector attached to the Interface Card, then replace the Interface Card. NOTE: A dirty motor or battery may make the brush wear indicator always show ON. 4. Remove the wire from the brush wear indicator at the brush rigging. If it shows OFF now, clean the motor. If it does not show OFF, go to step 5. 5. Remove JS11-2 and JS11-4 from the connector. If the operator display shows OFF, locate which wire is shorted to the vehicle. If it does not show OFF, go to step 6. 6. Remove JC10-8 and JC10-9 from the Interface Card. If the display shows OFF now, look for a wire shorted to the vehicle. If it still will not show OFF, replace the Interface Card.

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Input Tests

Test I14 - Traction Motor #2 (right) Brush Wear Indicator (upper) This test is used to observe the composite signal from the upper brush wear indicator switch in traction motor #2 (right).

Related messages, codes, and tests • Code HE - Brush Wear Indicator, Motor #2

! CAUTION When working around the motors, extreme caution should be taken to prevent small parts from falling into them.

Press Enter to run test: Use the following table as a guideline. Brush Status

Operator Display Message

Worn, needs replacing

OFF

Diagnosis and Repair NOTE: If the test will not show ON, go to step 1. If the test will not show OFF and the brushes are OK, go to step 4.

! CAUTION Observe proper ESD precautions. See Static Precautions on page 2-12. 1. Carefully attach a jumper from the brush wear indicator to the brush spring of the motor. If the display shows ON now, clean the brush wear indicator connection. If it does not show ON, go to step 2. 2. Attach the jumper from JPS12-2 to the brush spring. If it shows ON now, repair or replace the wiring. If it does not show ON, go to step 3. 3. Attach the jumper from JPC10-13 to the brush spring. If the display shows ON, repair or replace the wiring. If it does not show ON with the jumper in place and the connector attached to the Interface Card, replace the Interface Card. NOTE: A dirty motor or battery may make the brush wear indicator always show ON. 4. Remove the wire from the brush wear indicator at the brush rigging. If it shows OFF now, clean the motor. If it does not show OFF, go to step 5. 5. Remove JS12-2 from the connector. If the operator display shows OFF, locate which wire is shorted to the vehicle. If it does not show OFF, go to step 6. 6. Remove JC10-13 from the Interface Card. If the display shows OFF now, look for a wire shorted to the vehicle. If it still will not show OFF, replace the Interface Card.

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Messages, Codes, and Tests Input Tests

Test I15 - Traction Motor #2 (right) Brush Wear Indicator (lower) This test is used to observe the composite signal from the lower brush wear indicator switch in traction motor #2 (right).

Related messages, codes, and tests • Code HE - Brush Wear Indicator, Motor #2

! CAUTION When working around the motors, extreme caution should be taken to prevent small parts from falling into them.

Press Enter to run test: Use the following table as a guideline. Brush Status

Operator Display Message

Worn, needs replacing

OFF

Diagnosis and Repair NOTE: If the test will not show ON, go to step 1. If the test will not show OFF and the brushes are OK, go to step 4.

! CAUTION Observe proper ESD precautions. See Static Precautions on page 2-12. 1. Carefully attach a jumper from the brush wear indicator to the brush spring of the motor. If the display shows ON now, clean the brush wear indicator connection. If it does not show ON, go to step 2. 2. Attach the jumper from JPS12-4 to the brush spring. If it shows ON now, repair or replace the wiring. If it does not show ON, go to step 3. 3. Attach the jumper from JPC10-10 to the brush spring. If the display shows ON, repair or replace the wiring. If it does not show ON with the jumper in place and the connector attached to the Interface Card, replace the Interface Card. NOTE: A dirty motor or battery may make the brush wear indicator always show ON. 4. Remove the wire from the brush wear indicator at the brush rigging. If it shows OFF now, clean the motor. If it does not show OFF, go to step 5. 5. Remove JS12-4 from the connector. If the operator display shows OFF, locate which wire is shorted to the vehicle. If it does not show OFF, go to step 6. 6. Remove JC10-10 from the Interface Card. If the display shows OFF now, look for a wire shorted to the vehicle. If it still will not show OFF, replace the Interface Card.

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Messages, Codes, and Tests

Prime-Mover CRX30/35/40/50 Service Manual

Input Tests

Test I16 - Lift Motor Brush Wear Indicator (upper) This test is used to observe the composite signal from the upper brush wear indicator switch in lift motor.

Related messages, codes, and tests • Code 6U - Brush Wear Indicator, Lift Motor

! CAUTION When working around the motors, extreme caution should be taken to prevent small parts from falling into them.

Press Enter to run test: Use the following table as a guideline. Brush Status

Operator Display Message

Worn, needs replacing

OFF

Diagnosis and Repair NOTE: If the test will not show ON, go to step 1. If the test will not show OFF and the brushes are OK, go to step 4.

! CAUTION Observe proper ESD precautions. See Static Precautions on page 2-12. 1. Carefully attach a jumper from the brush wear indicator to the brush spring of the motor. If the display shows ON now, clean the brush wear indicator connection. If it does not show ON, go to step 2. 2. Attach the jumper from JPS8-2 to the brush spring. If it shows ON now, repair or replace the wiring. If it does not show ON, go to step 3. 3. Attach the jumper from JPC10-14 to the brush spring. If the display shows ON, repair or replace the wiring. If it does not show ON with the jumper in place and the connector attached to the Interface Card, then replace the Interface Card. NOTE: A dirty motor or battery may make the brush wear indicator always show ON. 4. Remove the wire from the brush wear indicator at the brush rigging. If it shows OFF now, clean the motor. If it does not show OFF, go to step 5. 5. Remove JS8-2 from the connector. If the operator display shows OFF, locate which wire is shorted to the vehicle. If it does not show OFF, go to step 6. 6. Remove JC10-14 from the Interface Card. If the display shows OFF now, look for a wire shorted to the vehicle. If it still will not show OFF, replace the Interface Card.

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Messages, Codes, and Tests Input Tests

Test I17 - Lift Motor Brush Wear Indicator (lower) This test is used to observe the composite signal from the lower brush wear indicator switch in lift motor.

Related messages, codes, and tests • Code 6U - Brush Wear Indicator, Lift Motor

! CAUTION When working around the motors, extreme caution should be taken to prevent small parts from falling into them.

Press Enter to run test: Use the following table as a guideline. Brush Status

Operator Display Message

Worn, needs replacing

OFF

Diagnosis and Repair NOTE: If the test will not show ON, go to step 1. If the test will not show OFF and the brushes are OK, go to step 4.

! CAUTION Observe proper ESD precautions. See Static Precautions on page 2-12. 1. Carefully attach a jumper from the brush wear indicator to the brush spring of the motor. If the display shows ON now, clean the brush wear indicator connection. If it does not show ON, go to step 2. 2. Attach the jumper from JPS8-4 to the brush spring. If it shows ON now, repair or replace the wiring. If it does not show ON, go to step 3. 3. Attach the jumper from JPC10-15 to the brush spring. If the display shows ON, repair or replace the wiring. If it does not show ON with the jumper in place and the connector attached to the Interface Card, then replace the Interface Card. NOTE: A dirty motor or battery may make the brush wear indicator always show ON. 4. Remove the wire from the brush wear indicator at the brush rigging. If it shows OFF now, clean the motor. If it does not show OFF, go to step 5. 5. Remove JS8-4 from the connector. If the operator display shows OFF, locate which wire is shorted to the vehicle. If it does not show OFF, go to step 6. 6. Remove JC10-15 from the Interface Card. If the display shows OFF now, look for a wire shorted to the vehicle. If it still will not show OFF, replace the Interface Card.

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Prime-Mover CRX30/35/40/50 Service Manual

Input Tests

Test I18 - Traction Motor #1 (left) Speed Sensor This test is to observe the signal from the speed sensor on traction motor #1 in mph.

Related messages, codes, and tests • Code 2H - Failure Detected in Speed Feedback Circuit #1

! WARNING This test should be conducted in an area free of obstructions with ample room for maneuvering.

1. Use the following table as a guideline. Sensor Signal Status

Operator Display Message

Present

0.0 MPH

Absent

OFF

The operator display will show speed as seen by the velocity sensor. 2. The speed and direction of each drive motor will depend on the position of the steer tire. For best results, the steer tire should be in the straight ahead position.

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1. The cable from JPS3 to the Interface Card may be bad. Check for continuity. Repair or replace as necessary. 2. Measure the voltage from JPS3-1 (+) to JPS3-3 (-). The meter should show approx. 10.9V. If it does not, run the +12V test (Test A07). 3. Connect a voltmeter from JPS3-2 (+) to JPS3-3 (-) with no metal over the sensor. The meter should show approx. 5V. With a flat metal object over the sensor, the meter should show approx. 0V. If these figures are not seen, replace the speed sensor. The clearance from the sensor to the impeller is 0.050 to 0.080 in. (0.127 to 0.203 mm).

Press Enter to run test:

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Diagnosis and Repair

4. The Interface Card may be bad.

Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Input Tests

Test I19 - Traction Motor #2 (right) Speed Sensor This test is to observe the signal from the speed sensor on traction motor #2 in mph.

Diagnosis and Repair 1. The cable from JPS4 to the Interface Card may be bad. Check for continuity. Repair or replace as necessary.

• Code HB - Motor #2 Speed Feedback Error

2. Measure the voltage from JPS4-1 (+) to JPS4-3 (-). The meter should show approx. 11.5V. If it does not, run the +12V test (Test A07).

! WARNING

3. Connect a voltmeter from JPS4-2 (+) to JPS4-3 (-) with no metal over the sensor. The meter should show approx. 5V.

Related messages, codes, and tests

This test should be conducted in an area free of obstructions with ample room for maneuvering.

With a flat metal object over the sensor, the meter should show approx. 0V. If these figures are not seen, replace the speed sensor.

Press Enter to run test:

The clearance from the sensor to the impeller is 0.050 to 0.080 in. (0.127 to 0.203 mm).

1. Use the following table as a guideline.

4. The Interface Card may be bad. Sensor Signal Status

Operator Display Message

Present

0.0 MPH

Absent

OFF

The operator display will show speed as seen by the speed sensor. 2. The speed and direction of each drive motor will depend on the position of the steer tire. For best results, the steer tire should be in the straight ahead position.

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Input Tests

Test I20 - Traction Motor #1 (left) Thermostat This test measures the temperature of the left traction motor.

Diagnosis and Repair

! CAUTION Observe proper ESD precautions. See Static Precautions on page 2-12.

Related messages, codes, and tests • Code 2A - Traction Motor #1 Overheated • Code H6 - Traction Motor #2 Overheated

Limits: • Ambient to +145°C (293°F) normal operation • Operation cutback at 145°C to 155°C (293 to 311°F)

Press Enter to run test: 1. With the truck at rest and at ambient temperature, observe the operator display. It should show “I20 CLSD”. 2. If the message on the operator display is different, the test has failed.

1. Disconnect JPS11 from the motor. 2. With an ohmmeter, check resistance of the temperature switch at JPS11-3 and JPS11-1. Use the following table as a guideline (all values are approximate). Motor Temperature

Switch Position

Resistance

°C

°F

<145

<293

Closed

0 ohms

>145

>293

Open

Infinite

If the resistance measured does not match the values listed above, replace the temperature sensor. 3. Check for continuity of JPS11 to JC10. Repair or replace the cable as required. 4. The Interface Card may be bad.

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Messages, Codes, and Tests Input Tests

Test I21 - Traction Motor #2 (right) Thermostat This test measures the temperature of the right traction motor.

Diagnosis and Repair

! CAUTION Observe proper ESD precautions. See Static Precautions on page 2-12.

Related messages, codes, and tests • Code H6 - Traction Motor #2 Overheated • Code 2A - Traction Motor #1 Overheated

Limits: • Ambient to +145°C (293°F) normal operation • Operation cutback at 145°C to 155°C (293 to 311°F)

Press Enter to run test: 1. With the truck at rest and at ambient temperature, observe the operator display. It should show “I21 CLSD”. 2. If the message on the operator display is different, the test has failed.

1. Disconnect JPS12 from the motor. 2. With an ohmmeter, check resistance of the temperature switch at JPS12-3 and JPS12-1. Use the following table as a guideline (all values are approximate). Motor Temperature

Switch Position

Resistance

°C

°F

<145

<293

Closed

0 ohms

>145

>293

Open

Infinite

If the resistance measured does not match the values listed above, replace the temperature sensor. 3. Check for continuity of JPS12 to JC10. Repair or replace the cable as required. 4. The Interface Card may be bad.

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Messages, Codes, and Tests

Prime-Mover CRX30/35/40/50 Service Manual

Input Tests

Test I22 - Lift Motor Thermostat

Diagnosis and Repair

This test measures the temperature of the lift motor.

Related messages, codes, and tests • Code 6F - Lift Motor Overheated • Code 6G - Lift Motor Temperature Out-of-Range

Limits: • Ambient to +145°C (293°F) normal operation • Operation cutback at 145°C to 155°C (293 to 311°F)

Press Enter to run test: 1. With the truck at rest and at ambient temperature, observe the operator display. It should show “I22 CLSD”. 2. If the message on the operator display is different, the test has failed.

! CAUTION Observe proper ESD precautions. See Static Precautions on page 2-12. 1. Disconnect JPS8 from the motor. 2. With an ohmmeter, check resistance of the temperature switch at JPS8-3 and JPS8-1. Use the following table as a guideline (all values are approximate). Motor Temperature

Switch Position

Resistance

°C

°F

<145

<293

Closed

0 ohms

>145

>293

Open

Infinite

If the resistance measured does not match the values listed above, replace the temperature sensor. 3. Check for continuity of JPS8 to JC10. Repair or replace the cable as required. 4. The Interface Card may be bad.

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Messages, Codes, and Tests Input Tests

Test I23 - Lift Switch (S13) This test is to observe ON/OFF signal from the lift switch in the operator’s control handle/lift linkage assembly.

Related messages, codes, and tests None.

Press Enter to run test: 1. Use the following table as a guideline. Lift Switch Position

Operator Display Message

Depressed

Released

OFF

2. If the display does not change when the switch is depressed, the test has failed.

Diagnosis and Repair 1. Check to make sure that switch S13 is functioning mechanically. 2. Replace the suspect switch with a new switch and repeat this test. 3. If test fails, troubleshoot wiring.

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Messages, Codes, and Tests

Prime-Mover CRX30/35/40/50 Service Manual

Input Tests

Test I24 - Lower Switch (S14) This test is to observe ON/OFF signal from the lower switch in the operator’s control handle/ lift linkage assembly.

Related messages, codes, and tests None.

Press Enter to run test: 1. Use the following table as a guideline. Lower Switch Position

Operator Display Message

Depressed

Released

OFF

2. If the display does not change when the switch is depressed, the test has failed.

Diagnosis and Repair 1. Check to make sure that switch S14 is functioning mechanically. 2. Replace the suspect switch with a new switch and repeat this test. If test fails, troubleshoot wiring.

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Messages, Codes, and Tests Input Tests

Test I25 - Attachment Spool Valve Switch (S17) This test is to observe the ON/OFF signal from the attachment spool valve switch (if installed).

Related messages, codes, and tests None.

! CAUTION Use extreme caution when working around an elevated mast.

Press Enter to run test: The following table indicates the correct messages on the operator display for this test: Switch Button Position

Operator Display Message

Depressed

Raised

OFF

If the message does not match, the test has failed.

Diagnosis and Repair

! CAUTION Observe proper ESD precautions. See Static Precautions on page 2-12. 1. Check the mechanical operation of the switch (S17). 2. Check the continuity of the cable from JPA3 on the Attachment Card to the switch (S17) through JPA4. Repair or replace as necessary. 3. Carefully jumper from JPA3-6 to JPA3-2. If the display changes, replace the switch. If the display does not change, replace the Attachment Card. 4. If the problem still exists, replace the Interface Card.

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Input Tests

Test I26 - Tilt Limit Switch (optional) This test is to observe the ON/OFF signal from the tilt limit switch (if installed).

Diagnosis and Repair

! CAUTION Observe proper ESD precautions. See Static Precautions on page 2-12.

Related messages, codes, and tests • Test A07 - Power Supply +12 VDC

2. Check the continuity of the cable from the Interface Card (JC12) to the switch (JS5). Repair or replace as necessary.

! WARNING Do not attempt high speeds during this test. Speed limiting while elevated may be defeated during this test.

! CAUTION Use extreme caution when working around an elevated mast.

Press Enter to run test: The following table indicates the correct messages on the operator display in relation to the mast and tilt position: NOTE: This option uses two switches (S11 and S18) working together to operate. Mast Tilt Position

Mast Elevated Position

Operator Display Message

<3° Forward

Within Free-Lift

OFF

>3° Forward

Above Free-Lift

<3° Forward

Above Free-Lift

OFF

>3° Forward

Within Free-Lift

OFF

If the message does not match the above conditions, the test has failed.

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1. Check the mechanical operation of the switches (S11 and S18).

3. Check the clearance from the sensor head to the adjacent metal switch actuator. The clearance should be 0.050 to 0.100 in. (1.27 to 2.54 mm) when the mast is tilted back and the carriage is lowered. 4. Using a voltmeter, measure the +12V supply to the switch (+) JS5-1, (-) JS5-3. If the +12V supply is out-of-range, run the +12V Power Supply Test (Test A07). 5. Carefully jumper from JS5-2 to JS5-3. If the display changes, replace the switch. If the display does not change, replace the Interface Card.

Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Input Tests

Test I27 - TPC_L Signal This test is used to observe the command from the left power amplifier to either energize or de-energize the TPC contactor. The command is sent from JPTL1-17 to JPX2-13.

Related messages, codes, and tests • Code 2M - Power Amplifier #1 (left) Fault • Code HK - Power Amplifier #2 (right) Fault

Press Enter to run test: NOTE: The deadman pedal must be depressed for this test to function. Use the following table as a guideline.

Deadman Pedal

Key and Deadman Outputs From Translator Card

Operator Display Message

Down

Off

OFF

Diagnosis and Repair Check the TPC Contactor to verify that it is either energized (closed) or de-energized (open) in accordance with the input to the Translator Card. NOTE: It may be helpful to run Test I28 and compare the results to this test. Check to see that the left and right power amplifiers are not sending conflicting commands to the Translator Card.

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Input Tests

Test I28 - TPC_R Signal This test is used to observe the command from the right power amplifier to either energize or de-energize the TPC contactor. The command is sent from JPTR1-17 to JPX1-13.

Related messages, codes, and tests • Code HK - Power Amplifier #2 (right) Fault • Code 2M - Power Amplifier #1 (left) Fault • Test I27 - TPC_L Signal

Press Enter to run test: NOTE: The deadman pedal must be depressed for this test to function. Use the following table as a guideline.

Deadman Pedal

Key and Deadman Outputs From Translator Card

Operator Display Message

Down

Off

OFF

Diagnosis and Repair Check the TPC Contactor to verify that it is either energized (closed) or de-energized (open) in accordance with the input to the Translator Card. NOTE: It may be helpful to run Test I27 and compare the results to this test. Check to see that the left and right power amplifiers are not sending conflicting commands to the Translator Card.

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Messages, Codes, and Tests Input Tests

Test I29 - Left Power Amplifier Switch Inputs The left power amplifier requires five (5) digital input signals to operate: KEY, EPO, DM (deadman), FWD directional signal, and REV directional signal. These signals are created by the Interface Card and sent to the power amplifiers via the Translator Card. The amplifiers read these inputs and communicate what has been read back to the Translator Card using communication lines TXD_L and RXD_L. This test displays what is being communicated back to the Translator Card from the left power amplifier.

Related messages, codes, and tests

2. The Interface Card will then change the outputs to the power amplifier sequentially that will operate all of the switch inputs to the amplifier. The correct sequence that should be displayed on the operator display during this test is as follows:. Sequence of Operator Display Message

Condition Message Represents

XXX

Test not started yet.

00B

EPO off; DM off; both forward and reverse inputs on.

01B

EPO off; DM on; both forward and reverse inputs on.

10B

EPO on; DM off; both forward and reverse inputs on.

00F

EPO off; DM off; forward direction on, reverse direction off.

00R

EPO off; DM off; forward direction off, reverse direction on.

00N

EPO off; DM off; forward direction off, reverse direction off.

• Code HK - Power Amplifier #2 (right) Fault • Code 2M - Power Amplifier #1 (left) Fault • Test I30 - Right Power Amp Switch Inputs

Press Enter to run test: 1. The Interface Card will generate a test pattern that will be monitored by the Operator Display during this test. The display will show a three-character code. The first character represents the EPO switch input status, the second represents the deadman switch input status, and the third represents the directional input status. For the first two characters, a “1” indicates that the input is being read as “on” and a “0” indicates that the input is being read as “off.” For the directional, or third, character, a “B” indicates that both directional inputs are being read as “on,” an “F” indicates that only the forward directional is “on,” an “R” indicates that only the reverse directional is “on,” and an “N” indicates that neither directional is “on.” NOTE: The signals that are sent to the amplifiers are not physically connected to the key, deadman, and EPO switches.

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If “XXX” is displayed while the test is running, then communication shutdown has occurred. If “OFF” is displayed when this test is run, then the key switch input is detected as OFF. If “---” is displayed when this test is run, then the voltage output of the TPC Contactor has dropped below 16V. The amplifiers require at least 16V to turn on.

Diagnosis and Repair It may be helpful to compare the results of this test with the Translator Card LEDs while the test is running. Troubleshoot deviations accordingly.

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Input Tests

Test I30 - Right Power Amplifier Switch Inputs The right power amplifier requires five digital input signals to operate: KEY, EPO, DM (deadman), FWD directional signal, and REV directional signal. These signals are created by the Interface Card and sent to the power amplifiers via the Translator Card. The amplifiers read these inputs and communicate what has been read back to the Translator Card using communication lines TXD_R and RXD_R. This test displays what is being communicated back to the Translator Card from the right power amplifier.

Related messages, codes, and tests

Condition Message Represents

XXX

Test not started yet.

00B

EPO off; DM off; both forward and reverse inputs on.

01B

EPO off; DM on; both forward and reverse inputs on.

10B

EPO on; DM off; both forward and reverse inputs on.

00F

EPO off; DM off; forward direction on, reverse direction off.

00R

EPO off; DM off; forward direction off, reverse direction on.

00N

EPO off; DM off; forward direction off, reverse direction off.

• Code HK - Power Amplifier #2 (right) Fault • Code 2M - Power Amplifier #1 (left) Fault • Test I29 - Left Power Amp Switch Inputs

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Diagnosis and Repair It may be helpful to compare the results of this test with the Translator Card LEDs while the test is running. Troubleshoot deviations accordingly.

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Messages, Codes, and Tests Output Tests

6:snMessages, Codes, and Tests

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Output Tests

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Output Tests

Test O01 - Toggle the Load Hold (SOL1) Solenoid This test is used to turn the load hold solenoid (SOL1) ON and OFF.

Related messages, codes, and tests None.

! WARNING Be sure the forks are fully lowered before performing this test.

! CAUTION The lowering function normally uses the proportional lower solenoid in conjunction with the load hold solenoid.

Press Enter to run test: ON/OFF will be displayed on the operator display. The test can be toggled ON and OFF with the UP/DOWN keys.

Diagnosis and Repair

5. If the solenoid is off when it should be on: a. Turn the truck OFF. b. Disconnect both wires from the solenoid coil. c. Connect the leads of an ohmmeter to the terminals on the solenoid coil. d. Set the ohmmeter scale to R x 1. e. The resistance should be approx. 33.7 ±5 ohms. If not, replace the solenoid coil. If OK, proceed to next step. f. Reconnect wire SOL1-1 to Solenoid 1. g. Turn the truck back on. Re-enter this test in the truck’s maintenance mode. h. Connect the (+) lead of a voltmeter to wire SOL1-1. Connect the (-) lead to wire SOL1-2. i. Toggle the test ON. The voltmeter should read positive battery voltage. If it does not, go to the next step. j. Connect the (-) lead of the voltmeter to JPC9-6. Connect the (+) lead to JPC9-3. k. If the voltmeter reads positive battery voltage when the test is toggled ON, replace the wires. If it does not, replace the Interface Card. 6. If the solenoid is on all the time:

Observe proper ESD precautions. See Static Precautions on page 2-12.

a. Disconnect wire to SOL1-2. If the solenoid drops out (you will hear a click), check the wiring to JPC9-6. Repair the wire as necessary. If the wire is OK, replace the Interface Card.

1. Enter this test in the truck’s maintenance mode.

b. If the solenoid did not drop out, check it for mechanical binding and repair or replace it.

! CAUTION

2. Disconnect wire SOL1-1 from solenoid 1. 3. Connect an ammeter between this wire and terminal SOL1-1 on the solenoid. 4. Toggle this test ON. When the operator display shows ON, the ammeter should read 900 to 1100mA (0.9 to 1.1A). If this reading is OK, the test is a success.

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Messages, Codes, and Tests Output Tests

Test O02 - Toggle the Sideshift (SOL2) Solenoid (optional)

e. The resistance should be approx. 33.7 ±5 ohms. If not, replace the solenoid coil. If OK, proceed to next step.

This test is used to turn the sideshift solenoid (SOL2) ON and OFF.

f. Reconnect wire SOL2-1 to Solenoid 2.

Related messages, codes, and tests None.

Press Enter to run test: ON/OFF will be displayed on the operator display. The test can be toggled ON and OFF with the UP/DOWN keys.

Diagnosis and Repair

! CAUTION Observe proper ESD precautions. See Static Precautions on page 2-12. NOTE: The sideshift option must be installed before this test is available. 1. Enter this test while in the truck’s Maintenance Mode. 2. Disconnect wire SOL2-1 from Solenoid 2. 3. Connect an ammeter between this wire and terminal SOL2-1 on the solenoid.

g. Turn the truck back on. Re-enter this test in Maintenance Mode. h. Connect the (+) lead of a voltmeter to wire SOL2-1. Connect the (-) lead to wire SOL2-2. i. Toggle the test ON. The voltmeter should read positive battery voltage. If it does not, proceed to next step. j. Connect the (-) lead of the voltmeter to JPC9-12. Connect the (+) lead to JPC9-3. k. If the voltmeter reads positive battery voltage when the test is toggled ON, replace the wires. If it does not, replace the Interface Card. 6. If the solenoid is on all the time: a. Disconnect wire to SOL2-2. If the solenoid drops out (you will hear a click), check the wiring to JPC9-12. Repair the wire as necessary. If the wire is OK, replace the Interface Card. b. If the solenoid did not drop out, check it for mechanical binding and repair or replace it as necessary.

4. Toggle this test ON. When the operator display shows ON, the ammeter should read 900 to 1100mA (0.9 to 1.1A). If this reading is OK, the test is a success. 5. If the solenoid is off when it should be on: a. Turn the truck OFF. b. Disconnect both wires from the solenoid coil. c. Connect the leads of an ohmmeter to the terminals on the solenoid coil. d. Set the ohmmeter scale to R x 1.

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Output Tests

Test O04 - Toggle the Tilt (SOL4) Solenoid This test is used to turn the tilt solenoid (SOL4) ON and OFF.

Related messages, codes, and tests None.

Press Enter to run test: NOTE: ON/OFF will be displayed on the operator display. The test can be toggled ON and OFF with the UP/DOWN keys.

Diagnosis and Repair

! CAUTION Observe proper ESD precautions. See Static Precautions on page 2-12. 1. Enter this test in Maintenance Mode. 2. Disconnect wire SOL4-1 from Solenoid 4. 3. Connect an ammeter between this wire and terminal SOL4-1 on the solenoid. 4. Toggle this test ON. When the operator display shows ON, the ammeter should read 900 to 1100mA (0.9 to 1.1A). If this reading is OK, the test is a success. 5. If the solenoid is off when it should be on: a. Turn the truck OFF. b. Disconnect both wires from the solenoid coil. c. Connect the leads of an ohmmeter to the terminals on the solenoid coil. d. Set the ohmmeter scale to R x 1. e. The resistance should be approx. 33.7 ±5 ohms. If not, replace the solenoid coil. If it is, proceed to next step. f. Reconnect wire SOL4-1 to Solenoid 4.

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g. Turn the truck back on. Re-enter this test in Maintenance Mode. h. Connect the (+) lead of a voltmeter to wire SOL4-1. Connect the (-) lead to wire SOL4-2. i. Toggle the test ON. The voltmeter should read positive battery voltage. If it does not, proceed to next step. j. Connect the (-) lead of the voltmeter to JPC9-1. Connect the (+) lead to JPC9-3. k. If the voltmeter reads positive battery voltage when the test is toggled ON, replace the wires. If it does not, replace the Interface Card. 6. If the solenoid is on all the time: a. Disconnect wire to SOL4-2. If the solenoid drops out (you will hear a click), check the wiring to JPC9-1. Repair the wire as necessary. If the wire is OK, replace the Interface Card. b. If the solenoid did not drop out, check it for mechanical binding. Repair or replace it as necessary.

Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Output Tests

Test O05 - Toggle the Aux PSI Select (SOL5) Solenoid This test is used to turn the Aux PSI Select Solenoid (SOL5) ON and OFF.

Related messages, codes, and tests None.

Press Enter to run test: NOTE: ON/OFF will be displayed on the operator display. The test can be toggled ON and OFF with the UP/DOWN keys.

j. Connect the (-) lead of the voltmeter to JPC9-7. Connect the (+) lead to JPC9-3. k. If the voltmeter reads positive battery voltage when the test is toggled ON, replace the wires. If it does not, replace the Interface Card. 6. If the solenoid is on all the time: a. Disconnect wire to SOL5-2. If the solenoid drops out (you will hear a click), check the wire to JPC9-7. Repair the wire as necessary. If the wire is OK, replace the Interface Card. b. If the solenoid did not drop out, check it for mechanical binding and repair or replace it.

Diagnosis and Repair 1. Enter this test while in Maintenance Mode. 2. Disconnect wire SOL5-1 from Solenoid 5. 3. Connect an ammeter between this wire and terminal SOL5-1 on the solenoid. 4. Toggle this test ON. When the operator display shows ON, the ammeter should read 900 to 1100mA (0.9 to 1.1A). If this reading is OK, the test is a success. 5. If the solenoid is off when it should be on: a. Turn the truck OFF. b. Disconnect both wires from the solenoid coil. c. Connect the leads of an ohmmeter to the terminals on the solenoid coil. d. Set the ohmmeter scale to R x 1. e. The resistance should be approx. 33.7 ±5 ohms. If not, replace the solenoid coil. If it is, go to the next step. f. Reconnect wire SOL5-1 to Solenoid 5. g. Turn the truck back on. Re-enter this test in Maintenance Mode. h. Connect the (+) lead of a voltmeter to wire SOL5-1. Connect the (-) lead to wire SOL5-2. i. Toggle the test ON. The voltmeter should read positive battery voltage. If it does not, proceed to next step.

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Output Tests

Test O06 - Toggle the Auxiliary Direction A Solenoid (SOL6)

e. The resistance should be approx. 33.7 ±5 ohms. If not, replace the solenoid coil. If it is, go to the next step.

This test is used to turn the auxiliary direction A solenoid (SOL6) ON and OFF.

f. Reconnect wire SOL6-1 to solenoid 6.

Related messages, codes, and tests None.

Press Enter to run test: NOTE: ON/OFF will be displayed on the operator display. Test can be toggled ON and OFF with the UP/DOWN keys.

Diagnosis and Repair 1. Enter this test in the truck’s maintenance mode. 2. Disconnect wire SOL6-1 from solenoid 6. 3. Connect an ammeter between this wire and terminal SOL6-1 on the solenoid. 4. Toggle this test ON. When the operator display shows ON, the ammeter should read 900 to 1100mA (0.9 to 1.1A). If this reading is OK, the test is a success. 5. If the solenoid is off when it should be on: a. Turn the truck OFF. b. Disconnect both wires from the solenoid coil. c. Connect the leads of an ohmmeter to the terminals on the solenoid coil. d. Set the ohmmeter scale to R x 1.

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g. Turn the truck back on. Re-enter this test in the truck’s maintenance mode. h. Connect the (+) lead of a voltmeter to wire SOL6-1. Connect the (-) lead wire SOL6-2. i. Toggle the test ON. The voltmeter should read positive battery voltage. If it does not, proceed to next step. j. Connect the (-) lead of the voltmeter to JPC9-8. Connect the (+) lead to JPC9-3. k. If the voltmeter reads positive battery voltage when the test is toggled ON, replace the wires. If it does not, replace the Interface Card. 6. If the solenoid is on all the time: a. Disconnect wire to SOL6-2. If the solenoid drops out (you will hear a click), check the wiring to JPC9-8. Repair the wire as necessary. If the wire is OK, replace the Interface Card. b. If the solenoid did not drop out, check it for mechanical binding and repair or replace it.

Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Output Tests

Test O07 - Toggle the Equalization (SOL7) Solenoid

i. Toggle the test ON. The voltmeter should read positive battery voltage. If it does not, proceed to next step.

This test is used to turn the equalization solenoid (SOL7) ON and OFF.

j. Connect the (-) lead of the voltmeter to JPC9-9. Connect the (+) lead to JPC9-3.

Related messages, codes, and tests None.

Press Enter to run test:

k. If the voltmeter reads positive battery voltage when the test is toggled ON, replace the wires. If it does not, replace the Interface Card. 6. If the solenoid is on all the time:

NOTE: ON/OFF will be displayed on the operator display. This test can be toggled ON and OFF with the UP/DOWN keys.

a. Disconnect wire to SOL7-2. If the solenoid drops out (you will hear a click), check the wiring to JPC9-9. Repair the wire as necessary. If the wire is OK, replace the Interface Card.

Diagnosis and Repair

b. If the solenoid did not drop out, check it for mechanical binding and repair or replace it.

1. Enter this test in Maintenance Mode. 2. Disconnect wire SOL7-1 from solenoid 7. 3. Connect an ammeter between this wire and terminal SOL7-1 on the solenoid. 4. Toggle this test ON. When the operator display shows ON, the ammeter should read 900 to 1100mA (0.9 to 1.1A). If this reading is OK, the test is a success. 5. If the solenoid is off when it should be on: a. Turn the truck OFF. b. Disconnect both wires from the solenoid coil. c. Connect the leads of an ohmmeter to the terminals on the solenoid coil. d. Set the ohmmeter scale to R x 1. e. The resistance should be approx. 33.7 ±5 ohms. If not, replace the solenoid coil. If it is, proceed to next step. f. Reconnect wire SOL7-1 to solenoid 7. g. Turn the truck back on. Re-enter this test in Maintenance Mode. h. Connect the (+) lead of a voltmeter to wire SOL7-1. Connect the (-) lead to wire SOL7-2.

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Output Tests

Test O08 - Toggle the Auxiliary Direction B (SOL8) Solenoid

i. Toggle the test ON. The voltmeter should read positive battery voltage. If it does not, proceed to next step.

This test is used to turn the auxiliary direction B solenoid (SOL8) ON and OFF, if installed.

j. Connect the (-) lead of the voltmeter to JPC9-10. Connect the (+) lead to JPC9-3.

Related messages, codes, and tests

k. If the voltmeter reads positive battery voltage when the test is toggled ON, replace the wires. If it does not, replace the Interface Card.

None.

Press Enter to run test: NOTE: ON/OFF will be displayed on the operator display. This test can be toggled ON and OFF with the UP/DOWN keys.

Diagnosis and Repair 1. Enter this test in Maintenance Mode. 2. Disconnect wire SOL8-1 from solenoid 8. 3. Connect an ammeter between this wire and terminal SOL8-1 on the solenoid. 4. Toggle this test ON. When the operator display shows ON, the ammeter should read 900 to 1100mA (0.9 to 1.1A). If this reading is OK, the test is a success. 5. If the solenoid is off when it should be on: a. Turn the truck OFF. b. Disconnect both wires from the solenoid coil. c. Connect the leads of an ohmmeter to the terminals on the solenoid coil. d. Set the ohmmeter scale to R x 1. e. The resistance should be approx. 33.7 ±5 ohms. If not, replace the solenoid and coil. If it is, proceed to next step. f. Reconnect wire SOL8-1. g. Turn the truck back on. Re-enter this test in the truck’s maintenance mode. h. Connect the (+) lead of a voltmeter to wire SOL8-1. Connect the (-) lead to wire SOL8-2.

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6. If the solenoid is on all the time: a. Disconnect wire to SOL8-2. If the solenoid drops out (you will hear a click), check the wiring to JPC9-10. Repair the wire as necessary. If the wire is OK, replace the Interface Card. b. If the solenoid did not drop out, check it for mechanical binding and repair or replace it.

Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Output Tests

Test O09 - Toggle the High Flow Auxiliary (SOL9) Solenoid (Optional) This test is used to turn the high flow auxiliary solenoid (SOL9) ON and OFF.

Related messages, codes, and tests None.

Press Enter to run test: NOTE: ON/OFF will be displayed on the operator display. This test can be toggled ON and OFF with the UP/DOWN keys.

Diagnosis and Repair

! CAUTION Observe proper ESD precautions. See Static Precautions on page 2-12. 1. Enter this test in Maintenance Mode. 2. Disconnect wire SOL9-1 from Solenoid 9. 3. Connect an ammeter between this wire and terminal SOL9-1 on the solenoid. 4. Toggle this test ON. When the operator display shows ON, the ammeter should read 900 to 1100mA (0.9 to 1.1A). If this reading is OK, the test is a success. 5. If the solenoid is off when it should be on: a. Turn the truck OFF. b. Disconnect both wires from the solenoid coil.

g. Turn the truck back on. Re-enter this test in Maintenance Mode. h. Connect the (+) lead of a voltmeter to wire SOL9-1. Connect the (-) lead to wire SOL9-2. i. Toggle the test ON. The voltmeter should read positive battery voltage. If it does not, proceed to next step. j. Connect the voltmeter to the SOL9-1 wire (+) and to JPA2-5 (-). The meter should show battery positive voltage. If it does not, move the positive lead of the meter to JPA2-4. The meter should show battery positive, with the key ON. If it does, replace the cable at JPA2-4. k. If it does not, move the positive meter lead to JPA2-3 (+). With the key ON, the meter should show battery (+). If it does not, repair or replace the wiring back to the key switch. l. If there is B+ at the meter, replace the Attachment Card. m. Toggle the test ON. n. Remove the wires from JPA2-3 and JPA2-8. Connect the voltmeter to those terminals on the Attachment Card. o. If the meter shows (+) voltage with the test ON, repair or replace the wire from JPA2-8 to SOL9-2. If there was no voltage, remove cable JPA1 from the Attachment Card and JPC7 from the Interface Card. Check it for continuity and repair or replace it as necessary. p. Connect the voltmeter to JPA1-7 (+) and JPA1-9 (-). With the test toggled ON, the meter should read approx. 4.5V. If it does, replace the Attachment Card. If it does not, replace the Interface Card.

c. Connect the leads of an ohmmeter to the terminals on the solenoid coil. d. Set the ohmmeter scale to R x 1. e. The resistance should be approx. 33.7 ±5 ohms. If not, replace the solenoid coil. If it is, go to the next step. f. Reconnect wire SOL9-1 to Solenoid 9.

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Output Tests

Test O10 - Toggle the High Flow Attachment 1 (SOL10) Solenoid (Optional) This test is used to turn the high flow attachment 1 solenoid (SOL10) ON and OFF.

Related messages, codes, and tests None.

Press Enter to run test: NOTE: ON/OFF will be displayed on the operator display. This test can be toggled ON and OFF with the UP/DOWN keys.

Diagnosis and Repair

! CAUTION Observe proper ESD precautions. See Static Precautions on page 2-12. 1. Enter this test in Maintenance Mode. 2. Disconnect wire SOL10-1 from Solenoid 10. 3. Connect an ammeter between this wire and terminal SOL10-1 on the solenoid. 4. Toggle this test ON. When the operator display shows ON, the ammeter should read 900 to 1100mA (0.9 to 1.1A). If this reading is OK, the test is a success. 5. If the solenoid is off when it should be on: a. Turn the truck OFF. b. Disconnect both wires from the solenoid coil. c. Connect the leads of an ohmmeter to the terminals on the solenoid coil. d. Set the ohmmeter scale to R x 1. e. The resistance should be approx. 33.7 ±5 ohms. If not, replace the solenoid coil. If it is, go to the next step. f. Reconnect wire SOL10-1 to Solenoid 10.

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g. Turn the truck back on. Re-enter this test in Maintenance Mode. h. Connect the (+) lead of a voltmeter to wire SOL10-1. Connect the (-) lead to wire SOL10-2. i. Toggle the test ON. The voltmeter should read positive battery voltage. If it does not, proceed to next step. j. Connect the voltmeter to the SOL10-1 wire (+) and to JPA2-5 (-). The meter should show battery positive voltage. If it does not, move the positive lead of the meter to JPA2-4. The meter should show battery positive, with the key ON. If it does, replace the cable at JPA2-4. k. If it does not, move the positive meter lead to JPA2-3 (+). With the key switch ON, the meter should show battery (+). If it does not, repair or replace the wiring back to the key switch. l. If there is B+ at the meter, replace the Attachment Card. m. Toggle the test ON. n. Remove the wires from JPA2-4 and JPA2-9. Connect the voltmeter to those terminals on the Attachment Card. o. If the meter shows (+) voltage with the test ON, repair or replace the wire from JPA2-9 to SOL10-2. If there was no voltage, remove cable JPA1 from the Attachment Card and JPC7 from the Interface Card. Check it for continuity and repair or replace it as necessary. p. Connect the voltmeter to JPA1-7 (+) and JPA1-9 (-). With the test toggled ON, the meter should read approx. 4.5V. If it does, replace the Interface Card. If it does not, replace the Interface Card.

Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Output Tests

Test O11 - Toggle the High Flow Attachment 2 (SOL11) Solenoid (Optional) This test is used to turn the high flow attachment 2 solenoid (SOL11) ON and OFF.

Related messages, codes, and tests None.

Press Enter to run test: NOTE: ON/OFF will be displayed on the operator display. This test can be toggled ON and OFF with the UP/DOWN keys.

Diagnosis and Repair

! CAUTION Observe proper ESD precautions. See Static Precautions on page 2-12. 1. Enter this test in Maintenance Mode. 2. Disconnect wire SOL11-1 from Solenoid 11. 3. Connect an ammeter between this wire and terminal SOL11-1 on the solenoid. 4. Toggle this test ON. When the operator display shows ON, the ammeter should read 900 to 1100mA (0.9 to 1.1A). If this reading is OK, the test is a success. 5. If the solenoid is off when it should be on: a. Turn the truck OFF. b. Disconnect both wires from the solenoid coil.

g. Turn the truck back ON. Re-enter this test in Maintenance Mode. h. Connect the (+) lead of a voltmeter to wire SOL11-1. Connect the (-) lead to wire SOL11-2. i. Toggle the test ON. The voltmeter should read positive battery voltage. If it does not, proceed to next step. j. Connect the voltmeter to the SOL11-1 wire (+) and to JPA2-5 (-). The meter should show battery positive voltage. If it does not, move the positive lead of the meter to JPA2-4. The meter should show battery positive, with the key ON. If it does, replace the cable at JPA2-4. k. If it does not, move the positive meter lead to JPA2-3 (+). With the key ON, the meter should show battery (+). If it does not, repair or replace the wiring back to the key switch. l. If there is B+ at the meter, replace the Attachment Card. m. Toggle the test ON. n. Remove the wires from JPA2-4 and JPA2-10. Connect the voltmeter to those terminals on the Attachment Card. o. If the meter shows (+) voltage with the test ON, repair or replace the wire from JPA2-10 to SOL11-2. If there was no voltage, remove cable JPA1 from the Attachment Card and JPC7 from the Interface Card. Check it for continuity and repair or replace it as necessary. p. Connect the voltmeter to JPA1-8 (+) and JPA1-9 (-). With the test toggled ON, the meter should read approx. 4.5V. If it does, replace the Attachment Card. If it does not, replace the Interface Card.

c. Connect the leads of an ohmmeter to the terminals on the solenoid coil. d. Set the ohmmeter scale to R x 1. e. The resistance should be approx. 33.7 ±5 ohms. If not, replace the solenoid coil. If it is, proceed to next step. f. Reconnect wire SOL11-1 to Solenoid 11.

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Messages, Codes, and Tests

Prime-Mover CRX30/35/40/50 Service Manual

Output Tests

Test O12 - Toggle the TPC Contactor This test turns the TPC contactor ON and OFF.

Related messages, codes, and tests

Diagnosis and Repair

! CAUTION Observe proper ESD precautions. See Static Precautions on page 2-12.

• Code 44 - TPC Contactor Detected Closed When Commanded Open

1. Check for binding in the contactor. Repair or replace as necessary.

• Code 45 - TPC Contactor Detected Open When Commanded Closed

2. Using an ohmmeter, check the resistance of the coil. With the wires removed from the X and Y terminals, the resistance should be 10-50 ohms. Replace as necessary.

! CAUTION Jack the drive wheels off the floor for this test. See Jacking Safety on page 2-14.

! WARNING The traction system may not act as expected during this test. If the traction power amplifier is shorted, the truck may start to travel when the contactor is toggled ON/OFF.

Press Enter to run test: NOTE: This test can be toggled by using the UP/DOWN keys on the operator display. If the contactor does not cycle in/out when the test is toggled, the test has failed.

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3. The cable JPC8 from the Interface Card to the contactor coil may be bad. Check it for continuity. Repair or replace cable as necessary. 4. Using a voltmeter, check for B+KC (36V) at JPC8-14 (+) with reference to TP4 (B-). If B+KC exists at JPC8-13 but not at JPC8-14, replace the Interface Card. 5. Measure the voltage at TP1 (contactor fuse panel) with reference to TP4 (B-). It should read B+ (36V). If it does not, then check the K3 relay. Replace as necessary. 6. If B+KC is present at JPC8-14 (+) with reference to JPC8-12 (B-F) and the contactor still will not operate, replace the Interface Card.

Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Output Tests

Test O13 - Toggle the LPC Contactor This test is used to turn the LPC contactor ON and OFF.

Diagnosis and Repair

! CAUTION Observe proper ESD precautions. See Static Precautions on page 2-12.

Related messages, codes, and tests • Code 42 - LPC Contactor Detected Closed When Commanded Open • Code 43 - LPC Contactor Detected Open When Commanded Closed

! CAUTION The ceiling height should be higher than maximum elevated height of the vehicle under test.

1. Check for binding in the contactor. Repair or replace as necessary. 2. Using an ohmmeter, check the resistance of the coil. With the wires removed from the X and Y terminals, the resistance should be 10-50 ohms. Replace as necessary. 3. The cable JPC8 from the Interface Card to the contactor coil may be bad. Check it for continuity. Repair or replace cable as necessary.

! WARNING

4. Using a voltmeter, check for B+KC (36V) at JPC8-14 (+) with reference to TP4 (B-). If B+KC exists at JPC8-13 but not at JPC8-14, replace the Interface Card.

The lift system may not act as expected during this test. If the lift power amplifier is shorted, the mast may lift when the contactor is toggled ON/OFF.

5. Measure the voltage at TP1 (contactor fuse panel) with reference to TP4 (B-). It should read B+ (36V). If it does not, then check the K3 relay. Replace as necessary.

Press Enter to run test:

6. If B+KC is present at JPC8-14 (+) with reference to JPC8-12 (B-F) and the contactor still will not operate, replace the Interface Card.

NOTE: This test can be toggled by using the UP/DOWN keys on the operator display. If the contactor does not cycle in/out when the test is toggled, the test has failed.

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Messages, Codes, and Tests

Prime-Mover CRX30/35/40/50 Service Manual

Output Tests

Test O14 - Toggle the STR Contactor This test is used to turn the STR contactor ON and OFF.

Related messages, codes, and tests • Code 4B - STR Contactor Detected Closed When Commanded Open • Code 4C - STR Contactor Detected Open When Commanded Closed

! WARNING DO NOT attempt to drive the truck while conducting this test.

! CAUTION The steer system may not act as expected during this test. The steer motor will run when the contactor is toggled ON and OFF.

Press Enter to run test: NOTE: This test can be toggled by using the UP/DOWN keys on the operator display. If the contactor does not cycle in/out when the test is toggled, the test has failed.

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Diagnosis and Repair 1. Check for binding in the contactor. Repair or replace as necessary. 2. Using an ohmmeter, check the resistance of the coil. With the wires removed from the X and Y terminals, the resistance should be 10-50 ohms. Replace as necessary. 3. The cable JPC8 from the Interface Card to the contactor coil may be bad. Check it for continuity. Repair or replace cable as necessary. 4. Using a voltmeter, check for B+KC (36V) at JPC8-14 (+) with reference to TP4 (B-). If B+KC exists at JPC8-13 but not at JPC8-14, replace the Interface Card. 5. Measure the voltage at TP1 (contactor fuse panel) with reference to TP4 (B-). It should read B+ (36V). If it does not, then check the K3 relay. Replace as necessary. 6. If B+KC is present at JPC8-14 (+) with reference to JPC8-12 (B-F) and the contactor still will not operate, replace the Interface Card.

Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Output Tests

Test O15 - Toggle the AUX Contactor This test is used to turn the AUX contactor ON and OFF.

Related messages, codes, and tests None.

! WARNING

DO NOT attempt to drive the truck while conducting this test.

4. Using a voltmeter, check for B+KC (36V) at JPC8-14 (+) with reference to TP4 (B-). If B+KC exists at JPC8-13 but not at JPC8-14, replace the Interface Card.

! CAUTION

5. Measure the voltage at TP1 (contactor fuse panel) with reference to TP4 (B-). It should read B+ (36V). If it does not, then check the K3 relay. Replace as necessary.

The steer system may not act as expected during this test. The steer motor will run when the contactor is toggled ON and OFF.

Press Enter to run test:

6. If B+KC is present at JPC8-14 (+) with reference to JPC8-12 (B-F) and the contactor still will not operate, replace the Interface Card.

NOTE: This test can be toggled by using the UP/DOWN keys on the operator display. If the contactor does not cycle in/out when the test is toggled, the test has failed.

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Messages, Codes, and Tests

Prime-Mover CRX30/35/40/50 Service Manual

Output Tests

Test O16 - Ramp Command to Traction Power Amp #1 (left) This test turns on the left traction power amplifier (#1) by gradually increasing the command to it through the CAN bus.

Related messages, codes, and tests • Code 29 - No Movement Detected When Travel is Requested

! WARNING

Press Enter to run test: NOTE: The deadman pedal must be depressed for the brake to release. 1. This test will ramp from 0 to 100% in 10% increments when the UP/DOWN buttons are pushed. To change directions, press the enter button. The voltage readings should change according to the table below. The voltages may vary slightly from those in the table depending on the battery voltage. Operator Display Message

Approximate Voltage

36.0V

10%

34.0V

20%

30.0V

30%

26.0V

40%

22.0V

50%

19.0V

60%

15.0V

70%

12.0V

80%

8.0V

90%

5.0V

100%

0.0V

The left traction motor may rotate during this test. Jack the drive wheels up or allow sufficient room for maneuvering.

! CAUTION Current level of 100A for 5 seconds or 50A for 10 seconds should not be exceeded without wheel movement.

! CAUTION Prolonged application of the current to the motor without movement will cause damage to the motor.

NOTE: The (+) meter lead connects to the A2 (+) hookup and the (-) lead connects to the F1 or F2 (B-) hookup on the motor. 2. During this test, the field terminal F1 and F2 will drop approx. 6V (while the test is running). Meter Lead Connection (Forward)

Meter Lead Connection (Reverse)

(+)

(-)

(+)

(-)

The meter will start at battery voltage and drop approx. 6V when the test is operating.

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Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Output Tests

Diagnosis and Repair

! CAUTION Observe proper ESD precautions. See Static Precautions on page 2-12. 1. If the percentage on the operator display changes and the voltage on the meter changes according to the table above but the motor does not turn, check the motor and repair or replace as necessary. 2. If the percentage on the operator display changes but the voltage on the power amplifier does not change, then replace the power amplifier. 3. If the percentage on the display does not change, replace the Interface Card.

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Messages, Codes, and Tests

Prime-Mover CRX30/35/40/50 Service Manual

Output Tests

Test O17 - Ramp the #2 (right) Traction Power Amplifier This test turns on the right traction power amplifier (#2) by gradually increasing the command to it through the CAN bus.

Related messages, codes, and tests • Code 29 - No Movement Detected When Travel is Requested

! WARNING

Approximate Voltage

36.0V

10%

34.0V

20%

30.0V

30%

26.0V

40%

22.0V

50%

19.0V

60%

15.0V

70%

12.0V

80%

8.0V

90%

5.0V

100%

0.0V

The right traction motor may rotate during this test. Jack the drive wheels up or allow sufficient room for maneuvering.

! CAUTION Current level of 100A for 5 seconds or 50A for 10 seconds should not be exceeded without wheel movement.

! CAUTION Prolonged application of the current to the motor without movement will cause damage to the motor.

Meter Lead Connection (Reverse)

(+)

(-)

(+)

(-)

The meter will start at battery voltage and drop approx. 6V when the test is operating.

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Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Output Tests

Diagnosis and Repair

! CAUTION Observe proper ESD precautions. See Static Precautions on page 2-12. 1. If the percentage on the operator display changes and the voltage on the meter changes according to the preceding table but the motor does not turn, check the motor and repair or replace as necessary. 2. If the percentage on the operator display changes but the voltage on the power amplifier does not change, then replace the power amplifier. 3. If the percentage on the display does not change, replace the Interface Card.

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Messages, Codes, and Tests

Prime-Mover CRX30/35/40/50 Service Manual

Output Tests

Test O18 - Toggle Traction Motor Brake #1 (left)

4. If the meter shows battery voltage, repair or replace the cable and go to step 5. If it does not, replace the Interface Card.

This test turns the brake on traction motor #1 (left) ON or OFF.

5. Connect a voltmeter to JB1-2(-) and JPB1-1(+). With the test toggled ON, the meter should show B+. If it does not, replace the Interface Card.

Related messages, codes, and tests • Code 29 - No Movement Detected When Travel is Requested

! WARNING Do not drive the truck while conducting this test.

! CAUTION The left brake may not operate as expected during this test.

Press Enter to run test: NOTE: ON/OFF will appear on the operator display. This test can be toggled ON and OFF with the UP/DOWN keys.

Diagnosis and Repair

! CAUTION Observe proper ESD precautions. See Static Precautions on page 2-12. NOTE: In order to make the brakes operate, the deadman pedal must be depressed. 1. Disconnect connection JPB1. 2. Using an ohmmeter, measure the resistance of the brake coil. The resistance should be 21 to 25 ohms. If it is not correct, replace the brake coil. 3. With the key switch ON, connect a voltmeter at JPB1-1(+) and TP4(B-). The meter should show battery voltage. If it does not, move the meter lead to JPC10-20 at the Interface Card.

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Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Output Tests

Test O19 - Toggle Traction Motor Brake #2 (right)

4. If the meter shows battery voltage, repair or replace the cable and go to step 5. If it does not, replace the Interface Card.

This test turns the brake on traction motor #2 (right) ON or OFF.

5. With connector JPB2 disconnected, connect a voltmeter to JB2-2(-) and JPB2-1(+). With the test toggled ON, the meter should show B+. If it does not, replace the Interface Card.

Related messages, codes, and tests • Code 29 - No movement detected when travel is requested

! WARNING Do not drive the truck while conducting this test.

! CAUTION The right brake may not operate as expected during this test.

Press Enter to run test: NOTE: ON/OFF will appear on the operator display. This test can be toggled ON and OFF with the UP/DOWN keys.

Diagnosis and Repair

! CAUTION Observe proper ESD precautions. See Static Precautions on page 2-12. NOTE: In order to make the brakes operate, the deadman pedal must be depressed. 1. Disconnect connection JPB2. 2. Using an ohmmeter, measure the resistance of the brake coil. The resistance should be 21 to 25 ohms. If it is not correct, replace the brake coil. 3. With the key switch ON, connect a voltmeter at JPB2-1(+) and TP4(B-). The meter should show battery voltage. If it does not, move the meter lead to JPC10-21 at the Interface Card.

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Messages, Codes, and Tests Output Tests

Test O20 - Ramp the Frequency to the Operator Display Alarm This test turns on the operator display alarm by gradually increasing the signal sent.

Related messages, codes, and tests None.

Press Enter to run test: If the sonalert does not sound when the ENTER key is pushed, the test has failed.

Diagnosis and Repair

! CAUTION Observe proper ESD precautions. See Static Precautions on page 2-12. 1. If you are able to access Maintenance Mode, then the keypad and associated wiring are working properly. 2. If the sonalert does not work, the operator display cable may be bad. Use an ohmmeter to check its continuity. Repair or replace as necessary. 3. The operator display may be bad. Replace as necessary. 4. The Interface Card may be bad. Replace as necessary.

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Prime-Mover CRX30/35/40/50 Service Manual

Messages, Codes, and Tests Output Tests

Test O21 - Toggle the Horn This test turns the truck’s horn ON and OFF.

Related messages, codes, and tests • Test I10 - Horn switch

Press Enter to run test: NOTE: ON/OFF will appear on the operator display. This test can be toggled ON and OFF with the UP/DOWN keys. When the ENTER key is pressed the horn should sound. If it does not sound, the test has failed. NOTE: Check all hydraulic functions of the truck for operation. They receive battery voltage from the same source as the horn. If they work, B+KA to the Interface Card is present.

Diagnosis and Repair

! CAUTION Observe proper ESD precautions. See Static Precautions on page 2-12. 1. Disconnect the terminals from the horn. Using an ohmmeter, the resistance of the horn should be 10 to 50 ohms. If it is not in this range, replace the horn. 2. The cable from the Interface Card (JPC8) to the horn may be bad. Check its continuity using an ohmmeter. 3. If test I10 (horn switch) passes and all of the above steps pass, then replace the Interface Card.

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Messages, Codes, and Tests Output Tests

Test O22 - Toggle the Travel Alarm (optional) This test turns the truck’s horn ON and OFF.

Related messages, codes, and tests None.

Press Enter to run test: NOTE: ON/OFF will appear on the operator display. This test can be toggled ON and OFF with the UP/DOWN keys. When the ENTER key is pressed the travel alarm should sound. If it does not sound, the test has failed.

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Component Procedures

7-1

Component Procedures

Prime-Mover CRX30/35/40/50 Service Manual

List of Component Procedures

List of Component Procedures A Adjusting Control Handle . . . . . . . . . . . . 7-38 Air Gap Adjustment, Brake . . . . . . . . . . . 7-76 Auxiliary Motor . . . . . . . . . . . . . . . . . . . .7-117 Auxiliary Pump . . . . . . . . . . . . . . . . . . . .7-141 Axle Seal . . . . . . . . . . . . . . . . . . . . . . . . . 7-49 B Battery Cleaning Exterior . . . . . . . . . . . . . . . 7-93 Connector . . . . . . . . . . . . . . . . . . . . . 7-91 Gates . . . . . . . . . . . . . . . . . . . . . . . . 7-93 Installation . . . . . . . . . . . . . . . . . . . . 7-92 Maintenance . . . . . . . . . . . . . . . . . . . 7-95 Procedures . . . . . . . . . . . . . . . . . . . . 7-91 Removal . . . . . . . . . . . . . . . . . . . . . . 7-92 Rollers . . . . . . . . . . . . . . . . . . . . . . . 7-93 Troubleshooting . . . . . . . . . . . . . . . . 7-96 Bleeding Hydraulic System . . . . . . . . . . .7-128 Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-76 Air Gap Adjustment . . . . . . . . . . . . . . 7-76 Assembly . . . . . . . . . . . . . . . . . . . . . 7-78 Coil Assembly . . . . . . . . . . . . . . . . . . 7-78 Inspection . . . . . . . . . . . . . . . . . . . . . 7-76 Location . . . . . . . . . . . . . . . . . . . . . . 7-76 Brake Air Gap Adjustment . . . . . . . . . . . 7-76 Brake Assembly . . . . . . . . . . . . . . . . . . . 7-78 Brake Coil Assembly . . . . . . . . . . . . . . . . 7-78 Brushes, Motor . . . . . . . . . . . . . . . . . . . .7-102

Tip Inspection . . . . . . . . . . . . . . . . . . . 7-85 Tip Replacement . . . . . . . . . . . . . . . . . 7-86 Traction . . . . . . . . . . . . . . . . . . . . . . . 7-84 Control Handle . . . . . . . . . . . . . . . . . . . . . 7-37 Assembly . . . . . . . . . . . . . . . . . . . . . . 7-40 Linkage Adjustment . . . . . . . . . . . . . . 7-38 Covers Console . . . . . . . . . . . . . . . . . . . . . . . 7-14 Front . . . . . . . . . . . . . . . . . . . . . . . . . 7-16 Steer Compartment . . . . . . . . . . . . . . 7-18 Cylinder, Tilt . . . . . . . . . . . . . . . . . . . . . 7-142 D Deadman Pedal . . . . . . . . . . . . . . . . . . . . 7-43 Deadman Switch . . . . . . . . . . . . . . . . . . . 7-43 Display Operator . . . . . . . . . . . . . . . . . . . . . . . 7-36 Drive Motor . . . . . . . . . . . . . . . . . . . . . . 7-111 Drive Tire . . . . . . . . . . . . . . . . . . . . . . . . . 7-27 Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . 7-46 Adding Oil . . . . . . . . . . . . . . . . . . . . . 7-46 Checking Oil . . . . . . . . . . . . . . . . . . . . 7-46 Replacement . . . . . . . . . . . . . . . . . . . . 7-47 Drive Wheel . . . . . . . . . . . . . . . . . . . . . . . 7-27 E Electric Motor Tests . . . . . . . . . . . . . . . . 7-108 Electric Steer Motor . . . . . . . . . . . . . . . . . 7-24 EPO (Emergency Power Off) Switch . . . . 7-121

Cards Interface Card . . . . . . . . . . . . . . . . . . 7-88 Translator Card . . . . . . . . . . . . . . . . . 7-90 Chains Free Lift . . . . . . . . . . . . . . . . . . . . . 7-153 Main Lift . . . . . . . . . . . . . . . . . . . . . 7-153 Changing Hydraulic Fluid . . . . . . . . . . . .7-126 Checking Hydraulic Fluid . . . . . . . . . . . .7-126 Commutator, Motor . . . . . . . . . . . . . . . .7-106 Connectors Battery . . . . . . . . . . . . . . . . . . . . . . . 7-91 Console Cover . . . . . . . . . . . . . . . . . . . . . 7-14 Contactor Fuse Panel . . . . . . . . . . . . . . . 7-83 Contactors . . . . . . . . . . . . . . . . . . . . . . . 7-84 Lift . . . . . . . . . . . . . . . . . . . . . . . . . . 7-84 Steer . . . . . . . . . . . . . . . . . . . . . . . . . 7-84 Testing Resistance . . . . . . . . . . . . . . . 7-84

Filters Hydraulic . . . . . . . . . . . . . . . . . . . . . 7-126 Fluids Bleeding Hydraulic System . . . . . . . . 7-128 Changing Hydraulic Fluid . . . . . . . . . 7-126 Checking Hydraulic Fluid Level . . . . 7-126 Hydraulic . . . . . . . . . . . . . . . . . . . . . 7-126 Hydraulic Reservoir . . . . . . . . . . . . . 7-137 Setting Hydraulic Pressure . . . . . . . . 7-135 Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-157 Free Lift Chains . . . . . . . . . . . . . . . . . . . 7-153 Front Covers . . . . . . . . . . . . . . . . . . . . . . 7-16 Fuse Panel . . . . . . . . . . . . . . . . . . . . . . . . 7-83 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-82 Removal, Testing, and Replacement . . 7-82

7-2

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Prime-Mover CRX30/35/40/50 Service Manual

Component Procedures List of Component Procedures

G Gates, Battery . . . . . . . . . . . . . . . . . . . . . 7-93 Guards Overhead . . . . . . . . . . . . . . . . . . . . . . 7-20 H Handle Control . . . . . . . . . . . . . . . . . . . . . . . 7-37 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-101 Hydraulic Fluid . . . . . . . . . . . . . . . . . . . 7-126 Hydraulic Pressure Adjustments . . . . . . 7-135 Hydraulic Reservoir . . . . . . . . . . . . . . . . 7-137 Hydraulic Steer Motor . . . . . . . . . . . . . . 7-133 I

Hydraulic Fluid . . . . . . . . . . . . . . . . .7-126 Hydraulic Reservoir . . . . . . . . . . . . .7-137 Operator Display . . . . . . . . . . . . . . . . . . . 7-36 Overhead Guard . . . . . . . . . . . . . . . . . . . . 7-20 P Pedal Deadman . . . . . . . . . . . . . . . . . . . . . .7-43 Power Amplifiers Traction . . . . . . . . . . . . . . . . . . . . . . .7-99 Pressure Adjustments . . . . . . . . . . . . . . . 7-135 Pump Lift . . . . . . . . . . . . . . . . . . . . . . . . . .7-140 Steer . . . . . . . . . . . . . . . . . . . . . . . . .7-139 Pumps Auxiliary . . . . . . . . . . . . . . . . . . . . . .7-141

Interface Card . . . . . . . . . . . . . . . . . . . . . 7-88 R K Key Switch . . . . . . . . . . . . . . . . . . . . . . 7-119 L Lift Contactor . . . . . . . . . . . . . . . . . . . . . 7-84 Lift Motor . . . . . . . . . . . . . . . . . . . . . . . 7-114 Lift Pump . . . . . . . . . . . . . . . . . . . . . . . 7-140 Lift Ram Seals . . . . . . . . . . . . . . . . . . . . . . . . 7-156 M Main Lift Chains . . . . . . . . . . . . . . . . . . 7-153 Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-148 Complete Removal . . . . . . . . . . . . . . 7-148 Installation . . . . . . . . . . . . . . . . . . . 7-150 Partial Removal . . . . . . . . . . . . . . . . 7-151 Motors Auxiliary . . . . . . . . . . . . . . . . . . . . . 7-117 Brush Tension . . . . . . . . . . . . . . . . . 7-105 Brushes . . . . . . . . . . . . . . . . . . . . . . 7-102 Cleaning . . . . . . . . . . . . . . . . . . . . . 7-102 Commutator . . . . . . . . . . . . . . . . . . 7-106 Drive . . . . . . . . . . . . . . . . . . . . . . . . 7-111 Hydraulic Steer . . . . . . . . . . . . . . . . 7-133 Lift . . . . . . . . . . . . . . . . . . . . . . . . . 7-114 Steer . . . . . . . . . . . . . . . . . . . . . . . . . 7-24 Tests . . . . . . . . . . . . . . . . . . . . . . . . 7-108 O

S Seals Axle . . . . . . . . . . . . . . . . . . . . . . . . . .7-49 Lift Ram . . . . . . . . . . . . . . . . . . . . . .7-156 Seat Pad . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19 Sensors Steer Position Proximity . . . . . . . . . .7-123 Solenoids . . . . . . . . . . . . . . . . . . . . . . . . 7-131 Speed Feedback Sensor Sensors Speed Feedback . . . . . . . . . . . . .7-122 Steer Compartment Cover . . . . . . . . . . . . . 7-18 Steer Contactor . . . . . . . . . . . . . . . . . . . . 7-84 Steer Motor . . . . . . . . . . . . . . . . . . . . . . . 7-24 Hydraulic . . . . . . . . . . . . . . . . . . . . .7-133 Steer Position Proximity Sensor . . . . . . . 7-123 Steer Pump . . . . . . . . . . . . . . . . . . . . . . 7-139 Steerable Tire . . . . . . . . . . . . . . . . . . . . . . 7-28 Steerable Wheel . . . . . . . . . . . . . . . . . . . . 7-28 Steerable Wheel Assembly . . . . . . . . . . . . 7-31 Switches Deadman . . . . . . . . . . . . . . . . . . . . . .7-43 EPO (Emergency Power Off) . . . . . . . .7-121 Key . . . . . . . . . . . . . . . . . . . . . . . . . .7-119 T

Oil Changing Hydraulic Fluid . . . . . . . . 7-126 Checking Hydraulic Fluid Level . . . . 7-126

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Ram Seals . . . . . . . . . . . . . . . . . . . . . . . . .7-156 Reservoir . . . . . . . . . . . . . . . . . . . . . . . . 7-137 Rollers, Battery . . . . . . . . . . . . . . . . . . . . . 7-93

Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . 7-142

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Component Procedures

Prime-Mover CRX30/35/40/50 Service Manual

List of Component Procedures Tire/Wheel Assemblies . . . . . . . . . . . . . . 7-27 Tires Assemblies . . . . . . . . . . . . . . . . . . . . 7-27 Drive . . . . . . . . . . . . . . . . . . . . . . . . . 7-27 Replacement . . . . . . . . . . . . . . . . . . . 7-30 Steerable . . . . . . . . . . . . . . . . . . . . . . 7-28 Traction Contactor . . . . . . . . . . . . . . . . . 7-84 Traction Power Amplifier . . . . . . . . . . . . . 7-99 Translator Card . . . . . . . . . . . . . . . . . . . 7-90 W Wheel/Tire Assemblies . . . . . . . . . . . . . . 7-27 Wheels Assemblies . . . . . . . . . . . . . . . . . . . . 7-27 Drive . . . . . . . . . . . . . . . . . . . . . . . . . 7-27 Steerable . . . . . . . . . . . . . . . . . . 7-28, 7-31 Wiring General . . . . . . . . . . . . . . . . . . . . . . . 7-97 Harness . . . . . . . . . . . . . . . . . . . . . . 7-98

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Prime-Mover CRX30/35/40/50 Service Manual

Component Procedures Component Locator Photos

7: Component Procedures

Component Locator Photos

Overhead Guard Mast

Load Backrest

Tilt Cylinder

Forks

Battery Gate

Drive Wheel

8D14017s.TIF

Figure 7-1:

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Tractor Components

7-5

Component Procedures

Prime-Mover CRX30/35/40/50 Service Manual

Component Locator Photos

Control Handle Operator Display

Steering Tiller

Deadman Pedal

Steerable Wheel 8d14086s.TIF

Figure 7-2:

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Tractor Components, Rear View

Prime-Mover CRX30/35/40/50 Service Manual

Component Procedures Component Locator Photos

Steering Tiller

Overhead Guard

Steer Motor Operator Display

Steer Pump

Auxiliary Pump/Motor

Horn

Hydraulic Filter

Tilt Cylinder

Brake

Drive Motor (Right)

Drive Motor (Left)

Drive Unit

Drive Tire

Lift Motor

Lift Pump 8d14086s.TIF

Figure 7-3:

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Tractor Compartments, Mast Removed

7-7

Component Procedures

Prime-Mover CRX30/35/40/50 Service Manual

Component Locator Photos

Main Hydraulic Manifold

Interface Card

EPO Switch

Steering Tiller

Key Switch

Lift/Lower Switch Assembly

Operator Display

Control Handle Assembly

Contactor Fuse Panel

8d14023s.TIF

Figure 7-4:

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Top Console (side view)

Prime-Mover CRX30/35/40/50 Service Manual

Component Procedures Component Locator Photos

Fuse FU8

Fuse FU6

Fuse FU10

Fuse FU7

Fuse FU5

Fuse FU9

Fuse FU3

Fuse FU1

Fuse FU2

Travel Contactor (TPC)

Lift Contactor (LPC)

Steer Contactor (STR)

Fuse FU4

Auxiliary Contactor (AUX)

8d14113sTIF

Figure 7-5:

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Contactor Fuse Panel

7-9

Component Procedures

Prime-Mover CRX30/35/40/50 Service Manual

Component Locator Photos

JC1

PC7

PC2

PC4

PC3

PC8

PC9

JC6

PC5

PC10

PC11

PC12

8d14121s.TIF

Figure 7-6:

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Interface Card and Connections

Prime-Mover CRX30/35/40/50 Service Manual

Component Procedures Component Locator Photos

JPX3 JPX1

Figure 7-7:

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JPX2

Translator Card Connections (Card Not Visible)

7-11

Component Procedures

Prime-Mover CRX30/35/40/50 Service Manual

Component Locator Photos

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Prime-Mover CRX30/35/40/50 Service Manual

Component Procedures Covers and Accessories

77: Component Procedures

Covers and Accessories

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Component Procedures

Prime-Mover CRX30/35/40/50 Service Manual

Covers and Accessories

Console Cover The console cover is located on top of the lift truck chassis. Removing it gives you access to the: • Contactor panel and current sensors • Control handle • Hydraulic manifold (top) • Hydraulic reservoir cap • Overhead guard attachment points • Steer valve • Interface Card • Translator Card

Removal To remove the console cover you’ll need a 4 mm Allen wrench:

Console Cover

1. Turn the key switch OFF and disconnect the battery connector. 2. Remove the seat pad. 3. Turn the steering tiller out of the way of the cover. 4. Remove the upper front cover by removing the two Allen head screws that attach it to the forward edge of the console cover. 5. Remove the Allen head screw located near the rear edge of the tractor frame. Store all screws in a safe area for later use. 6. Lift the console cover from the rear to a position that is approx. 45° angle to the top of the tractor frame. See Figure 7-8. 7. Carefully slide the cover up and over the control handle.

Installation 1. Turn the key switch OFF and disconnect the battery connector. 2. Fasten the upper front cover in place if it was previously removed. 3. Turn the steering tiller out of the way of the cover.

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8d14002S.TIF

Figure 7-8:

Console Cover

Prime-Mover CRX30/35/40/50 Service Manual

Component Procedures Covers and Accessories

4. Position the console cover in place by carefully guiding the control handle through the cutout portion of the console cover. 5. Make sure that the rear corner of the cover clears the rear of the tractor frame and correctly position the cover. 6. Loosely install the Allen head screw that secures the rear of the console cover. 7. Align the two screw holes in the rear edge of the upper front cover with the screw holes on the front of the console cover. 8. Loosely install the two Allen head screws that attach these two covers together and the two Allen head screws above the tilt cylinder. 9. Evenly tighten all Allen head screws that you installed in Steps 6 and 8. 10. Make sure the control handle moves freely.

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Component Procedures

Prime-Mover CRX30/35/40/50 Service Manual

Covers and Accessories

Front Covers There are four separate covers on the front of the truck. Removing these covers give you access to the: • Electric steer motor and pump • Brakes • Drive motors • Drive motor encoders • Drive units • Hydraulic filter • Hydraulic reservoir (for removal) • Lift motor and pump • Rear of the lift cylinders

8D14003S.TIF

Figure 7-9:

Front Side Cover

Removal Use the 4 mm Allen wrench: 1. Remove the upper front cover by removing the two Allen head screws that attach it. 2. Remove the two Allen head screws from the inner edge of either the right or left front cover. Remove the cover. Repeat this step for the other side. See Figure 7-9. 3. Remove the two Allen head screws that secure the side cover to the center front cover. Repeat this step for the other side. 4. Remove the two Allen head screws that secure the top of the center front cover to the frame. Then remove the two Allen head screws from the bottom of this cover. See Figure 7-10.

Center Front Cover Figure 7-10: Center Front Cover

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Prime-Mover CRX30/35/40/50 Service Manual

Component Procedures Covers and Accessories

Installation 1. Position the center front cover in place. Loosely install the two Allen head screws in the upper edge of this cover. Loosely install two Allen head screws in the lower end of this cover. Then evenly tighten all four Allen head screws. 2. Position the left front cover in place. Make sure that its rear edge is held in place by the retainer on the inner side of the truck’s chassis. 3. Loosely install the two Allen head screws on the inner edge of this cover. Then install the Allen head screw on the upper edge of this cover. Evenly tighten these screws. 4. Repeat steps 2 and 3 for the right cover. 5. Position the upper front cover in place. Attach with two Allen head screws.

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Component Procedures

Prime-Mover CRX30/35/40/50 Service Manual

Covers and Accessories

Steer Compartment Cover The steer compartment cover is located on the left side of the operator compartment. See Figure 7-11. Removing it gives you access to the: • Steer chain • Hydraulic steer motor • Bottom of the steer valve

Removal To open this cover, use a 4 mm Allen wrench:

Steer Compartment Cover

1. Remove the two bottom screws. 2. Remove the top screw. 3. Lift the cover off the bottom screws.

Installation 1. Put the cover in place and install the two bottom screws. 2. Install and tighten the top screw. 3. Tighten the two bottom screws. Figure 7-11: Steer Compartment Cover

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Component Procedures Covers and Accessories

Seat Pad The seat pad is attached to the right side of the operator compartment.

Removal 1. Loosen the two screws located below the seat pad which secure it in place. 2. Lift the seat pad straight up in the air and off the hanger which secures the top portion of the seat.

Installation 1. Slide the seat pad onto the metal hanger which is mounted on the right side of the operator’s compartment. 2. Guide the slots on the bottom of the seat pad under the two mounting screws. 3. Tighten mounting screws.

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Component Procedures Covers and Accessories

Overhead Guard Inspection Inspect the overhead guard before operating the lift truck. If the guard is damaged so that it will not protect the operator from falling objects, replace it. Inspect the overhead guard for: • Broken welds • Damaged, broken, missing, or bent struts or bars • Excessive corrosion • Loose fasteners

Removal ! CAUTION The overhead guard is heavy and awkward to handle. Use care when removing and installing it. 1. Position the lift truck so that the overhead guard is centered beneath a hoist or lift truck of suitable capacity. 2. Remove the console cover and front cover, See “Console Cover” on page 7-14 and “Front Covers” on page 7-16. 3. Fasten a hoist sling to the top of the overhead guard so that the guard will be supported and won’t swing when you remove the attachment bolts. 4. Take the slack out of the hoist chain. 5. Remove the four bolts that secure the front struts of the overhead guard to the frame. 6. Remove the two bolts that secure the rear strut of the overhead guard to the frame. 7. Using the hoist, lift the overhead guard off the frame. Guide it so that it doesn’t swing free and strike any persons or objects. 8. Slowly lower the overhead guard down to the ground.

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Prime-Mover CRX30/35/40/50 Service Manual

Component Procedures Covers and Accessories

Installation 1. Position the lift truck beneath the hoist or lift truck of suitable capacity. 2. Fasten the hoist sling to the top of the overhead guard so that the guard will be balanced when you lift it off the ground. 3. Using the hoist, raise and move the overhead guard into position over the frame of the lift truck. 4. Align the bolt holes in the flanges (on the bottom of the overhead guard struts) with the bolt holes in the lift truck frame. 5. Install all mounting bolts but do not tighten. Remove tension from the hoist. 6. Torque the mounting bolts to 75 ft. lb. (102 Nm). 7. Reinstall the console cover.

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Component Procedures

Prime-Mover CRX30/35/40/50 Service Manual

Covers and Accessories

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Component Procedures Steering and Controls

712: Component Procedures

Steering and Controls

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Component Procedures

Prime-Mover CRX30/35/40/50 Service Manual

Steering and Controls

Electric Steer Motor See “Motors, General” on page 7-102 for instructions on: • Cleaning the motor

Supply Hose

Steer Pump

Steer Pump Mounting Bolt (2)

• Testing the motor • Inspecting and changing the brushes

Location The steer motor is located in the center of the front of the truck, mounted to the frame, above the lift motor. See Figure 7-12.

Removal

Pressure Hose Steer Motor

1. Turn the key switch OFF and disconnect the battery connector. 2. Remove the front covers. See “Front Covers” on page 7-16.

Impeller Shroud

Power Cables (2) 8d14050s

Figure 7-12: Steer Pump and Motor

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Prime-Mover CRX30/35/40/50 Service Manual

Component Procedures Steering and Controls

3. Remove two steer pump mounting bolts and lift the pump off the motor. You may need to cut the tie wraps holding the drain hose to the supply hose. See Figure 7-13. 4. Remove power cables from the steer motor and label polarity if necessary. Use two wrenches to avoid twisting the terminal stud. See Figure 7-14. Coupling

5. Remove the two lower mounting bolts.

! CAUTION The steer motor is heavy. Use a suitable lifting device if necessary.

Steer Pump

6. While supporting the steer motor, remove the two top mounting bolts and remove the motor. 7. Remove the impeller shroud by removing three screws holding the impeller to the standoff studs. NOTE: Be careful not to break the blades when removing the impeller. 8. Remove the impeller by removing the center bolt holding the impeller to the motor shaft. 9. Remove the three standoff studs from the motor.

Electric Steer Motor 8d14063s

Figure 7-13: Remove the Steer Pump

10. Remove the coupling half from the motor.

Figure 7-14: Two Wrench Method

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Component Procedures

Prime-Mover CRX30/35/40/50 Service Manual

Steering and Controls

Installation 1. Using Loctite 242 (Blue), attach the three standoff studs to the motor.

Motor Cable Securing Nut Torque: 45-55 in. lb. (5.0-6.2 Nm)

2. Place the impeller over the motor shaft and secure with mounting bolt. 3. Attach the impeller shroud to the standoffs with three screws. Spin the impeller to verify it turns freely. 4. Attach the power cables to the motor, observing proper polarity. Use a second wrench on the stud terminal securing nut to avoid twisting the stud. Torque the motor cable securing nuts to 45-55 in. lb. (5.0-6.2 Nm). See Figure 7-15. 5. Install the motor, aligning the impeller shroud to the lift motor. Apply Loctite 242 (Blue), tighten, and torque the four motor mounting bolts. Reference “Torque Chart Standard (Ferrous)” on page A-4. 6. Attach the coupling half to the motor shaft. 7. Apply Loctite 242 (Blue) to the steer pump mounting bolts. 8. Attach the pump to the motor, mating the two halves of the coupling with the rubber coupling cushion in between. Tighten and torque the steer pump mounting bolts. See page A-4 in the Appendix. 9. Reconnect the battery connector and turn the key switch ON. Test the steering function. Check for leaks. 10. Attach the front covers. See “Front Covers” on page 7-16.

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Terminal Stud Torque: 45-55 in. lb. (5.0-6.2 Nm)

Motor Housing Flat Washer

Fiber Washer cablenut1.wmf

Figure 7-15: Correct Torque for Steer Motor Terminals

Prime-Mover CRX30/35/40/50 Service Manual

Component Procedures Steering and Controls

Wheel/Tire Assemblies Inspection Inspect the tire for: • Bond failure • Cracks • Excessive wear • Flat spots • Gouges Inspect the wheel for: • Cracks • Excessive corrosion • Excessive wear in the bolt holes (from loose mounting bolts) • Tightness of mounting bolts

Drive Wheel/Tire Removal 1. Slightly loosen all eight bolts that attach the wheel to the drive unit.

! WARNING Use extreme caution whenever the lift truck is jacked up. Never block the lift truck between the telescopic and the floor. Use a suitable hoist to stabilize the mast. Keep hands and feet clear from beneath vehicle while jacking the lift truck. After the lift truck is jacked up, place solid blocks or jack stands beneath it to support it. DO NOT rely on the jack alone to support the lift truck. See “Jacking Safety” on page 2-14.

110.tif

Figure 7-16: Removing the Drive Wheel/Tire Bolts

2. Jack the lift truck up so that the tire is raised off the ground. 3. Now remove all the eight bolts that you loosened in Step 1. Take the drive wheel/tire assembly off the lift truck.

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Component Procedures

Prime-Mover CRX30/35/40/50 Service Manual

Steering and Controls

Installation 1. Position the drive wheel/tire assembly next to the side of the drive unit. Align the holes. 2. Loosely install eight bolts that hold the drive wheel/tire assembly to the drive unit. 3. Tighten the eight bolts to 108 ft. lb. (151 Nm).

Steerable Wheel/Tire Removal 1. Turn the steerable wheel so that the axle nut is visible. 2. Turn the key switch OFF and disconnect the battery connector.

Axle Nut

dock43.tif

Figure 7-17: Remove Axle Nut

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Prime-Mover CRX30/35/40/50 Service Manual

Component Procedures Steering and Controls

5. Using a drift, dislodge then drive the axle approx. 0.5 in. (13 mm) toward the battery. See Figure 7-18. 6. Turn the steerable wheel so the opposite end of the axle is visible.

dock47.tif

Figure 7-18: Dislodge Axle

7. Remove the axle using a pry bar. Use a shim under the wheels to support the weight of the tires. This may help in removing the axle. See Figure 7-19. 8. With the axle removed, the wheels can be removed.

dock50.tif

Figure 7-19: Remove Axle

9. Remove, clean, and repack the wheel bearings. Add additional grease to the pivot spindle and hub so that when the unit is assembled, it will be 50-75% full of grease. NOTE: Anytime the wheels are removed, the axle bearings should be cleaned, inspected and repacked. Removing the bearings will require a new outer bearing seal. See Figure 7-20. Axle Seal

Bearing

Axle Seal

Bearing axleout.wmf

Figure 7-20: Axle Seals and Bearings

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Component Procedures

Prime-Mover CRX30/35/40/50 Service Manual

Steering and Controls

Tire Replacement 1. Press the old tire off the hub. 2. Press the new tire onto the hub. The hub must be flush with the tire within 1/16 in. (1.6 mm). NOTE: A minimum pressure of 5 tons (4545 kilograms) is required to press on the new tire. If the minimum pressure is not met, a new hub will be required.

Installation 1. Place the wheel assemblies under the lift truck and position them in the steer pivot. 2. Insert the axle through the steer pivot, through each wheel, and out the other side of the steer pivot. See Figure 7-21. NOTE: When you insert the axle, be careful not to damage the bearing seals. 3. Install the axle nut. Tighten the axle nut until the wheels start to bind when you turn them by hand. Then turn the axle nut 1/4 turn counterclockwise. 4. Lower the lift truck to the floor. 5. Replace any covers removed.

Wheel Assembly

Steer Pivot

axleout.wmf

Figure 7-21: Install Wheel Assemblies

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Component Procedures Steering and Controls

Steerable Wheel Assembly Removal 1. Turn the key switch OFF and disconnect the battery connector. 2. Remove the Steer Compartment Cover. See “Steer Compartment Cover” on page 7-18. 3. Take the steer chain off the steer plate by removing the nut on the threaded end of the chain anchor. See Figure 7-22. 4. Disengage the steer chain from the steer motor assembly. You can leave the chain attached to the other side of the steer plate.

Steer Chain Nut

030.tif

Figure 7-22: Steer Chain Nut

5. Remove the steer position proximity sensor bracket. See Figure 7-23.

Steer Prox Switch Bracket 137.tif

Figure 7-23: Steer Prox Switch Bracket

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Component Procedures

Prime-Mover CRX30/35/40/50 Service Manual

Steering and Controls 6. Remove the steer sensing ring from the top of the steer plate. See Figure 7-24. 7. Scribe a mark from the top of the steer hub onto the steer plate (so you can reinstall the steer plate in the proper position).

Steer Sensor Ring

138.tif

Figure 7-24: Steer Sensor Ring

8. Remove the bolts that hold the steer plate in place. Take the steer plate off. 9. Remove the six mounting bolts holding the steerable wheel assembly to the truck frame. See Figure 7-25. 10. Place chocks in front of the drive wheels.

Mounting Bolts

dock67.tif

Figure 7-25: Mounting Bolts

11. Reinstall one of the steer plate bolts. Wrap a piece of heavy wire around this screw. This will be used as a temporary support. You will use this temporary support to lower the steer assembly to the floor when the truck is jacked up. 12. Jack the rear of the truck up. As the truck is jacked up, the steerable wheel assembly will separate from the tractor frame.

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Prime-Mover CRX30/35/40/50 Service Manual

Component Procedures Steering and Controls

13. Continue to jack the truck up until the upper hub on the steerable wheel is flush with the tractor frame. Block the truck in this position. See Figure 7-26.

Temporary Wire Support

! CAUTION Steerable Wheel Assembly is heavy. Use a suitable lifting device if necessary. 14. While holding the wire, slowly move the steerable wheel assembly out from under the truck. As the wheels come out, lower the casting to the floor. Move the steerable wheel assembly down and out from beneath the truck.

Hub flush with tractor frame. dock65.tif

Figure 7-26: Steerable Wheel Removal

Disassembly 1. Remove the nut that holds the upper steer hub to the steer pivot. See Figure 7-27. 2. Use a 3-arm puller to remove the upper steer hub. 3. Pull the steer pivot out of the pivot hub. 4. Clean the inside of the pivot hub. 5. Clean and inspect the bearings. Replace any bad components. 6. Remove, clean, and inspect the key. Clean and inspect the keyway.

Wheel Assembly

Steer Pivot

strwhl.tif

Figure 7-27: Steerable Wheel Assembly

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Component Procedures

Prime-Mover CRX30/35/40/50 Service Manual

Steering and Controls

Assembly 1. Pack the bearings with grease. See the Appendix for lubrication specifications. Add additional grease to the pivot spindle and hub so that when the unit is assembled, it will be 50-75% full of grease. 2. Slide the steer pivot into the pivot hub. 3. Coat key and keyway using Loctite 242 (Blue) compound. 4. Install upper steer hub. 5. Install nut. Tighten nut while rotating the pivot hub that mounts to the tractor frame. Continue to tighten nut until the pivot hub just starts to resist rotation.

Installation 1. Position the steerable wheel assembly into the tractor frame. While holding the steer wheel assembly upright, lower the tractor down until it is near the mounting flange on the steer. Remove the wire from the steer plate bolt, then remove the bolt. See Figure 7-28.

Nut Key Bearing

Upper Steer Hub Pivot Hub Steer Pivot

2. Apply Loctite 242 (Blue) to the six mounting bolts.

dock64.tif

Figure 7-28: Steerable Wheel Installation

3. Install the mounting bolts and torque to 55 ft. lb. (77 Nm). See Figure 7-29. 4. Install the steer plate. Align the scribe marks made during disassembly between the hub and the steer plate. Install the four mounting bolts and tighten.

Steer Sensing Ring

5. Install the steer sensing ring on top of the steer plate. See Figure 7-29.

Mounting Bolts dock67.tif

Figure 7-29: Mounting Bolts and Steer Sensing Ring

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Component Procedures Steering and Controls

6. Install the steer position proximity sensor bracket. See Figure 7-30. For information on adjusting the steer position proximity sensor, refer to page 7-123. 7. Install the steer chain. See Figure 7-30. 8. Turn the steerable wheel assembly from stop to stop to find the tight point in the chain tension. 9. With the chain at its maximum tension position, adjust the steer chain tensioner so that the chain deflects approx. 1/8 in. (1.6 mm) at midpoint. 10. Reconnect the battery connector and turn the key switch ON. Run Test I08 on Page 6-100. This will verify that the steer position proximity sensor is adjusted properly.

Steer Chain Steer Chain Nut

Steer Prox Sensor Bracket 030.tif

Figure 7-30: Steer Chain Nut

11. Turn the key switch OFF and disconnect the battery connector. 12. Remove any blocks that might still be supporting the truck. Lower the truck to the floor. 13. Install the utility cover. 14. Reconnect the battery connector and turn the key switch ON. Test the steering function.

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Component Procedures

Prime-Mover CRX30/35/40/50 Service Manual

Steering and Controls

Operator Display NOTE: The Operator Display Card must be pre-programmed and ordered through your Prime-Mover Dealer.

Operator Display

Removal 1. Turn the key switch OFF and disconnect the battery connector. 2. Remove the console cover. See “Console Cover” on page 7-14.

! CAUTION

8d14121s

Figure 7-31: Operator Display

Observe proper ESD precautions. See “Static Precautions” on page 2-12. 3. Disconnect JPD1 from the operator display. 4. Scribe the mounting position of the operator display mounting bracket on the tractor frame.

JPD2

5. Remove the two 10 mm mounting bolts that secure the operator display bracket to the tractor frame.

JPD3

6. Remove six Allen screws holding the operator display card to the standoffs. See Figure 7-32. 7. Disconnect the operator display flat cables at connectors JPD2 and JPD3.

Replacement 1. Connect flat cables JPD2 and JPD3 to the Operator Display Card. 2. Install the Operator Display Card to the standoffs with six Allen screws. Do not overtighten. 3. Align the operator display mounting bracket with the scribe marks and install the two 10 mm mounting bolts. 4. Connect JPD1 from the Interface Card. 5. Install the console cover. See “Console Cover” on page 7-14.

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Standoffs 8d14089s

Figure 7-32: Operator Display Card

Prime-Mover CRX30/35/40/50 Service Manual

Component Procedures Steering and Controls

Control Handle The control handle assembly is located in the middle-left of the operator console, to the right of the steering wheel. See Figure 7-33.

Lift/Lower Linkage The lift/lower linkage connects the control handle to the main hydraulic manifold. This linkage may be disconnected from the control handle prior to removal.

Control Handle 8D14092S.TIF

Figure 7-33: Control Handle Location

Disassembly 1. Turn the key switch OFF and disconnect the battery.

Adjustment Bolt

Hydraulic Linkage Fulcrum Lever

2. Disconnect lift/lower switches S13 and S14 from the linkage bracket. See Figure 7-34. 3. Scribe the Linkage mounting plate for positioning reference. 4. Remove the 10 mm adjustment bolt connecting the linkage fulcrum lever to the control handle. See Figure 7-34. 5. Remove the main Allen bolt that secures the assembly.

S13 and S14 Figure 7-34: Lift/Lower Hydraulic Linkage

6. Carefully use a screw driver to remove the lock clip on the linkage.

Assembly 1. Carefully replace the lock clip on the linkage. 2. Use the scribe mark to position the linkage on the tractor frame. 3. Install the main Allen bolt in the assembly. 4. Install the 10 mm adjustment bolt that secures the connection between the lift linkage assembly and the control handle. 5. Reconnect lift/lower switches S13 and S14. 6. Test lift and lower functions. Use the adjustment bolt if necessary.

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Component Procedures Steering and Controls

Linkage Adjustment After repairs or through normal wear, the lift/lower control handle linkage may require adjustment. If the correct adjustments are not followed, excessive force, exceeding design specifications, can be applied to the base of the handle halves, linkage, and components, causing premature component failure. Use the following procedure to adjust the linkage: 1. Turn the key switch OFF and disconnect the battery. 2. Remove the top cover. 3. Disconnect the threaded rod from its pivot point on the valve lever end. 4. Scribe a mark noting the position of the switch bracket. 5. Loosen the switch bracket mounting screw. 6. Remove the chain link from the spool valve and tighten the small connecting block onto the spool valve using Loctite 242 (Blue). Clean any loctite from the spool. 7. Rotate the spool valve as required and reinstall the chain link between the valve lever and the spool. 8. Position the control handle so you can insert a 9/64 in. long shanked Allen wrench into the alignment hole in the control handle base. Push it through the handle halves and through the hole in the opposite side of the housing. This will provide positive centering. NOTE: It is extremely important that the handle remain centered during the adjustment of the linkage and switches. 9. Loosen the nut at the joint on the threaded rod, hold the rod and adjust the pivot joint on the threaded rod until the joint hole fits precisely over the valve lever hole without moving any linkage components. 10. Bolt the pivot joint back to the valve lever. Do not overtighten as damage to the threaded insert will occur. 11. Tighten the joint lock nut to 15 ft. lb. (20 Nm) after the adjustment process. 12. Remove the Allen key from the handle centering hole.

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Component Procedures Steering and Controls

13. Apply Loctite 242 (Blue) to the switch bracket screw threads. Position the screw in the center of the switch bracket mounting slot and tighten carefully. 14. Adjust the lift and lower switches individually to obtain the following settings: •

The lift switch should just contact the cam so that handle movement in the “lift” direction will activate the lift motor just prior to lift carriage movement. This will allow for precise fork lifting.

•

The lower switch should just contact the cam so that handle movement in the “lower” direction will activate the load holding solenoid just prior to lift carriage descent. This will allow for precise fork lowering.

15. Test the action of the linkage and readjust as necessary. NOTE: To prevent component damage, full lift or lower movement of the lever should result in the handle stopping on the handle housing and not at the end of the lift/lower spool travel.

Valve Lever

Rod End Threaded Rod

Lower Switch

Lift Switch

Manifold (Handle Side)

Switch Bracket (Top View)

Switch Bracket (Bottom View)

Chain Link Allen Wrench

Rod End

Figure 7-35: Control Handle and Linkage

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Component Procedures

Prime-Mover CRX30/35/40/50 Service Manual

Steering and Controls

Control Handle Assembly Removal 1. Turn the key switch OFF and disconnect the battery connector.

Allen Head Screws (4)

2. Remove the console cover. See “Console Cover” on page 7-14.

! CAUTION This assembly contains ESD sensitive devices. Wear a properly grounded ESD wrist strap. Observe proper ESD precautions. See “Static Precautions” on page 2-12.

JPH3 Figure 7-36: Control Handle Removal

3. Unplug the control handle wiring harness JPH3. See Figure 7-36. 4. Remove the four Allen head screws that secure the control handle assembly to its support bracket. See Figure 7-36. 5. Lift the control handle assembly off the tractor frame. If the handle needs to be completely removed, go to the next step. See Figure 7-37. 6. Disconnect the adjustment linkage between the control handle and the hydraulic linkage fulcrum lever by removing the 13 mm nut from the ball socket end.

Disassembly VR1 Replacement 1. Loosen retaining screw securing the actuating arm on the VR1 pot shaft. Remove arm. 2. Remove hardware securing VR1 to handle base. 3. Carefully remove the heat shrink tubing from the VR1 terminals. Identify the wires so they can be installed in the same location on the new pot. 4. Carefully unsolder the harness wires. 5. Slide 3/8 in. (9.5 mm) long shrink sleeving over previously sleeved wires.

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Figure 7-37: Control Handle Partially Removed

Prime-Mover CRX30/35/40/50 Service Manual

Component Procedures Steering and Controls

! CAUTION This assembly contains ESD sensitive devices. Wear a properly grounded ESD wrist strap. Observe proper ESD precautions. See “Static Precautions” on page 2-12. 6. Solder the harness wires to the correct terminals on the new pot. 7. Shrink sleeving as necessary. 8. Install new pot in handle base. 9. Install actuating arm on new VR1 pot shaft. Switch Replacement 1. Remove shoulder bolt securing handle in yoke and remove handle from handle base cap. 2. Remove retaining ring securing the umbrella to the control handle. 3. Remove the five screws holding the two halves of the handle together. See Figure 7-38. 4. Carefully remove the heat shrink tubing from the terminals of the bad switch. Identify the wires so they can be installed in the correct location on the new switch. 5. Carefully unsolder wires from the bad switch.

chandle.wmf

Figure 7-38: Control Handle Disassembled

6. Slide 3/8 in. (9.5 mm) long shrink sleeving over previously sleeved wires. 7. Solder the harness wires to the correct terminals on the new switch. 8. Shrink sleeving as necessary. 9. Install new switch in control handle. 10. Reconnect the two halves of the control handle. 11. Install handle into handle base.

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Component Procedures Steering and Controls

Installation 1. Align the control handle assembly mounting screws on the tractor frame. 2. Reconnect the adjustment nut which connects the control handle to the hydraulic linkage. 3. Tighten the four Allen screws to the tractor frame. 4. Connect control handle wiring harness JPH3. 5. Secure the control handle wiring harness in place with tie-straps. Make sure the cable extends out of the handle as straight as possible to avoid kinking. 6. Reconnect the battery connector and turn the key switch ON. Run Learn controls. 7. Test operation of control handle. 8. Reinstall the console cover. See “Console Cover” on page 7-14.

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Component Procedures Steering and Controls

Deadman Pedal The deadman pedal is located on the left side of the operator compartment floor. See Figure 7-39.

Deadman Mounting

Removal of Deadman Switch 1. Turn the key switch OFF and disconnect the battery connector. 2. Remove the two 13 mm bolts that hold the deadman pedal bracket to the side of the compartment. 8d14022s.tif

Figure 7-39: Deadman Pedal Mounting

Deadman Mounting Bolts

Deadman Switch 8D14094S.TIF

Figure 7-40: Deadman Pedal Assembly

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Steering and Controls

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Prime-Mover CRX30/35/40/50 Service Manual

Component Procedures Drive and Brake

7: Component Procedures

Drive and Brake

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Component Procedures

Prime-Mover CRX30/35/40/50 Service Manual

Drive and Brake

Drive Unit

Drive Motor

Brake

The drive units are located at the forward corners of the tractor end of the lift truck. You can access them by removing the top forward cover, the right forward cover, and the left forward cover.

Drive Wheel/Tire

A drive motor is bolted to the top of each of the drive units. A drive tire is mounted to the lower outside face of each drive unit. The rear of the drive unit is bolted to the inner side of the lift truck frame. The forward end of the drive unit provides support for the mast.

Lubrication See “Lubrication Equivalency Chart” on page A-2.

Drive Units 8D14080S.TIF

Checking the Drive Unit Oil Level

Figure 7-41: Drive Unit Location (mast removed for clarity)

1. Park the lift truck on a level floor. 2. Turn the key switch OFF and disconnect the battery connector. 3. Remove the oil level check screw from the inner side of the drive unit casting, beneath the mounting flange for the traction motors. 4. The oil level should be even with the bottom of this screw hole.

Adding Oil to a Drive Unit 1. Remove the oil level check screw by following the instructions in “Checking the Drive Unit Oil Level.”

Vent Screw Check Screw Fill Screw

2. Remove the fill screw. See Figure 7-42. 3. Remove the vent screw. 4. Determine the correct type of gear lubricant (or oil for cold storage lift trucks) by using the chart on page A-2. NOTE: The drive motor must be installed before filling the drive unit with oil. 5. Slowly pour the lubricant in the fill hole. Watch the oil check screw hole. When the lubricant is level with the bottom of the screw hole, stop pouring. 6. Reinstall the oil level check screw, fill screw, and vent screw.

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108.TIF

Figure 7-42: Drive Unit Oil Screws

Prime-Mover CRX30/35/40/50 Service Manual

Component Procedures Drive and Brake

Drive Unit Replacement NOTE: The drive unit is heavy. Get an assistant to help you when you remove and install it.

Removal 1. Turn the key switch OFF and disconnect the battery connector. 2. Remove the mast from the lift truck. See “Mast” on page 7-148. 3. Drain all the lubricant out of the drive unit you will be removing. Use a drain pan that is approx. 1.5 gallons (5.7 liters). 4. Remove the brake assembly. See “Brake Assembly” on page 7-78. 5. Remove the drive motor. See “Drive Motor” on page 7-111. 6. Loosen but do not remove the eight bolts that secure the wheel and tire assembly to the drive unit.

8D14044S.TIF

Figure 7-43: Drive Wheel Removal

7. Jack up the side of the lift truck from which you’ll be removing the drive unit. Place blocks beneath the lift truck to support it. See Figure 7-43. 8. Remove the eight bolts that secure the wheel and tire assembly to the drive unit. Remove the wheel and tire assembly from the drive unit.

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Component Procedures

Prime-Mover CRX30/35/40/50 Service Manual

Drive and Brake

! CAUTION Drive unit weighs approx. 175 lb. (79 kg). Use a suitable lifting device if necessary. 9. Remove the six bolts securing the drive unit to the lift truck frame. See Figure 7-44. NOTE: It is recommended that you use some type of lifting device to lift and support the drive unit. See Figure 7-45. 8D14072.TIF

Figure 7-44: Drive Unit Mounting Bolts (6)

Installation 1. Make sure the drain plug is installed in the drive unit. 2. If the locating pins need to be installed, apply Loctite 242 (Blue) to the two pins. Install the locating pins into the drive unit casting.

Install a lifting hook eye into one of the drive motor mounting holes.

3. Position the drive unit in place. Align the bolt holes in its mounting flange with the bolt holes in the tractor frame. 4. Install the six bolts that hold the drive unit to the tractor frame and torque them to 120 ft. lb. (168 Nm). du-pins.wmf

5. Install the drive wheel and tire assembly on the drive unit. Install the wheel mounting bolts. 6. Lower the lift truck to the floor. Torque the wheel mounting bolts to 108 ft. lb. (151.2 Nm). 7. Reinstall the drive motor. See “Drive Motor” on page 7-111. 8. Reinstall the brake assembly. See “Brake Assembly” on page 7-78. Be sure to remove the brake release bolts from the brakes. 9. Refill the drive unit with gear oil until the fluid is even with the bottom of the fluid check hole located on the side of the drive unit. 10. Install the mast. See “Mast” on page 7-148.

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Figure 7-45: Installing the Drive Unit

Prime-Mover CRX30/35/40/50 Service Manual

Component Procedures Drive and Brake

Axle Seal Replacement If the axle is removed for any reason, replace the axle oil seal.

Removal 1. Turn the key switch OFF and disconnect the battery connector. 2. Remove the mast from the lift truck. See “Mast” on page 7-148. 3. Loosen, but do not remove, the screws holding the drive tire to the axle shaft.

dso1.tif

Figure 7-46: Draining Fluid from Drive Unit

4. Jack the drive tire off the floor. See page 2-14. 5. Place a suitable container under the drive unit. Remove the drain plug. Allow the fluid to drain from the drive unit. See Figure 7-46. 6. Remove the drive tire. 7. Remove the drive unit cover by removing the screws that secure it. Break the adhesive bond and remove the cover plate. See Figure 7-47.

dso4.tif

Figure 7-47: Cover Plate Removal

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Component Procedures

Prime-Mover CRX30/35/40/50 Service Manual

Drive and Brake 8. Loosen the clamp nut locking screw. See Figure 7-48. 9. Use a spanner tool to remove the clamp nut from axle. See Figure 7-49. 10. Support the spiral bevel gear and drive the axle out of the drive unit housing enough to allow you to remove the spiral bevel gear. See Figure 7-50. 11. Remove the axle from the drive unit housing using a rubber mallet if necessary. Be sure not to damage the gear surfaces. NOTE: The brake and drive motor can be removed as one assembly if the weight of the combined assembly does not pose a hazard.

ds08.tif

Figure 7-48: Loosen Clamp Nut Locking Screw

12. Remove the brake. Refer to page 7-76. 13. Remove the drive motor. Refer to page 7-111.

Spanner Tool

14. Use a bearing puller to carefully remove the bearing cone from the axle. See Figure 7-51. NOTE: Observe the orientation of the axle seal on the axle shaft before removing it.

ds12.tif

Figure 7-49: Remove Clamp Nut

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Component Procedures Drive and Brake

ds19.tif

Figure 7-50: Spiral Bevel Gear Removal

Bearing Puller

ds21.tif

Figure 7-51: Bearing Cone Removal

15. Remove the axle seal from the axle shaft. 16. Clean and inspect all components. See Figure 7-52.

Axle Shaft

Bearing Cone Axle Seal

ds23.tif

Figure 7-52: Axle Shaft, Bearing Cone, and Axle Seal

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Component Procedures

Prime-Mover CRX30/35/40/50 Service Manual

Drive and Brake

Installation 1. Lubricate the lip of the new seal and place new axle seal onto the axle shaft. This can be done by hand. Make sure that the seal is oriented properly. 2. Carefully place bearing cone onto axle. Press the bearing onto the axle shaft. Press the bearing cone until it is properly seated. 3. Place axle assembly into housing. Mate axle with the spiral bevel gear. See Figure 7-53. 4. Install the clamp nut on the axle shaft and hand tighten. See Figure 7-54. ds19.tif

5. Place a seal pressing tool (P/N 313666-460) between the axle seal and tire mounting flange on the axle shaft. 6. Tighten the clamp nut; this will draw the axle shaft inward. The axle seal will be pressed into the housing. The seal must be flush with the drive unit housing.

Figure 7-53: Spiral Bevel Gear

Clamp Nut

7. Loosen the clamp nut. 8. Drive the axle shaft out of the drive unit housing just enough to allow removal of the pressing tool. Remove pressing tool. See Figure 7-55. 9. Tighten the clamp nut to draw the unit until the bearing cone and bearing cup make contact. ds15.tif

10. Remove the clamp nut.

Figure 7-54: Install Clamp Nut

11. Apply thread-locking compound to the clamp nut threads. 12. Apply thread-locking compound to the threads of the screw in the clamp nut. 13. Install the clamp nut on the axle shaft and hand tighten. 14. Turn the axle several revolutions by hand (in both directions). This seats the bearings in the bearing cones. 15. Torque the clamp nut to 125 ft. lb. (170 Nm). This process establishes the proper preload on the bearings.

ds29.tif

Figure 7-55: Install Seal Pressing Tool Halves

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Component Procedures Drive and Brake

16. Torque the screw in the clamp nut using Loctite 272 to 70 in. lb. (8 Nm). See Figure 7-56. 17. There should be no axle end play. The axle shaft should rotate smoothly. 18. Clean cover plate and mating surface on the drive unit. Apply adhesive (P/N 313666-461) to sealing surface. 19. Install cover. Torque all screws equally to 6 ft. lb. (8.6 Nm). 20. Install the drain plug. 21. Install the drive motor. See “Drive Motor” on page 7-111. 22. Fill the drive unit with the proper lubricant. See page A-2 for the “Lubrication Equivalency Chart”.

ds10.tif

Figure 7-56: Torque Clamp Nut Screw

NOTE: The drive motor must be installed before filling the drive unit with oil. 23. Install the brake. See “Brake Assembly” on page 7-78. 24. Install the drive tire. Torque the wheel mounting screws to 108 ft. lb. (151.2 Nm). 25. Lower the lift truck to the floor. 26. Install the mast. See “Mast” on page 7-148.

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Component Procedures

Prime-Mover CRX30/35/40/50 Service Manual

Drive and Brake

Drive Unit Rebuild NOTE: Excessive damage, wear, or cracks in the housing indicate that the drive unit must be replaced.

Necessary Tools The following tools are required to rebuild the drive unit. Make sure that any maintenance performed does not void warranty. Bearing puller

Screwdriver

Allen wrench (5/16 in., 1/4 in., 5 mm)

Bearing press

Magnetic dial indicator

Putty knife (1 in. wide)

Micrometer

Pry bars

Tube (6 in. dia. x 6 in. long)

Hammer or mallet

Tube (8 in. dia. x 6 in. long)

Brass punch

3/8 drive sockets (10 and 13 mm)

Pinion gauge

3/8 ratchet

Bearing heater

3/8 wrench

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Torque wrench, 150 ft. lb. (210 Nm) capacity

Prime-Mover CRX30/35/40/50 Service Manual

Component Procedures Drive and Brake

Drive Unit Parts Breakdown Legend: 1. Housing 2. Bearing Cup and Cone Set 3. Helical Gear and Pinion Set 4. Spiral Pinion and Bevel Gear Set 5. Oil Seal 6. Axle Shaft 7. Bearing Cup and Cone Set 8. Bearing Cup and Cone Set 9. Bearing Cup and Cone Set 10. Thrust Washer 11. Shim 12. Spacer 13. Clamp Nut 14. Clamp Nut 15. HHCS M10 16. Main Cover 17. Drain Plug 18. Filler Plug (Not Shown)

13 10

4 10 11 4

12 7 9

1 14

8 5

P31151.cgm

Figure 7-57: Drive Unit P/N’s 313666-177 and 313666-203 Exploded View

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Component Procedures

Prime-Mover CRX30/35/40/50 Service Manual

Drive and Brake

Troubleshooting Symptom

Probable Cause

Required Action

Available Kits

Oil leaks

Damaged lip seal

Replace lip seal, main cover & bearing shims, output shaft bearings

Kit #1, Seal Kit.

Worn or damaged axle shaft

Replace lip seal, main cover & bearing shims, output shaft bearings, and output shaft

Kit #2, Axle Shaft Kit.

Plugged vent

Unclog vent and clean motor

Overfilled

Drain some oil and clean motor

Motor to housing flange Reseal joint or main cover joint

Drive wheel wobbles

Noise

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Worn or damaged housing

Replace drive unit

Worn or damaged axle shaft bearings

Replace lip seal, main cover & bearing shims, output shaft bearings

Kit #1, Seal Kit.

Worn or damaged axle shaft

Replace lip seal, main cover & bearing shims, output shaft bearings, and output shaft

Kit #2, Axle Shaft Kit.

Loose wheel mounting hardware

Inspect housing and main cover for damage. Re-torque mounting hardware

Worn or damaged axle shaft bearings

Replace lip seal, main cover & bearing shims, output shaft bearings

Worn or damaged pinion bearings

Replace pinion bearings & clamp nut

Worn or damaged gear set - axle shaft is in good condition

Replace lip seal, main cover & bearing shims, output shaft bearings, pinion bearings, gear set, and clamp nut

Kit #1, Seal Kit. Kit #3, Drive Gear Kit.

Worn or damaged gear set - axle shaft is worn or damaged

Replace lip seal, main cover & bearing shims, output shaft bearings, pinion bearings, gear set, clamp nut, and output shaft

Kit #2, Axle Shaft Kit. Kit #3, Drive Gear Kit.

Worn or damaged helical gear and pinion

Replace helical gear and pinion

Kit #1, Seal Kit.

Prime-Mover CRX30/35/40/50 Service Manual

Component Procedures Drive and Brake

Kit Options There are three repair kits available for these drive units. Contact your local, authorized Prime-Mover Dealer.

! CAUTION To ensure a high quality product, we strongly recommend replacing all components in a kit. For ease of ordering, suggested kit contents and part numbers are listed below. Kit #1, Seal Kit. P/N 313666-462 • Oil Seal • Bearing Cup and Cone • Clamp Nut • Plugs • Cover Screws Kit #2, Axle Shaft Kit. P/N 313666-463 • Oil Seal • Bearing Cup and Cone • Axle Shaft • Clamp Nut • Plugs • Cover Screws Kit #3, Drive Gear Kit. P/N 313666-464 • Bevel Gear and Pinion Set • Helical Gear and Pinion Set • Clamp Nut • Bearing Cup and Cone • Bearings • Shims • Spacer • Thrust Washers

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Component Procedures

Prime-Mover CRX30/35/40/50 Service Manual

Drive and Brake

Disassembly Procedures All item numbers refer to the exploded view (refer to Figure 7-57 on page 7-55). Clean the outside of the drive unit thoroughly and drain any remaining oil from the drive unit. Visually inspect the outside of the housing (Item 1) for damage, wear or cracks. Pay particular attention to the area where hub wear may be evident, the mast pivot area, motor area, and around all bolts.

1826_006.tif

Figure 7-58: Inspect Housing for Hub Wear

Inspection Cover Removal 1. Remove the drain plug (Item 17) using a 5/16 in. Allen wrench.

2610_067.tif

Figure 7-59: Remove Drain Plug

2. Remove the fill level plug using a 1/4 in. Allen wrench.

2610_068.tif

Figure 7-60: Remove Fill Level Plug

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Component Procedures Drive and Brake

3. Remove the ten 10 mm screws (Item 15) from the inspection cover.

2610_069.tif

Figure 7-61: Remove Cover Screws

4. Pry the cover (Item 16) or tap with a mallet to loosen the cover’s seal to the housing. 5. Remove the cover from the housing. 6. Inspect the inside of the cover for damage or wear.

2610_071.tif

Figure 7-62: Remove Cover from Housing

Axle Shaft and Bevel Gear Removal 1. Remove the set screw locking the clamp nut (Item 13) using a 5 mm Allen socket or Allen wrench. 2. Remove the clamp nut. 3. Remove the thrust washer (Item 10). 4. Lift the bevel gear from the housing. 5. Remove the thrust washer, shim, and spacer (Items 10, 11, and 12). 6. Drive the axle from the housing using a rubber mallet.

1826_027.tif

Figure 7-63: Loosen Clamp Nut Set Screw

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Prime-Mover CRX30/35/40/50 Service Manual

Drive and Brake

Spiral Gear and Helical Gear Removal 1. Remove the set screw locking the clamp nut (Item 14) using a 5 mm Allen wrench.

2610_077.tif

Figure 7-64: Remove Clamp Nut Set Screw

2. Place a screwdriver in the clamp nut slot to turn the clamp nut off. (The gear may need to be wedged to keep it from turning.) Inspect the clamp nut for damage.

2610_078.tif

Figure 7-65: Remove Clamp Nut

3. Drive the spiral gear (Item 4) from the housing using a rubber mallet. NOTE: Save the shims for reference at reassembly.

2610_079.tif

Figure 7-66: Remove Spiral Pinion

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Component Procedures Drive and Brake

4. Lift the helical gear (Item 3), spacer and bearing (Item 2) from the housing. 5. Inspect the helical gear and the spiral gear for damage or wear. NOTE: The bevel gear and spiral gear are a matched set. Their alignment is critical. Do not replace them separately.

2610_080.tif

Figure 7-67: Lift Helical Gear from Housing

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Prime-Mover CRX30/35/40/50 Service Manual

Drive and Brake

Bearing Cup and Shim Removal NOTE: The bearing cups and cones are usually damaged during removal. They must be replaced as sets, and are included in replacement kit #3. 1. Drive the spiral gear bearing cup (Item 7) from the housing using a mallet and a long punch. Take care not to damage the shims. Save the shims for reference in reassembly.

2610_081.tif

Figure 7-68: Remove Spiral Gear Bearing Cup

2. Drive the helical gear bearing cup (Item 2) from the housing using a mallet and a punch.

2610_082.tif

Figure 7-69: Remove Helical Gear Bearing Cup

3. Remove the outer bearing cup (Item 8) (toward the axle) from the housing using the punch and mallet.

2610_075.tif

Figure 7-70: Remove Axle Shaft Bearing Cups

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Component Procedures Drive and Brake

4. Drive the inner bearing cup (Item 9) (toward the bevel gear) from the housing using a mallet and a punch. Take care not to damage the shims. Save the shims for reference in reassembly. 5. Inspect the housing bores and sealing surfaces for damage or wear.

Housing Cleaning and Inspection Thoroughly degrease the housing. Visually inspect the entire housing again for excessive damage, cracks or wear.

2610_076.tif

Figure 7-71: Remove Bevel Gear Bearing Cup

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Prime-Mover CRX30/35/40/50 Service Manual

Drive and Brake

Axle Shaft Disassembly

! CAUTION Always watch for pinch points when using a press or pressing tools. 1. Place a bearing puller clamp between the axle seal (Item 5) and the axle bearing cone (Item 8). 2. Press the bearing from the axle using a bearing press and a 6 in. tube.

2610_084.tif

Figure 7-72: Press Bearing from Axle

3. Lift the axle seal from the axle.

1826_034.tif

Figure 7-73: Lift Seal from Axle

4. Inspect the axle for damage or wear.

1826_035.tif

Figure 7-74: Inspect Axle for Wear

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Component Procedures Drive and Brake

Spiral Gear Disassembly

! CAUTION Always watch for pinch points when using a press or pressing tools. 1. Place a bearing puller clamp beneath the bearing cone (Item 7) on the spiral gear.

2610_087.tif

Figure 7-75: Place Puller Clamp on Spiral Gear

2. Press the bearing from the spiral gear using a bearing press.

2610_086.tif

Figure 7-76: Press Bearing from Spiral Gear

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Prime-Mover CRX30/35/40/50 Service Manual

Drive and Brake

Assembly Procedures

! CAUTION Safety glasses are required. Prepare the housing for assembly by running a tap through all bolt and screw holes. Gear Set Assembly

! CAUTION Always watch for pinch points when using a press or pressing tools. Place the bearing cone (Item 7) on the spiral gear shaft. Press until it is fully seated. 4

2610_088.tif

Figure 7-77: Press Bearing onto Spiral Gear

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Component Procedures Drive and Brake

Housing Bearing Cup and Shim Assembly 1. Place the spiral gear shims (0.015 in. [0.38 mm] thickness) in the housing, then place the bearing cup (Item 7) in the housing. Press until fully seated.

2610_092.tif

Figure 7-78: Install Spiral Gear Bearing Cup

2. Turn the drive unit housing over. Install the helical bearing cup (Item 2) in the housing. Use a press or mallet to seat the bearing cup in the housing.

2610_093.tif

Figure 7-79: Install Helical Bearing Cup

3. Install the bearing cone in the housing bore without shims. NOTE: Be sure to wipe away any chips or excess metal pieces resulting from driving the race to seat it.

2610_095.tif

Figure 7-80: Install Bevel Gear Bearing Cup

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Prime-Mover CRX30/35/40/50 Service Manual

Drive and Brake 4. Place the drive axle bearing cup (Item 8) in the housing. Use a mallet or press to seat the axle bearing cup in the housing. Helical Gear/Spiral Pinion Gear Assembly NOTE: The pinion shaft and bevel gear are a matched set. Their alignment is critical. Do not replace them separately.

! WARNING Bearing can become extremely hot. Use gloves to protect hands from burns.

2610_094.tif

Figure 7-81: Install Axle Bearing Cup

1. Preheat the bearing cone (Item 2) with a bearing heater. NOTE: Steps 2 thru 5 must be completed before the bearing cools to provide a proper installation. 2. Install the heated bearing cone in the bearing cup in the housing.

1826_087.tif

Figure 7-82: Preheat Bearing Cone

3. Place the spacer over the bearing cone.

2610_098.tif

Figure 7-83: Install Spacer

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Component Procedures Drive and Brake

4. Place the helical gear (Item 3) into the housing.

2610_097.tif

Figure 7-84: Install Helical Gear

5. Install the spiral pinion (Item 4) up through the bearing cone (Item 7), spacer, and helical gear (Item 3). Push up until the spiral gear bearing is seated against its race.

2610_100.tif

Figure 7-85: Install Spiral Gear

6. Apply thread-locking compound to the spiral pinion gear threads. Then install the clamp nut (Item 14) on the end of the spiral pinion. Turn the helical gear as the clamp nut is tightened. Do not fully tighten until the bearing cools. See the NOTE following Step 1.

2610_099.tif

Figure 7-86: Install Clamp Nut

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Drive and Brake 7. Measure for end play using a dial indicator.

2610_101.tif

Figure 7-87: Measure End Play

8. Remove any end play in the bearings between the helical gear (Item 3) and the spiral gear (Item 4) using a nut driver tool and a wedge. Slowly tighten the clamp nut (Item 14) on the end of the spiral gear until there is no end play between the gears. Use a spin and tighten method to tighten the clamp nut as the bearings are seating in the races. Repeat until there is no end play. 9. Tighten the clamp nut the distance of a spanner nut space to preload the bearings. 2610_102.tif

Figure 7-88: Remove End Play

10. Apply thread-locking compound to the set screw in the clamp nut. Torque the set screw to 140 in. lb. (15.8 Nm). 11. Wipe off any excess thread-locking compound. 12. Spin the helical gear to be sure there is no end play or that the bearings are not too tight.

2610_103.tif

Figure 7-89: Apply Locking Compound to Set Screw

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Component Procedures Drive and Brake

Axle Assembly 1. Lightly oil the axle seal (Item 5). Place the seal over the axle shaft with the spring side up.

2610_089.tif

Figure 7-90: Install Axle Seal

2. Place the axle bearing cone (Item 8) over the axle shaft. Press the bearing cone on the axle shaft until it is fully seated.

! CAUTION

Always watch for pinch points when using a press or pressing tools.

2610_090.tif

Figure 7-91: Install Axle Bearing Cone

3. Apply a thin layer of gasket compound to the housing to seal the axle seal.

2610_096.tif

Figure 7-92: Apply Gasket Compound to Sealing Surface

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Drive and Brake

Axle/Bevel Gear Installation 1. Place a seal driver tool beneath the axle seal (Item 5). Place the axle shaft through the housing.

2610_105.tif

Figure 7-93: Tool Beneath Axle Seal

2. Place the bearing cone (Item 9) over the axle shaft. Install a spacer (Item 12), shim (Item 11), and thrust washer (Item 10) on the axle shaft. Place the bevel gear (Item 4) onto the axle shaft.

! CAUTION Always watch for pinch points when using a press or pressing tools. 3. Press the axle and bevel gear assembly until the bearing cones are fully seated in the housing.

2610_104.tif

Figure 7-94: Install Bevel Gear

4. Remove the seal driver tool. 5. Place a thrust washer (Item 10) on the axle shaft. 6. Apply thread-locking compound to the threads of the axle shaft.

2610_107.tif

Figure 7-95: Apply Locking Compound to Shaft Threads

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Component Procedures Drive and Brake

7. Install the clamp nut (Item 13). Hold the axle to keep it from turning as the clamp nut is tightened. 8. Torque the clamp nut to 18 ft. lb. (24 Nm).

2610_108.tif

Figure 7-96: Install Clamp Nut

9. Install a rotating device on the end of the axle. 10. Rotate the axle and tighten the clamp nut. Repeat this step six times to be sure the bearing cones are seated into the cups.

1826_109.tif

Figure 7-97: Tighten Clamp Nut to Seat Bearings

11. Loosen the clamp nut, then retighten to 5 ft. lb. (7 Nm) using the rotate, tightening process until the clamp nut does not turn any further. 12. Apply thread-locking compound to the set screw in the clamp nut. Torque the set screw to 140 in. lb. (15.8 Nm). Measuring Backlash NOTE: Backlash tolerance is critical to the performance of the drive unit. Improperly adjusted units will experience premature failure.

1826_107.tif

Figure 7-98:

Apply Locking Compound to Set Screw

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Prime-Mover CRX30/35/40/50 Service Manual

Drive and Brake 1. Position the probe of the dial indicator on the bevel gear crown. The dial indicator probe should be perpendicular to the gear surface.

Bevel Gear

2. Zero the indicator. Clasp the bottom of the gear and rotate it. Read the backlash measurement on the dial indicator. Total backlash tolerance is between 0.004 in. (0.1 mm) and 0.008 in. (0.2 mm). 3. Calculate any necessary adjustments to the shims if the tolerance is not within the acceptable limits. Remove the clamp nut, axle assembly and bevel gear. Install the proper amount of shims, and repeat Steps 3 and 4 (see “Housing Bearing Cup and Shim Assembly” on page 7-67). Repeat steps 1 through 3 until the backlash is between 0.004 in. (0.1 mm) and 0.008 in. (0.2 mm).

dial.tif

Figure 7-99:

Dial Indicator Position to Measure Backlash

4. When backlash is within the acceptable range, continue assembly of the drive unit. Inspection Cover Installation 1. Clean the cover mating surface. Apply gasket compound to the surface where the cover (Item 16) contacts the housing (Item 1).

2610_110.tif

Figure 7-100: Apply Gasket Compound

2. Install the ten 10 mm inspection cover screws (Item 15). Torque to 20 ft. lb. (27 Nm). 3. Apply teflon tape to the drain plug (Item 17) and the fill level plug (Item 18).

2610_111.tif

Figure 7-101: Tighten Cover Bolts

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Component Procedures Drive and Brake

4. Use a 5/16 in. Allen wrench to install the drain plug in the inspection cover. Torque to 15 ft. lb. (20 Nm). 5. Apply thread-locking compound to the drain plug (Item 17).

2610_112.tif

Figure 7-102: Install Drain Plug

6. Install the fill level plug in the housing using a 1/4 in. Allen wrench.

2610_113.tif

Figure 7-103: Install Fill Level Plug

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Drive and Brake

Brake A brake assembly is located on top of each drive motor. See Figure 7-104.

Inspection If a brake is not functioning properly, inspect the following items: 1. Check that the brake coil harness connector JPB2 or JPB3 is connected.

Brakes

2. To check brake coil resistance, disconnect the brake coil harness connector JPB2 or JPB3. 3. Check the brake coil electrical resistance. With the brake assembly at room temperature, resistance should be approx. 31.5 ohms. The resistance will increase to approx. 40 ohms when the brake assembly is at 200°F (93°C). 4. With the brake applied, the total air gap should be 0.008-0.018 in. (0.20-0.45 mm). 5. Check the thickness of the friction plate. With the brake applied, measure the distance between the bottom of the armature disk and the top of the mounting plate. A new friction plate is 0.249 ±0.002 in. (6.3 ±0.05 mm) thick. A friction plate that is 0.207 in. (5.3 mm) or less should be replaced. See Figure 7-105. 6. Check the friction plate for damaged splines or a rough surface. The brake must be disassembled for inspection.

Drive Motors

8D14080S.TIF

Figure 7-104: Brake Location (Mast Removed for Clarity)

New friction plate: 0.249 in. (6.3 mm) Minimum thickness: 0.207 in. (5.3 mm)

Brake Air Gap The proper air gap is between 0.008-0.018 in. (0.20-0.45 mm). During normal use, the friction plate will wear (get thinner). This causes the air gap to increase. Refer to See Figure 7-106. With the brake turned off, use a feeler gauge to determine the gap between the main coil body and the first armature plate around the entire diameter of the brake. The air gap should be uniform when measured around the circumference of the brake.

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eurobrak.wmf

Figure 7-105: Measuring Friction Plate

Prime-Mover CRX30/35/40/50 Service Manual

Component Procedures Drive and Brake

If the gap is less than 0.008 in. (0.20 mm) or greater than 0.018 in. (0.45 mm), adjustment is necessary. If an air gap of 0.018 in. (1.4 mm) or less cannot be achieved by turning the adjustable spacers, replace the friction plate. Adjust both brakes at the same time.

Assembly Screw

Compression Spring

Brake Release Bolt These bolts are normally located on the tractor frame.

Brake Coil Assembly

Air Gap 0.008 - 0.018 in. (0.20 - 0.45 mm)

Armature Disk

Spacer

Friction Plate (Wearable Material)

Friction Plate Splines

Mounting Plate

Brake Assembly Mounting Bolt eurobrak.wmf

Figure 7-106: Brake Assembly Components

Adjustment 1. Slightly loosen the three assembly screws. 2. Turn the three black adjustable spacers clockwise to decrease the air gap and counterclockwise to increase the air gap as necessary. See Figure 7-107. NOTE: Turning the adjustable spacers approx. 1/6 turn will produce a change of approx. 0.008 in. (0.203 mm).

Assembly Screw

Adjustable Spacer

Make sure the air gap is uniform around the circumference of the brake. 3. Tighten the three assembly screws to 16 ft. lb. (21.7 Nm). 4. Operate the truck and test the brake for proper stopping distance. See page 4-6.

eurobrak.wmf

Figure 7-107: Adjustable Spacer Location

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Prime-Mover CRX30/35/40/50 Service Manual

Drive and Brake

Brake Assembly Removal of Brake Assembly

Brake Coil Connection JPB1/JPB2

Speed Sensor JPS3/JPS4

1. Lower the forks all the way. 2. Turn the key switch OFF and disconnect the battery connector. 3. Remove the front covers. See page 7-16. 4. Cut tie wraps joining the brake coil harness and the speed feedback sensor harness. Disconnect the brake coil assembly electrical connector JPB1 or JPB2 from the lift truck’s harness. See Figure 7-108. 5. Install the brake release bolts. Tighten to release the brake.

Brake Coil 8D14052S.TIF

Figure 7-108: Brake Coil Connector JPB1 or JPB2

6. Remove the three screws that hold the brake assembly to the motor. Lift the brake assembly off the drive motor. NOTE: Do not lose the spacers between the brake and motor.

Disassembly of Brake 1. Remove the three bolts that hold the lower friction plate to the brake coil. See Figure 7-109.

Brake Coil

Top Plate and Springs

NOTE: Be careful not to lose the shims or spacers. 2. Remove and inspect the brake friction disc. 3. Remove the brake release bolts and top friction plate from the brake coil. See Figure 7-109. NOTE: When removing the top friction plate from the brake coil, hold the coil inverted so the brake springs will remain in the coil assembly.

Inspection of Friction Disk Gear Visually inspect the friction disk gear prior to installation of the brake assembly. Make sure that the key is in the keyway shaft. If the key has burrs, damage, or excessive wear, replace the key. The friction disk gear is secured to the drive motor shaft with a washer and nut. Torque the nut to 65 ft.lb. (88 Nm).

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Lower Friction Plate

Friction Disc and Hub

Brake Release Bolts 8D14057S.TIF

Figure 7-109: Brake Components

Prime-Mover CRX30/35/40/50 Service Manual

Component Procedures Drive and Brake

Assembly and Installation of Brake 1. Place springs evenly in holds in brake coil. (There may be fewer springs used than there are holes.) 2. Place the top plate over the springs. See Figure 7-110.

8D14058S.TIF

Figure 7-110: Brake Coil Assembly, Top Plate

3. Place the top friction plate over the top plate. See Figure 7-111. 4. Install the brake release bolts and tighten. 5. Center the friction disc on the lower friction plate. 6. Place the shims and spacers into their original positions. 7. Apply Loctite 242 (Blue) to the three bolts previously removed and place them through the brake coil assembly.

8D14059S.TIF

Figure 7-111: Brake Coil Assembly, Top Friction Plate

8. Secure the brake coil assembly to the lower friction plate assembly and torque to 9 ft. lb. (12 Nm). 9. Install the brake assembly and spacers on the drive motor. Make sure the friction disc fits over the keyed hub.

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Prime-Mover CRX30/35/40/50 Service Manual

Drive and Brake 10. Tighten the three mounting bolts to 13 ft. lb. (18 Nm). See Figure 7-112. 11. Remove brake release bolts and store for future use. 12. Plug the wiring harness connector from the brake coil into the connector from the Interface Card (JPB2 for the right brake coil; JPB1 for the left brake coil).

Brake Mounting Bolt

13. Re-install front covers. See “Front Covers” on page 7-16.

! WARNING Make sure that all the brake release bolts are removed before using the lift truck. The brake will not work if the brake release bolts are not removed. 14. Reconnect the battery connector and turn the key switch ON. 15. Check operation of the brake.

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Spacer

8D14054S.TIF

Figure 7-112: Brake Mounting Bolt, Spacer

Prime-Mover CRX30/35/40/50 Service Manual

Component Procedures Electrical Components

7112: Component Procedures

Electrical Components

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Electrical Components

Fuses All fuses are located on the fuse and contactor panel assembly located on the right front frame of the top console. See Figure 7-113 and Figure 7-114.

Contactor/Fuse Panel 8D14023S.TIF

Figure 7-113: Fuse Panel Location

Removal, Testing, and Replacement 1. Turn the key switch OFF and disconnect the battery connector. 2. Remove the console cover. See “Console Cover” on page 7-14.

! CAUTION Observe proper ESD precautions. See “Static Precautions” on page 2-12. Fuse FU2

3. Remove the fuse from the circuit before testing continuity. 4. When removing FU1, FU2, FU3, or FU4, be sure wires and cables are labeled for reconnection. Note routing of cables. 5. Always find the cause of a blown fuse and repair it before replacing the fuse. 6. Always use fuses of the proper amperage. 7. Remove the nut and washer holding the fuse in place for removal.

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Fuse FU3

Fuse FU1

Fuse FU4 8D14113S.TIF

Figure 7-114: Contactor/Fuse Panel

Prime-Mover CRX30/35/40/50 Service Manual

Component Procedures Electrical Components

Contactor Fuse Panel The Contactor Fuse Panel is located on the upper right portion of the operator compartment to the right of the control handle.

Access to Contactors 1. Turn the key switch OFF and disconnect the battery connector. 2. Remove the console cover. See “Console Cover” on page 7-14.

! CAUTION Observe proper ESD precautions. See “Static Precautions” on page 2-12. 3. Remove fuses FU1, FU2, FU3. and FU4. See “Fuses” on page 7-82. 4. Remove cable TP1. 5. Remove cables TPC1, TPC2 and TPC1 control wire. 6. Remove cables LPC1, LPC2 and LPC1 control wire. 7. Remove cables STR1, STR2 and STR control wire. 8. Remove cables AUX1 and AUX2.

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Electrical Components

Contactors The Traction Power Control (TPC), Lift Power Control (LPC), Steering (STR), and Auxiliary (AUX) contactors are located on the contactor panel on the top right side of the frame, underneath the console cover. See Figure 7-115.

Travel (TPC) Contactor

Lift (LPC) Contactor

Steer (STR) Contactor Auxiliary (AUX) Contactor

Testing Resistance Visually inspect the contactor for any signs of burning or physical damage. 1. Turn the truck’s key switch OFF and disconnect the battery connector. 2. Disconnect the two wires from the base of the contactor. These two wires are marked X and Y. 3. Connect one lead of the ohmmeter to the X lead from the contactor. Connect the other lead to the Y lead from the contactor. 4. The reading should be between 93 and 103 ohms. If the reading is not correct, replace the contactor.

Removal 1. Turn the key switch OFF and disconnect the battery connector. 2. Remove the console cover. See “Console Cover” on page 7-14. 3. Remove the main power fuse bolts at the contactor assembly. 4. Remove the B+ bus bar with fuses. 5. Remove cables and control wires from contactor. Label if necessary. 6. Remove the wires from the X and Y terminals of the contactor coil. Label if necessary. 7. Remove the 2 nuts securing the contactor to the contactor panel.

Installation 1. Place contactor on the mounting studs on the contactor panel and secure it with the 2 mounting nuts.

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8D14113S.TIF

Figure 7-115: Contactor Location

Prime-Mover CRX30/35/40/50 Service Manual

Component Procedures Electrical Components

2. Reinstall wires to the X and Y terminals of the contactor coil. 3. Reinstall cables and control wires to the contactor. 4. Install the B+ bus bar with fuses. 5. Install the main power fuse bolts at the contactor assembly. 6. Reconnect the battery connector and turn the key switch ON. 7. Test truck operation. 8. Reinstall the console cover.

Contactor Tip Inspection When you inspect contactor tips, follow these guidelines: • Darkened points do not indicate burning. • Burning indicates a loss of contact point material. • Replace the contact points if there is not enough contact point material to last until the next regular inspection or severe pitting is evident. See Figure 7-116. • The silver alloy part of the point is usable contact material; the copper backing is not. • Do not file contact points to remove discoloration or minor irregularities. This practice produces a surface more susceptible to sticking.

8a21032s.tif

Figure 7-116: Severely Pitted Contactor

• If a cone and crater appear, replace the contactor tips.

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Contactor Tip Replacement Removal 1. Turn the key switch OFF and disconnect the battery connector. 2. Remove the tractor cover. 3. Disconnect cables by removing hex nuts. Identify cables and their location and label if necessary for proper reinstallation. 4. Remove the two contactor coil wires by pulling the wire connector. Note their locations and label if necessary. 5. Remove the two nylon nuts securing the two upper retaining blocks. 6. Remove the upper retaining blocks. 7. Remove the two stationary tips. 8. Remove the nut on top of the core and rod assembly shaft. 9. Remove the fiber washer. 10. Remove the contact spring. 11. Remove the movable contactor tips. 12. Remove the insulator bushing.

Replacement 1. Install the new insulator bushing over the core and rod assembly shaft. 2. Install the new movable tips over the insulator bushing, with the contact tip faces down. 3. Install the new contact spring over the insulator bushing. 4. Install the new fiber washer over the rod assembly shaft. 5. Secure the movable tip assembly with the nut on top of the core and rod assembly shaft.

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Component Procedures Electrical Components

6. Install the two new stationary contactor tips, with tip faces up (facing the movable contactor tips). Make sure the cable posts face up, and are on the same side as the contactor coil spade terminals. Make sure studs on lower retaining block lock into holes in contact tip bar.

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Prime-Mover CRX30/35/40/50 Service Manual

Electrical Components

Interface Card The Interface Card is located to the left of the operator display under the console cover. See Figure 7-117. Interface Card

Removal 1. Turn the key switch OFF and disconnect the battery connector. 2. Remove the console cover. See “Console Cover” on page 7-14.

8D14121S.TIF

! CAUTION Observe proper ESD precautions. See “Static Precautions” on page 2-12.

Figure 7-117: Interface Card Location

Interface Card Mounting Bolts

3. Disconnect all connectors to the Interface Card. Label if necessary. 4. Using a wrench, loosen and remove the two front fasteners and one back fastener from the Interface Card. 5. Remove the Interface Card, making sure to check for any remaining attached wires. 6. If necessary, carefully remove the Interface Card shield which protects the actual circuit card. Figure 7-118: Interface Card Mounting Bolts (1 Not Shown)

Installation 1. Position the Interface Card on the truck and align the mounting holes. 2. Replace and tighten the two front fasteners and one rear fastener onto the Interface Card. NOTE: Make sure not to pinch any wires or cables while reinstalling the Interface Card. 3. Reconnect all wiring harness connectors that were previously removed. 4. Reconnect the operator display connector. 5. Attach with two mounting bolts. 6. Reinstall the console cover. See “Console Cover” on page 7-14.

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Component Procedures Electrical Components

7. Reconnect the battery connector and turn the key switch ON. 8. Test the lift truck for proper operation. NOTE: After Interface Card replacement, LEARN must be run on the truck. Also, any configurable setting should be checked and reset if necessary.

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Prime-Mover CRX30/35/40/50 Service Manual

Electrical Components

Translator Card The Translator Card is located under the Interface Card mounting bracket.

Mounting Bolts

Removal ! CAUTION Observe proper ESD precautions. See “Static Precautions” on page 2-12. 1. Turn the key switch OFF and disconnect the battery connector.

JPX1

JPX3

JPX2

2. Remove the Interface Card. 3. Remove connections JPX1, JPX2, and JPX3 from the side of the translator card. 4. Remove the four 10 mm mounting bolts that secure the Interface Card mounting bracket to the tractor frame.

Figure 7-119: Translator Card Connections

Translator Card

Mounting Bracket

5. Carefully lift the mounting bracket away from the tractor frame. The Translator Card is mounted to the underside. 6. Remove the four Allen head screws that secure the Translator Card to the standoffs. See Figure 7-120.

Installation 1. Carefully position the Translator Card over the four standoffs on the underside of the Interface Card mounting bracket. 2. Secure the card to the standoffs with four Allen head screws. Do not overtighten. See Figure 7-120. 3. Place the mounting bracket over the four mounting holes on the tractor frame and secure it with the 10 mm mounting bolts. 4. Reconnect JPX1, JPX2, and JPX3. 5. Install the Interface Card. 6. Reconnect the battery and turn the key switch ON. 7. Test truck operation.

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Figure 7-120: Translator Card Removed

Allen Head Screws

Prime-Mover CRX30/35/40/50 Service Manual

Component Procedures Electrical Components

Battery Procedures ! CAUTION Before working on the battery, review “Battery Safety” on page 2-7. Use extreme care during replacement. Use a suitable battery moving device. Do not extend a battery more than 1/3 of its length outside the battery compartment without being attached to a battery moving device.

Battery Connector The battery connector is located on the right side of the truck, above the battery. See Figure 7-121. One half of the battery connector is attached to the battery cables. The other half of the battery connector is secured to the right side of the truck, above and slightly forward of the battery.

8D14127S.TIF

Figure 7-121: Battery Connector (Shown Disconnected)

Inspection 1. Check the battery connector for damaged wires. 2. Check to see if the battery cables are pulling out of the connector. See Figure 7-122. 3. Check the cables where they go into the battery terminals. They should be tight and there should be no corrosion. 4. Look inside the connector. Check the internal contacts for damage, dirt, or corrosion. Do not use a metal object to clean the connector. See Figure 7-123.

BATTCON1.TIF

Figure 7-122: Battery Connector Cable Removal

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Prime-Mover CRX30/35/40/50 Service Manual

Electrical Components

Installation The cables to either half of the connector have a lip on their forward end. This lip snaps over a spring-loaded retainer that is part of the battery connector. To remove a cable from the connector, you must push this retainer down while pulling the battery cable rearward, out of the connector. Lip

BATTCON2.TIF

Figure 7-123: Battery Cable Removed from Connector

Battery Removal 1. Turn the key switch OFF and disconnect the battery connector. 2. Position the battery moving device in accordance with the manufacturer’s recommendations.

Battery Gate

3. Remove the battery gate. See Figure 7-124.

8D1410S.TIF

Figure 7-124: Battery Gate

4. Remove the battery with a suitable battery moving device.

Installation 1. With a fully charged and tested battery on the battery moving device, position the battery moving device at the truck in accordance with the manufacturer’s recommendations. 2. Install the battery of the proper voltage in the compartment. Be sure the battery has no more than 0.50 in. (1.27 cm) of free play movement in the battery compartment. 3. Install the battery gate. 4. Remove the battery moving device from the area.

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BATTOUT.EPS

Prime-Mover CRX30/35/40/50 Service Manual

Component Procedures Electrical Components

5. Reconnect the battery connector and turn the key switch ON. 6. Test truck operation.

Battery Gates Inspection Inspect the battery gates for bending or cracks. Replace if necessary.

Battery Rollers Inspection Inspect the battery rollers to ensure they can turn freely. Clean off electrolyte using a solution of 1 lb. (0.45 kg) of baking soda added to 1/2 gal. (1.9 liters) of hot water.

Replacement Lift damaged roller from its slot and replace with a new one.

Battery Exterior Cleaning 1. Read, understand, and follow procedures, recommendations and specifications in the battery and battery charger manufacturer’s manuals. 2. Wear personal protective equipment. See “Battery Safety” on page 2-7. 3. Turn the key switch OFF and disconnect the battery connector. Remove the battery from the truck. See Battery - Removal on page 7-92.

25L6S016.EPS

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Prime-Mover CRX30/35/40/50 Service Manual

Electrical Components 4. Inspect the battery cables to make sure they are not frayed or loose. Inspect the battery connector to ensure there is no foreign material inside the connector. Make sure the filler plugs are tight and the vent holes in the filler plugs are open. See Figure 7-125.

Battery Cable

Filler Plug

9G6S047.TIF

Figure 7-125: Filler Plug and Battery Cable

TITECAPS.EPS

5. Keep the top of the battery clean and dry. Corrosion, dust, and moisture provide a conducting path to short-circuit cells or create grounds.

! CAUTION Do not clean the top of the battery with the soda solution while it is installed in the truck. Water can seep into the electrical components and cause serious damage. 6. Wash dirty batteries (or any that have had electrolyte spilled on them) with a solution of 1 lb. (0.45 kg) of baking soda added to 1/2 gal. (1.9 liters) of hot water. 7. Use a brush with flexible bristles to clean the entire top of the battery with the soda solution. Wait until all foaming stops, indicating that the battery exterior is neutralized.

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Component Procedures Electrical Components

8. Rinse the battery with clean water. 9. Dry the battery completely with compressed air (max. 30 psi or 207 kPa or 2.1 kg/cm2) before re-installing it. 10. Apply a thin coat of petroleum jelly to the battery posts and cable terminals. 11. Reinstall the battery in the truck, using a suitable battery moving device. Reconnect the battery connector. BATTIN.EPS

Battery Testing, Charging, and Maintenance For information on testing, charging, and maintaining the battery in this lift truck, consult the battery manufacturer’s specifications and instruction manual.

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

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Prime-Mover CRX30/35/40/50 Service Manual

Electrical Components

Troubleshooting the Battery Problem Electrolyte leakage

Warped plates inside battery

Possible Cause

Solution

Over filling Over charging

Refer to battery charger manual. Charge battery within limits.

Crack in battery case

Replace battery.

Constant over charging and over discharging battery

Refer to battery charger manual. Charge battery within limits.

Excessive charging current

Sulfation (a whitish deposit on the battery plates)

Too high of an operating temperature

Operating environment is too hot.

Over discharge

Do not run the battery all the way down before recharging it. [You could set lift cut-out (in the Configure Mode) to a higher value.]

Low charges

Fully charge battery before operating truck.

Disuse

Charge battery once a month when truck is not being used.

Not enough electrolyte

Fill cells up to correct level.

Bad electrolyte

Replace battery.

Internal battery short Internal short circuit

Damaged plate inside battery

Replace battery.

Contaminants in electrolyte shorting out plates Loose or corroded connections

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Dirty connector

Clean connectors. (Do not use a metal object.)

Bad connection

Make sure connectors push together all the way.

Prime-Mover CRX30/35/40/50 Service Manual

Component Procedures Electrical Components

Wiring, General Inspection See “Troubleshooting Wiring Problems” on page 5-18.

Repair Whenever working on the truck, use care around wiring harnesses.

! CAUTION Observe proper ESD precautions. See “Static Precautions” on page 2-12.

25L6S014.EPS

• Do not pull on wires. • Carefully connect and disconnect all connections. • Do not pry connectors apart with unspecified tools. There should be a wire marker at each termination. If the marker is missing or unreadable, remark the wire to allow easier identification. NOTE: It is normal to find unused connectors for uninstalled options that have had heat shrink applied over them and have been strapped to the harness. When replacing wires, in some cases you will be able to tape or solder one end of a new wire to one end of the failed wire. Then you can pull the old wire out of the bundle and pull the new wire into the bundle, all at the same time. Be sure to disconnect the old wire from the new wire. In other cases, it will be easier to secure a new wire to the outside of the existing wire bundle with straps of an appropriate size. The failed wire can be left in the bundle, or can be pulled by one end to remove it from the bundle.

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Component Procedures Electrical Components When replacing wires, follow these guidelines: • Use the appropriate tools to remove and insert terminations at each connector. • Remove damaged terminations and discard. Never reuse a termination from a wire. • Do not cut away a terminal lug and reuse the wire strands that were crimped into the original lug. • When stripping wire, use new wire strands for new terminations. Be sure to use a new wire with extra length to allow for cutting and stripping of the ends to install new terminations. • Use a new wire that is the same gauge (typically gauge 18 AWG), size, type, and color as the wire it is replacing. • Use a hand stripper capable of stripping by wire gage number. Use care not to nick or cut any of the wire strands. Discard and replace a wire with damaged strands. Insert the wire strands the proper length into termination before crimping.

Wiring Harness General Whenever you replace a wiring harness, be sure to note how it is routed through the truck. Also be sure to note where any tie-straps are used to secure the wiring harness to keep it out of the way. Before disconnecting any wires, make sure you turn the key switch OFF and disconnect the battery connector.

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Component Procedures Electrical Components

Traction Power Amplifiers Location The traction power amplifiers are mounted on hinged plates which can be accessed from the battery compartment. See Figure 7-126.

Removal 1. Turn the key switch OFF and disconnect the battery connector.

Power Amplifier Mounting Bolts

2. Remove the battery. 3. Remove the bolts securing the hinged plate to the tractor frame and fold down the plate. 4. Disconnect the Molex connectors JPTL1 (left) or JPTR1 (right). 5. Disconnect the cables and wire from the B+ terminal of the amplifier (LAB+ left or RAB+ right). Label if necessary for later installation.

Figure 7-126: Power Amplifier Exposed

6. Disconnect the bolt securing the power amplifier B- terminal to the bus bar (LAB- left or RAB- right). 7. Remove the bolts and washers securing the power amplifier to the hinged plate.

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Electrical Components

Installation 1. Fasten the amplifier to the hinged mounting plate with six bolts. Do not overtighten. 2. Install the bolt connecting the bus bar to the B- terminal of the amplifier (LAB- left or RAB- right). 3. Connect the cables and the wire to the B+ terminal (LAB+ left or RAB+ right) on the amplifier. 4. Reconnect connectors JPTL1 (left) or JPTR1 (right). 5. Secure the hinged plate to the tractor frame with four bolts. 6. When closing the plate, observe the wires and cables to make sure the adjacent terminals do not short to each other or the tractor frame. 7. Install the battery. 8. Reconnect the battery connector and turn the key switch ON. 9. Test the driving functions of the lift truck. 10. Turn the key switch OFF and disconnect the battery connector. RAB-/LAB-

JPTL1\JPTR1

RAB+/LAB+

8D14133S.TIF

Figure 7-127: Traction Power Amplifier Connections

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Component Procedures Electrical Components

Horn

Mounting Bolts

Location The horn is located beneath the top front cover on the left side of the tractor. See Figure 7-128.

Removal 1. Turn the key switch OFF and disconnect the battery connector. 2. Remove the top front cover. See “Front Covers” on page 7-16.

Horn Horn Bracket 8D14108S.TIF

Figure 7-128: Horn location

3. Remove the mounting bolt that attaches the horn bracket to the frame. 4. Lift off horn and remove plastic insulators. 5. Remove the two connectors (HRN- and HRN+) from the terminals on the horn and label if necessary for reconnection.

Installation 1. Reconnect the two connectors (HRN- and HRN+) to the terminals on the horn. 2. Making sure that the plastic insulators are clean, secure horn, bracket and two insulators (one on each side of the bolt), to the truck. Tighten mounting bolt.

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Electrical Components

Motors, General Motor Cleaning Periodic cleaning is essential to prevent overheating and electrical leakage (shorts). To clean a motor properly: 1. Wear safety glasses or goggles to protect your eyes from dust and debris. 2. Using an OSHA approved air nozzle, use clean, dry, low pressure (30 psi or 207 kPa or 2.1 kg/cm2) compressed air to blow carbon dust and other foreign matter from: •

Motor housing

•

Brush holders

•

Commutator

•

Field and armature windings (if accessible)

MOTOR.WMF

Figure 7-129: Motor Cleaning

! CAUTION Never use a chemical solvent to clean a motor, as it can carry carbon dust to inaccessible areas and cause shorts within the motor. NOTE: Cleaning a motor requires complete disassembly and drying, and should only be attempted by an authorized motor repair shop.

Motor Brushes Inspection Conduct a partial inspection of the motor after every 500 hours of truck operation. If you work in an abnormally severe or caustic environment or if the truck has a rigorous duty cycle, inspect the motor more frequently. Set up and rigidly adhere to a strict inspection schedule to obtain the maximum efficiency from the electrical equipment. MTRBRUSH.PCX

Figure 7-130: Motor Brush, Typical Location

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Component Procedures Electrical Components

Each partial inspection of the motor should include the following: 1. Inspect the brushes for wear and for proper contact with the commutator. Record the level of wear on the brushes. This history will give you an indication of whether a brush should be changed or if it can wait until the next inspection. See the table on page 7-105 for proper brush length. NOTE: Overloading a unit is ultimately reflected in the motor and brush wear; therefore, you must take this into account when considering brush replacement.

Put brush spring in this position for brush removal

Brush Spring

Brush Spring Holding Bracket

2. Check brush spring tension. See “Motor Brush Spring Tension” on page 7-105. 3. Clean brushes and holders. Wipe the commutator with a dry, lint-free cloth. Do not use lubricants of any kind on or around the commutator.

BRUSHBOX.WMF

Figure 7-131: Brush Spring Positioning

4. Check brush holders for solid connection to the mounting support. Tighten the mounting screws as necessary. 5. Check the capscrews holding the brush cross connectors to the brush holder body. 6. Make sure the motor terminals are secured tightly to the motor frame. Be careful not to strip the threads or crush the insulating parts. 7. Check all the capscrews around the frame for tightness. 8. Keep the outside frame of the motor clean and free from dirt. Maintain a free air passage around the motor to permit heat radiation.

Replacement If one brush needs replacement, always replace the entire set of brushes. Use only genuine Prime-Mover brushes. Using another type of brush could damage the commutator or cause excessive brush wear.

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Component Procedures Electrical Components If the end of the brush is not already contoured to fit the commutator, use the following procedure to seat the brush to the commutator: NOTE: If the motor commutator is not accessible, form the brush contour using a brush seating stone. 1. Move the motor brush springs out of your way. 2. Wrap a piece of 00 sandpaper around the commutator. Do not use emery cloth to seat brushes. 3. Move the brushes back down in their holders so that the face of the brushes rests on the sandpaper. 4. Turn the armature until the curve on the face of the brushes matches the curve of the commutator. 5. Remove the sandpaper. 6. Blow any dust out of the motor with clean, compressed air at a maximum of 30 psi (207 kPa).

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Component Procedures Electrical Components

Motor Brush Spring Tension Inspection 1. Turn the key switch to OFF and disconnect the battery connector.

*Pull Paper in the Direction of Rotation

2. Remove front covers. See “Front Covers” on page 7-16. 3. Slide the brush up slightly in its holder. 4. Insert a paper strip between the brush face and the commutator. 5. Place a small leather loop around the coil spring for the brush. If the brush spring has a loop at the brush, hook the spring scale directly to the spring.

Spring Scale

Coil Spring Leather Loop

6. Attach a 5 lb. (2.27 kilogram) spring scale to the leather loop. 7. While gently pulling the scale outward, slowly pull the paper strip in the direction that the commutator normally rotates. 8. When the paper strip begins to move freely, the spring scale will read the spring brush tension.

Rotation

Paper* TENSION.PCX

Figure 7-132: Motor Brush Spring Tension Inspection

9. Refer to the table below for proper spring tension:

Minimum Brush Length

Spring Tension

Drive Motor

0.62 in. (16 mm)

40 to 65 oz. (1120 to 1820 grams)

Lift Motor

0.62 in. (16 mm)

40 to 65 oz. (1120 to 1820 grams)

Steer Motor

0.60 in. (15 mm)

35 to 55 oz. (980 to 1540 grams)

Aux Motor

0.62 in. (16 mm)

40 to 65 oz. (1120 to 1820 grams)

Motor

10. Repeat steps 3 through 9 for the remaining brushes.

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Electrical Components

Commutator

BRUSH LENGTH

Inspection The commutator should be inspected for surface condition and high mica. The commutator must be smooth and clean to provide maximum brush wear. When commutators are not properly maintained, carbon dust can collect in the grooves between the segments. This can lead to a short circuit in the armature. Good commutation will be indicated by a dark brown polished commutator and an evenly polished brush wearing surface. If the commutator appears rough, pitted, or has signs of burning or heavy arcing between the commutator bars, the motor should be removed for servicing.

High Mica Most armatures have the mica undercut. If the armature on your motor does not, do not attempt to cut it. The decision to undercut or not is determined by the type and grade of brush used in that particular motor. The mica should be undercut to a depth equal to the width of the mica (usually 1/32 in., but may vary in some motors). See Figure 7-133.

Servicing If the commutator requires service, you will need to remove the armature from the motor. DO NOT use a stone to even out high and low spots on the commutator. Use only a suitable abrasive rubber polisher.

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MICACUT.PCX

Figure 7-133: Mica Undercutting

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Component Procedures Electrical Components

Terminal Nuts ! CAUTION The power amplifiers have energy storage capacitors that should be discharged before removing any large fuse or motor cable for service. To discharge, turn the key switch OFF, disconnect the battery, and manually push in the plungers on all 3 contactors.

Terminal Stud Motor Cable Securing Nut

Flat Washer Fiber Washer

Stud Terminal Securing Nut

Motor Housing

CABLENUT.WMF

Whenever you disconnect and reconnect any power leads to a motor, always tighten the motor cable securing nuts with a torque wrench to prevent over-tightening them and damaging the motor. Use a second wrench on the stud terminal securing nut to avoid twisting the stud.

Figure 7-134: Motor Terminal Nuts

Stud Terminal Securing Nuts and Motor Cable Securing Nuts on the drive and lift motors should be torqued to 100-120 in. lb. (11.2-13.6 Nm). Securing Nuts on the Steer motors should be torqued to 45-55 in. lb. (5.0-6.2 Nm). Check these torques each time you check motor brushes.

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Electrical Components

Electric Motor Tests Motor Types See Figure 7-135.

Shunt-Wound or Series-Wound Drive Motor

• A shunt-wound or series-wound drive motor has four external connections: two armature (A), and two field (S, E, or D).

or E2 or D2

• A series-wound lift motor has only two external connections because the armature and field windings are connected internally. NOTE: Field connections may be labeled S. Shunt-wound motor field connections may be labeled E. Series wound motor field connections may be labeled D.

or E1 or D1

Series-Wound Lift Motor S or D

Open Circuit Motor Test An open circuit is one in which the electrical circuit within the motor has been broken. This can be caused by: •

Bad brushes or brush springs

•

A broken wire in the field or armature winding

•

A loose or bad connection

Refer to Figure 7-135 for the following procedure: 1. Isolate the motor from the truck circuit by removing the power cables. Use two wrenches to avoid twisting the terminal stud. 2. With the motor at room temperature, connect the leads of a digital ohmmeter between the individual circuits in the motor.

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DSCHEM.EPS

Figure 7-135: Motor Circuits

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Component Procedures Electrical Components

3. You should observe the following measurements: Motor

Drive Motor

Probe Points

Resistance

S1 to S2 (shunt)

0.9 to 1.5 ohms

S1 to S2 (series)

<1 ohm

A1 to A2

<1 ohm

A1 to S1; A1 to S2

>100,000 ohms

A2 to S1; A2 to S2

>100,000 ohms

A1 or A2 to Frame

>100,000 ohms

A to S

<1 ohm

A to Frame

>100,000 ohms

A1 to A2

<1 ohm

A1 or A2 to Frame

>100,000 ohms

A1 to A2

<1 ohm

A1 or A2 to Frame

>100,000 ohms

Lift Motor Auxiliary Motor Steer Motor

4. If the meter indicates high resistance in the armature, check the condition of the brushes before replacing the motor. 5. If you find an open circuit in a series-wound motor, the motor must be disassembled by a motor rebuilding facility to isolate the problem to the field or armature circuit.

Grounded Motor Test In a grounded motor, an electrical circuit exists between the current-carrying conductors and the motor housing. This can be caused either by direct contact or through conductive foreign material. The ground may be caused by: •

Insulation breakdown

•

Brush leads touching the motor housing

•

Build-up of carbon dust or other materials

To test for a grounded motor, follow the Shorts to Frame test procedure on page 5-14.

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Component Procedures Electrical Components

Short Circuited Armature or Field Winding A short circuited winding is one in which the insulation on the field or armature has broken down at two or more points. The breakdown creates a low resistance path, allowing current to flow from one turn of the coil to another adjacent coil turn, without actually flowing through the coil wire. The result is a decrease in total resistance of the motor winding and an increase in the current flow. The severity of the short circuit depends on its location. A shorted motor may be indicated by: •

Slow or sluggish operation

•

Running faster than normal (suggests a short in the field)

•

Overheating

•

Blowing a power fuse

•

Burning of brush wires

•

Severe burning or discoloration on armature coil

•

Severe burning or discoloration on one or two commutator segments every 90° of rotation.

These symptoms can be caused by problems other than the motor itself: •

Brake too tight or dragging

•

Wheel bearings too tight

•

Faulty transmission

•

Binding in an attached pump, hose, or solenoid valve

•

Load wheels not aligned properly

•

Rail guided with drive tire not aligned properly

Testing a motor for short circuited windings requires special equipment at a motor rebuilding facility.

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Component Procedures Electrical Components

Drive Motor See “Motors, General” on page 7-102 for instructions on:

Drive Motors

• Cleaning the motor • Testing the motor • Inspecting and changing the brushes

Location There are two drive motors on this lift truck, one above each front wheel. The drive motors are bolted directly to the top of the drive units. See Figure 7-136.

Drive Units 8D14080S.TIF

Figure 7-136: Location of Drive Motors

Removal 1. Turn the key switch OFF and disconnect the battery connector. 2. Remove the three front covers. See “Front Covers” on page 7-16. 3. Remove the brake assembly. See “Brake Assembly” on page 7-78. 4. Remove the friction plate retaining nut. 5. Disconnect the four power cables from the terminals on the drive motor and label if necessary for later installation. Use two wrenches to avoid twisting the terminal studs. See Figure 7-137.

Power Cables

6. Disconnect the drive speed feedback sensor harness connector JPS3 (left) or JPS4 (right). 7. Disconnect the brush wear sensor and temperature sensor connector JPS11 (left) or JPS12 (right). Power Cables 8D14067S.TIF

Figure 7-137: Drive Motor Power Cables

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Electrical Components 8. Place a drain pan beneath the drive unit. Remove the drain plug and drain approx. two pints (one liter) of drive unit oil. This prevents oil from spilling when the drive motor is removed. See Figure 7-138. 9. Remove the four bolts that attach the drive motor to the top of the drive unit. 10. To break the drive-motor-to-drive-unit seal: a. Install two of the bolts you removed in step 6 into the two “blind” holes on the drive motor mounting flange. See Figure 7-139. b. Evenly turn each bolt clockwise. c. As you turn the bolts, the drive motor will be pushed upward, breaking its seal to the drive unit.

8D14066S.TIF

Figure 7-138: Drive Unit Drain Plug Drive Motor

! CAUTION The drive motor is heavy. Use a suitable lifting device to move it if necessary. 11. Lift the drive motor off the drive unit. 12. If you won’t be reinstalling a drive motor, use plastic film and masking tape to seal the opening for the traction motor so that no debris can fall into the drive unit. 13. Remove the pinion gear from the drive motor shaft.

Installation 1. Install the pinion gear on the drive motor shaft and torque to 45 ft. lb. (63 Nm). 2. Thoroughly clean the mating areas on the top of the drive unit and the bottom of the drive motor mounting flange. 3. Apply a coat of gasket cement to the mating surface on the top of the drive unit. 4. Remove any burrs that may have been created in the removal of the drive motor mounting bolts. 5. Position the drive motor on top of the drive unit and align the mounting holes.

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Drive Unit

Bolt In “Blind” Hole 8D14068S.TIF

Figure 7-139: Drive Motor Removal, Breaking Seal

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Component Procedures Electrical Components

6. Apply Loctite 242 (Blue) to the four motor mounting bolts and install the bolts. Torque to 13 ft. lb. (18.2 Nm). NOTE: If installing a new motor, remove the snap ring from the top of the armature shaft and discard. Install an additional spacer (crush collar) to the shaft. Do not use a spacer from an old motor, and do not reinstall a snap ring prior to installing the brake. 7. Install the brake assembly. See “Brake Assembly” on page 7-78. 8. Reconnect the cables to the terminals on the drive motor. Use two wrenches to avoid twisting the terminal studs. Torque cable securing nuts to 100-120 in. lb. (11.2 to 11.36 Nm). 9. Reconnect the harnesses to the drive speed feedback sensors, brush wear indicators, and temperature sensors previously removed. 10. Add the drive unit gear oil previously removed to the drive unit through the filler plug hole. See page 7-46. 11. Install the mast. See “Mast” on page 7-148.

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Electrical Components

Lift Motor Electric Steer Motor

See “Motors, General” on page 7-102 for instructions on:

Lift Motor

• Cleaning the motor • Testing the motor • Inspecting and changing the brushes

Location The lift motor is located in the center of the lift truck, between the drive units, and under the electric steer motor. See Figure 7-140.

Lift Pump 8D14080S.TIF

Figure 7-140: Lift Motor Location

Removal 1. Turn the key switch OFF and disconnect the battery connector. 2. Remove the mast. See “Mast” on page 7-148. 3. Remove the three front covers. See “Front Covers” on page 7-16. 4. Remove the electric steer motor. See “Electric Steer Motor” on page 7-24. 5. Remove the two power cables, labeling if necessary for later installation. Use two wrenches to avoid twisting the terminal studs.

JPS8 Lift Motor Lift Pump

6. Disconnect connector JPS8 to the motor brush wear sensor. 7. Remove two bolts securing the front cover mounting bracket to the reservoir. 8D14064S.TIF

8. Remove the lift pump from the lift motor without disconnecting the lift pump hoses. See “Lift Pump” on page 7-140. 9. Place blocks of wood beneath the lift motor to help support it during removal. Leave no more than a 1/2 in. (13 mm) gap between the top of the blocks of wood and the bottom bell of the lift motor.

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Figure 7-141: Lift Motor and Pump

Prime-Mover CRX30/35/40/50 Service Manual

Component Procedures Electrical Components

! CAUTION The lift motor is heavy. Use a suitable lifting device if necessary. 10. Remove the mounting nuts that hold the lift motor to the frame. 11. Carefully slide the lift motor off the mounting studs.

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Installation 1. Apply Loctite 242 (Blue) to the lift motor mounting studs. 2. Carefully place the lift motor on the mounting bolts on the frame. Support the motor on the blocks of wood used during removal. 3. Install washers and mounting nuts and tighten. 4. Apply a thin coat of anti-seize compound (P/N 313666-465) to the spline on the end of the lift pump. 5. Mate the lift pump to the lift motor. Apply blue Loctite 242 (Blue) to the mounting bolts and install. 6. Reconnect the power cables to the lift motor. Use two wrenches to avoid twisting the terminal studs. Torque to 100-120 in. lb. (11.2-13.6 Nm). 7. Reconnect motor brush wear sensor connector JPS8. 8. Remove the blocks of wood from beneath the lift pump. 9. Reinstall the front cover mounting bracket. 10. Install the electric steer motor. See “Electric Steer Motor” on page 7-24. 11. Install the mast. See “Mast” on page 7-148. 12. Reconnect the battery connector and turn the key switch ON. 13. Test lift/lower functions. Check for hydraulic leaks where mast hoses were removed. 14. Install the 3 front covers. See “Front Covers” on page 7-16.

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Component Procedures Electrical Components

Auxiliary Motor See “Motors, General” on page 7-102 for instructions on: • Cleaning the motor • Testing the motor • Inspecting and changing the brushes

Location The auxiliary motor is located behind the operator display, mounted to the frame. See Figure 7-142. Auxiliary Motor

Removal 1. Turn the key switch OFF and disconnect the battery connector. 2. Remove the console cover. See “Console Cover” on page 7-14.

Auxiliary Pump

3. Remove the two power cables, labeling if necessary for later installation. Use two wrenches to avoid twisting the terminal studs. 4. Remove the auxiliary pump from the auxiliary motor without disconnecting the pump hoses. See “Auxiliary Pump” on page 7-141.

! CAUTION

Figure 7-142: Auxiliary Motor

The auxiliary motor is heavy. Use a suitable lifting device if necessary. 5. Remove the mounting bolts that hold the auxiliary motor to the frame. 6. Carefully remove the auxiliary motor from the frame.

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Component Procedures Electrical Components

Installation 1. Carefully place the auxiliary motor over the mounting holes on the frame. 2. Apply Loctite 242 (Blue), tighten, and torque the four motor mounting bolts. Reference “Torque Chart - Standard (Ferrous)” on page A-4. 3. Apply a thin coat of anti-seize compound (P/N 313666-465) to the spline on the end of the auxiliary pump. 4. Attach the coupling half to the motor shaft. 5. Attach the pump to the motor, mating the two halves of the coupling with the rubber coupling cushion in between. Install the two auxiliary pump mounting bolts. 6. Attach the power cables to the motor, observing proper polarity. Use a second wrench on the stud terminal securing nut to avoid twisting the stud. Torque the motor cable securing nuts to 45-55 in. lb. (5.0-6.2 Nm). 7. Reconnect the battery connector and turn the key switch ON. Test the steering function. Check for leaks. 8. Install the console cover. See “Console Cover” on page 7-14.

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Component Procedures Electrical Components

Key Switch Location The key switch is located on the operator display bezel to the left the operator display and beneath the Emergency Power Off knob.

Testing 1. Turn the key switch OFF and disconnect the battery connector. 2. Remove the console cover. See “Console Cover” on page 7-14.

Key Switch 8D14121S.TIF

Figure 7-143: Key Switch Location

3. Scribe a mark on the tractor frame noting the position of the key switch bezel. 4. Remove the mounting bolt that secures the bezel to the tractor frame. 5. Remove the two bolts that secure the bezel to the mounting bracket under the steering valve. 6. Remove the key switch bezel. This prevents possible shorts to frame at the key switch terminals, which are close to the frame. See Figure 7-144.

Key Switch Bezel EPO Switch

7. Remove the two wires (S1-1 and S1-2) from the terminals on the back of the key switch. 8. Connect a digital ohmmeter to the two terminals on the switch. Set the scale to Rx1. 9. Put the key in the key switch. Turn the key clockwise to its ON position. The ohmmeter should show continuity (0 ohms). 10. Turn the key to its OFF position. The ohmmeter should read open (infinity). 11. If you observe the expected readings from the previous two steps, the key switch itself is OK. Carefully reconnect the two wires you removed in step 3.

Key Switch

18o6S003.TIF

Figure 7-144: Key Switch, back view

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Removal 1. Turn the key switch OFF and disconnect the battery connector. 2. Remove the console cover. See “Console Cover” on page 7-14. 3. Remove the operator display bezel. See “Operator Display” on page 7-36. 4. Disconnect the two wires (S1-1 and S1-2) from the back of the key switch. 5. Loosen the round knurled nut on the key switch. Key switch can now be removed by hand.

Installation 1. Place key switch in the hole on the operator display, making sure it is positioned correctly. 2. Replace washer and nut on front of the key switch and tighten. 3. Reconnect the two wires (S1-1 and S1-2) to the terminals on the back of the switch. 4. Install the operator display bezel. See “Operator Display” on page 7-36. 5. Install the console cover. See “Console Cover” on page 7-14. 6. Reconnect the battery connector and turn the key switch ON. 7. Ensure the key switch functions properly.

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Component Procedures Electrical Components

Emergency Power Off (EPO) Switch Location The EPO switch is located above the Key Switch on the operator display bezel. See Figure 7-145.

Removal 1. Turn the key switch OFF and disconnect the battery connector. 2. Remove the console cover. See “Console Cover” on page 7-14. 3. Remove the two wires from the back of the EPO switch, labeling if necessary for later installation. See Figure 7-146. 4. Loosen the two retaining screws on the back of the switch body. 5. Hold switch body firmly while twisting knob counter clockwise to disengage the knob from the body. Remove both halves of the switch.

Installation

EPO Knob 8D14121S.TIF

Figure 7-145: Emergency Power Off (EPO) Switch Location EPO Switch

1. Insert the knob through the mounting hole in the operator display bezel.

Terminals

2. Mate the switch back to the knob shaft. 3. Whole holding the switch body firmly, press and twist the knob clockwise to engage the switch halves. 4. Tighten the retaining screws on the switch body. 5. Re-attach the two wires to the back of the EPO switch. 6. Reinstall the console cover. See “Console Cover” on page 7-14. 7. Reconnect the battery connector and turn the key switch ON. 8. Test operation of the EPO switch. Travel, lift, and auxiliary functions should be disabled. Key Switch 8D14101S.TIF

Figure 7-146: EPO Switch, back view

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Electrical Components

Speed Feedback Sensor Location A speed feedback sensor is located on each of the lift truck’s drive motors.

Speed Sensor (Left Drive Motor)

Removal 1. Turn the key switch OFF and disconnect the battery connector. 2. Remove the front covers. See “Front Covers” on page 7-16. 3. Disconnect the speed feedback sensor wiring harness connector JPS3 (left) or JPS4 (right). 4. Remove the sensor by removing the mounting bolt.

Installation 1. Apply Loctite 242 (Blue) to the mounting bolt. Install the sensor and bolt and tighten. 2. Connect wiring harness connector JPS3 or JPS4. 3. Reconnect the battery connector and turn the key switch ON. 4. Test the drive function. 5. Turn the key switch OFF and disconnect the battery connector. 6. Install the front covers. See “Front Covers” on page 7-16.

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Mounting Bolt

JPS3 8D14052S.TIF

Figure 7-147: Speed Feedback Sensor

Prime-Mover CRX30/35/40/50 Service Manual

Component Procedures Electrical Components

Steer Position Proximity Sensor Location JPS2

The steer position proximity sensor is located on the left side of the operator compartment.

Removal 1. Turn the key switch OFF and disconnect the battery connector. 2. Remove the steer compartment cover. See “Steer Compartment Cover” on page 7-18.

Steer Position Proximity Sensor 8D14024S.TIF

Figure 7-148: Steer Position Proximity Sensor Location

3. Cut tie wraps as necessary. Note their location for installation later. 4. Disconnect connector JPS2 near the sensor. See Figure 7-148. 5. Mark a line around the base of the sensor bracket, so you can reinstall it in the same position. Bracket

6. Remove the two bolts securing the sensor mounting bracket to compartment floor. See Figure 7-149. 7. Remove the four screws mounting the sensor to the sensor bracket.

Steer Position Proximity Sensor 137.TIF

Figure 7-149: Steer Position Proximity Sensor Bracket

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Installation 1. Apply Loctite 242 (Blue) to the sensor mounting screws. Mount the sensor to the sensor bracket and tighten the screws evenly. 2. Position the sensor bracket assembly over the scribed mark on the compartment floor. 3. Apply Loctite 242 (Blue) to the bracket mounting bolts. Secure the bracket in place with the two bolts. 4. Check the gap between the bottom face of the sensor and the upper surface of the steer plate. This gap should be 0.080 in. (2 mm), ±0.020 in. (0.005 mm). 5. Connect the sensor wiring harness at connector JPS2. 6. Replace any tie wraps previously removed. 7. Reconnect the battery connector and turn the key switch ON. 8. Run Test I08. 9. Turn the key switch OFF and disconnect the battery connector. 10. Install the steer compartment cover. See “Steer Compartment Cover” on page 7-18.

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Component Procedures Hydraulic Components

7149: Component Procedures

Hydraulic Components

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Hydraulic Components

Hydraulic Fluid Checking Hydraulic Fluid Level To check the level of the hydraulic fluid in the system: NOTE: The temperature of the hydraulic fluid should be approximately room temperature. 1. Tilt the mast all the way back. 2. Remove the front cover. 3. Unscrew the fill cap from the hydraulic reservoir. 4. Look inside the hydraulic reservoir. The hydraulic fluid should be 1/2 to 1 in. (13 to 25.4 mm) above the bottom of the screen inside the reservoir. 8D14083S.TIF

Selecting Hydraulic Fluid Type Refer to the Lubrication Equivalency Chart in the Appendix on page A-2.

Changing Hydraulic Fluid and Filter 1. Lower the forks all the way to the floor. 2. Turn the key switch OFF and disconnect the battery connector. 3. Remove the top front and right front covers. See “Front Covers” on page 7-16. 4. Place a large drain pan next to the right side drive wheel. 5. Remove the tie wrap securing the drain hose and lay the hose behind the right side drive wheel into the drain pan. 6. Lay the drain hose behind the right hand drive wheel. 7. Remove the plug from the end of the drain line and allow fluid to drain into the container. 8. After all the hydraulic fluid has been drained, replug the drain hose and secure with a tie wrap to the steer pump supply hose.

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Figure 7-150: Hydraulic Fluid Filler Strainer

Prime-Mover CRX30/35/40/50 Service Manual

Component Procedures Hydraulic Components

9. If the hydraulic fluid was contaminated, try to determine the source of contamination. 10. Replace the hydraulic filter as follows: a. Place shop rags under the filter to absorb hydraulic fluid. b. Use a filter wrench if necessary to loosen the hydraulic filter. c. Unscrew the filter from its mount. d. Thoroughly clean the filter’s mounting surface on the hydraulic manifold. e. Rub a thin film of hydraulic fluid on the rubber seal on the new filter. f. Screw the new filter onto its mount on the hydraulic manifold. g. When the new filter just touches the mounting surface on the hydraulic manifold, give it an additional 3/4 to 1 full turn (do not overtighten). NOTE: If the specifications on the filter housing differ from the manual, refer to the filter for the correct specifications. 11. Fill the hydraulic reservoir with new hydraulic fluid. 12. Operate the mast tilt and (optional) sideshift several times. 13. Check the level of the hydraulic fluid in the reservoir. See “Checking Hydraulic Fluid Level” on page 7-126. Add hydraulic fluid as necessary. 14. Bleed the hydraulic system. See “Bleeding the Hydraulic System” on page 7-128.

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Hydraulic Components

Bleeding the Hydraulic System You must bleed the hydraulic system (to remove any trapped air) whenever you: • Change a hydraulic hose • Disconnect a hydraulic fitting • Notice that the load is bouncing • Remove a hydraulic cylinder • Remove a hydraulic pump • Remove the hydraulic reservoir NOTE: When bleeding the hydraulic system, be sure to bleed all three cylinders. 1. Turn the key switch to ON. Step on the deadman pedal and lift the forks 6 to 12 in. (150 to 300 mm) off the ground. 2. Bleed the lift system as follows: a. Loosen (don’t remove) the bleed screw on the lift cylinder to let any air escape. Hold the rag close to and beneath the bleed screw to keep any hydraulic fluid from spraying out. See Figure 7-151. b. When all the air has escaped and hydraulic fluid starts coming out of the bleed screw hole, securely tighten the bleed screw.

Bleed Screw 8D14012S.TIF

3. Lower the forks all the way down to the floor. 4. Bleed the auxiliary system as follows: a. Tilt the mast all the way forward and backward several times. b. If this truck has sideshift, shift the carriage all the way to the left and right several times. 5. Check the hydraulic fluid level. See “Checking Hydraulic Fluid Level” on page 7-126. Add hydraulic fluid as necessary.

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Figure 7-151: Main Lift Cylinder Bleed Screw

Prime-Mover CRX30/35/40/50 Service Manual

Component Procedures Hydraulic Components

Steer Valve Removal 1. Turn the key switch OFF and disconnect the battery connector. 2. Remove the console cover. See “Console Cover” on page 7-14. 3. Remove the steering tiller and steer cover. 4. Remove the key switch bezel. See “Key Switch” on page 7-119. 5. Remove the five shoulder bolts securing the steer valve plate to the tractor frame.

Steer Valve Assembly 8d14019.tif

Figure 7-152: Steering Tiller Removal

6. Place shop rags beneath the steer valve to catch any spilled hydraulic fluid. 7. Disconnect and cap the two hoses attached to the steer valve and the two steel lines to the hydraulic manifold. 8. Remove the three bolts that hold the steer valve assembly bracket in place. Remove the steer valve assembly. 9. Remove the steer valve from the bracket.

Installation 1. Attach the steer valve to its mounting bracket, making sure the holes for the hoses are pointing forward. Do not tighten the mounting bolts yet. 2. Reinstall the valve assembly bracket with three mounting bolts. 3. Tighten the orbitrol mounting bolts. 4. Reconnect the hoses and steel lines to the front of the steer valve. 5. Reinstall the steer cover and steering wheel. 6. Reconnect the battery connector and turn the key switch ON. 7. Turn the steering wheel fully clockwise and fully counterclockwise several times. 8. Turn the key switch OFF. 9. Check the level of the hydraulic fluid in the reservoir. See “Checking Hydraulic Fluid Level” on page 7-126. Add hydraulic fluid as necessary.

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Component Procedures Hydraulic Components 10. Check for any signs of leakage from where the hoses mount to the front of the steer valve. 11. Reinstall the console cover. See “Console Cover” on page 7-14. 12. Reinstall the steer compartment side cover. See “Steer Compartment Cover” on page 7-18.

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Component Procedures Hydraulic Components

Solenoids Tilt/Sideshift Manifold

The main manifold solenoids and tilt/sideshift solenoids are located on the left side of the tractor frame. See Figure 7-153. If the truck is configured for high speed auxiliary functions, there will be an auxiliary manifold and control handle mounted behind the operator display. See Figure 7-154. The individual solenoids for the main manifold are identified in Figure 7-155.

Main Manifold 8D14080S.TIF

Figure 7-153: Manifold Location

Solenoid 1: Load Holding Solenoid Solenoid 2: Sideshift Solenoid Solenoid 4: Tilt Solenoid Solenoid 5: Aux PSI Select Solenoid Solenoid 6: Direction A Solenoid Solenoid 7: Equalization Solenoid Solenoid 8: Direction B Solenoid Solenoid 9: High Flow Aux Select Solenoid Solenoid 10: High Flow Aux 1 Solenoid Solenoid 11: High Flow Aux 2 Solenoid Auxiliary Manifold Figure 7-154: Auxiliary Manifold

Removal 1. Make sure that the forks are lowered all the way to the floor.

SOL1

SOL6

SOL4

SOL8

2. Turn the key switch to OFF. Disconnect the battery connector. 3. Remove the console cover for access to main manifold solenoids. See “Console Cover” on page 7-14. Remove front covers for access to attachments manifold. See “Front Covers” on page 7-16. 4. Remove the two wires from the terminals on the solenoid.

Lift Valve

REL-1

CV2

CV1

SOL7 P1812.EPS

Figure 7-155: Main Manifold Solenoid Layout

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Hydraulic Components 5. Remove the nut that secures the solenoid coil to the solenoid valve. 6. Lift the solenoid coil off the solenoid valve. 7. Remove the solenoid valve from the manifold.

Installation 1. Inspect the seat where the solenoid seals against the manifold. The sealing surface should be completely clean and free from any nicks or damage. 2. Inspect the O-ring for any damage. If the O-ring is damaged or deformed in any way, replace it. 3. Install the solenoid valve into the port and torque to 60 ft. lb. (81 Nm). 4. Install the solenoid coil onto the solenoid valve. 5. Install the nut on top of the solenoid coil and tighten to 5 ft. lb. (7 Nm). 6. Connect the wires to the terminals. 7. Reconnect the battery connector and turn the key switch ON. 8. Test the functions of the truck. 9. Turn the key switch OFF and disconnect the battery connector. 10. Install any covers that were removed.

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Figure 7-156: Attachments Manifold

Prime-Mover CRX30/35/40/50 Service Manual

Component Procedures Hydraulic Components

Hydraulic Steer Motor The hydraulic steer motor is located in the steering compartment, on the left side of the operator compartment.

Removal 1. Turn the key switch OFF and disconnect the battery connector. 2. Remove the steer compartment cover. See “Steer Compartment Cover” on page 7-18. 3. Remove the steer chain adjusting nut and steer chain (Cut tie wraps as needed on hydraulic hoses).

030.tif

Figure 7-157: Steer Chain Nut Removal

4. Place a drain pan beneath the steer motor. Disconnect the two hydraulic hoses to the steer motor. Note their location for reinstallation. 5. Remove four mounting bolts. 6. Remove sprocket from motor.

Installation 1. Apply thread-locking compound to the sprocket shaft set screws. Attach the sprocket to the steer motor shaft with two set screws. 2. Place the hydraulic steer motor in position. Mount with four mounting bolts and tighten.

035.tif

Figure 7-158: Steer Motor Hose Removal

3. Reinstall the hoses to the steer motor. 4. Reinstall the steer chain and tighten. Allow 1/16 in. (1.6 mm) deflection at its midpoint. 5. Reconnect the battery connector and turn the key switch ON. Check for leaks at the hydraulic connections. 6. Test the steering functions. 7. Bleed the hydraulic system. See page 7-128. Check the hydraulic fluid level. See page 7-126. 8. Reinstall the steer compartment cover. 037.tif

Figure 7-159: Hydraulic Steer Motor Mounting Bolts

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Reversing Steering Action 1. Turn the key switch OFF and disconnect the battery connector. 2. Remove the steer compartment cover. See “Steer Compartment Cover” on page 7-18. 3. Place a container under the hoses to catch any fluid that escapes when the hose connections are loosened. 4. Disconnect the hydraulic hoses at the steer motor. See Figure 7-158 on page 7-133. 5. Reconnect the hoses to the opposite fittings on the steer motor. 6. Reconnect the battery connector and turn the key switch ON. Test the steering function. Check for leaks at the hydraulic steer motor hydraulic fittings. 7. Turn the key switch OFF and disconnect the battery connector. 8. Reinstall the steer compartment cover.

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Component Procedures Hydraulic Components

Pressure, Setting System Lift Relief Valve The following procedure applies to the main manifold.

Relief Valve REL-1

1. Remove the protective cap (if used) on the lift relief valve. See Figure 7-160. 2. Loosen the lock nut. 3. Place a rated load +500 lb. (227 kg) on the forks. 4. Adjust the relief valve screw until the load begins to lift. 5. Elevate the load through freelift and tighten the screw to allow minimum telescopic lifting.

Figure 7-160: Lift Relief Valve

6. Tighten the lock nut. 7. Install the protective cap (if used). 8. Remove the load from the forks and check the relief pressure by dumping full lift flow through the relief valve (by elevating the mast against stop).

Auxiliary Relief Valve The following procedure applies to the main manifold which is used for low-speed auxiliary functions: 1. Remove protective cap (if used) on the auxiliary relief valve located on the auxiliary pump. 2. Loosen the lock nut. 3. Install an auxiliary pressure gauge in the main manifold at auxiliary port AP. 4. Enable a relief condition by tilting the forks forward. 5. Verify the pump relief pressure of 2000 ±100 psi (13789 ±689 kPa). 6. Use an Allen wrench to adjust the auxiliary relief pressure if necessary. Turning the screw clockwise will increase pressure and counterclockwise will decrease pressure. NOTE: The pump may only have a protective cap and adjustable screw that requires a flathead screwdriver for adjustment. There will not be a locknut to remove.

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Component Procedures Hydraulic Components 7. Tighten the lock nut. 8. Install protective cap (if used). The manifold used for high-speed auxiliary functions is located behind the operator display. This auxiliary relief valve should be set to a pressure that is specified by the manufacturer of the attachment being used. Perform the following procedure: 1. Remove protective cap (if used) on the auxiliary relief valve. 2. Loosen lock nut. 3. Install auxiliary pressure gauge in the hydraulic circuit at the attachment. 4. Enable a relief condition by advancing the high speed attachment. 5. Verify the pump relief pressure recommended by the attachment manufacturer. Turn the adjustment screw clockwise to increase pressure or counterclockwise to decrease pressure. 6. Tighten the lock nut. 7. Install protective cap (if used).

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Component Procedures Hydraulic Components

Reservoir Removal 1. Turn the key switch OFF and disconnect the battery connector. 2. Remove the mast. See “Mast” on page 7-148. 3. Drain the reservoir into a suitable container. See “Changing Hydraulic Fluid and Filter” on page 7-126. 4. Remove the steer motor and pump. See “Steer Pump” on page 7-139. 5. Remove the lift pump and place hose out of the way. See “Lift Pump” on page 7-140. 6. Remove the left drive motor and all connected components. Place a cover over the drive unit in order to prevent contamination. See “Drive Motor” on page 7-111. 7. Remove the left cover support bracket. 8. Disconnect hoses from the tilt cylinders and place them out of the way. 9. Disconnect the fluid return line from the bottom of the reservoir and from the manifold. 10. Lift the manifold sufficiently to allow removal of the rigid metal hydraulic line to the steer valve. 11. Place the rigid metal hydraulic line in a secure location. 12. Route all cables from in front of the reservoir to a safe location. 13. Remove the reservoir by removing all six bolts from its brackets. NOTE: It may be beneficial to mark the hoses and their connections in some manner, to facilitate replacement later.

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Installation 1. Reverse removal procedure. See page 7-137. 2. Refill the drive units with the correct grade fluid. See “Lubrication Equivalency Chart” on page A-2. 3. Refill the reservoir with the correct grade fluid to the proper level. Check all reservoir hoses for tightness or leaks. See “Lubrication Equivalency Chart” on page A-2. 4. Change the fluid filter to prevent system contamination. 5. Check all hoses for chafing and tightness. 6. Reconnect the battery connector and turn the key switch ON. 7. Bleed the hydraulic system. See “Bleeding the Hydraulic System” on page 7-128. 8. Check all truck functions for proper operation. Check hydraulic fluid level.

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Component Procedures Hydraulic Components

Steer Pump Removal 1. Tilt the mast all the way forward. 2. Turn the key switch OFF and disconnect the battery connector. 3. Remove the front covers. See “Front Covers” on page 7-16. 4. Place shop rags beneath the steer pump and around the electric steer motor impeller to prevent parts from falling into the lift motor.

Steer Pump

5. Place a drain pan beneath the steer pump. Disconnect and cap the two steer pump hydraulic hoses. 6. Remove the two bolts securing the steer pump to the steer motor. 7. Remove the coupling from the pump shaft. See Figure 7-161.

Steer Motor

Installation 1. Attach the coupling to the steer pump shaft. 2. Apply a thin coat of anti-seize (P/N 313666-465) compound to the couplings and coupling cushion.

8D14063S.TIF

Figure 7-161: Steer Pump Mating to Steer Motor

3. Attach the pump to the motor, mating the two halves of the coupling with the rubber cushion in between. Apply Loctite 242 (Blue) to the two pump mounting bolts and tighten. 4. Connect the two hydraulic hoses to the steer pump. 5. Check the fluid level in the hydraulic reservoir. See “Checking Hydraulic Fluid Level” on page 7-126.

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Hydraulic Components

Lift Pump

Lift Motor

Removal 1. Remove the mast. See “Mast” on page 7-148. 2. Turn the key switch OFF and disconnect the battery connector. 3. Remove the front covers. See “Front Covers” on page 7-16. 4. Place a drain pan beneath the lift pump. NOTE: When the hydraulic hoses are disconnected from the lift pump, the hydraulic reservoir will drain. Make sure that the drain pan has the capacity to hold at least 8 gallons (30 liters). 5. Disconnect the hydraulic hoses to the lift pump. 6. Remove the bolts that secure the lift pump to the bottom of the lift motor. See Figure 7-162.

Installation 1. Apply a thin coat of anti-seize compound (P/N 313666-465) to the lift pump spline. 2. Mate the lift pump spline to the lift motor and attach the lift pump to the lift motor with the two mounting bolts. Tighten and torque. 3. Reconnect the two hydraulic hoses to the lift pump. 4. Install the mast. See “Mast” on page 7-148. 5. Fill the reservoir with hydraulic fluid. See “Lubrication Equivalency Chart” on page A-2. Reservoir holds approx. 5.8 gal. (22 liters). 6. Reconnect the battery connector and turn the key switch ON. 7. Bleed the hydraulic system. See “Bleeding the Hydraulic System” on page 7-128. 8. Check the fluid level in the hydraulic reservoir. See “Checking Hydraulic Fluid Level” on page 7-126. 9. Reinstall front covers.

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Lift Pump 8D14074S.TIF

Figure 7-162: Lift Pump Removal

Prime-Mover CRX30/35/40/50 Service Manual

Component Procedures Hydraulic Components

Auxiliary Pump Removal 1. Turn the key switch OFF and disconnect the battery connector. 2. Remove the console cover. See “Console Cover” on page 7-14. 3. Place shop rags beneath the pump. and around the motor. 4. Place a drain pan beneath the pump. Disconnect and cap the two auxiliary pump hydraulic hoses. 5. Remove the two bolts securing the auxiliary pump to the auxiliary motor. 6. Remove the coupling from the pump shaft.

Auxiliary Pump

Mounting Bolt

Installation 1. Attach the coupling to the auxiliary pump shaft. 2. Apply a thin coat of anti-seize (P/N 313666-465) compound to the couplings and coupling cushion. 3. Attach the pump to the motor, mating the two halves of the coupling with the rubber cushion in between. Apply Loctite 242 (Blue) to the two pump mounting bolts and tighten. 4. Connect the two hydraulic hoses to the auxiliary pump.

Figure 7-163: Auxiliary Pump

5. Check the fluid level in the hydraulic reservoir. See “Checking Hydraulic Fluid Level” on page 7-126.

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Hydraulic Components

Tilt Cylinder Removal 1. Lower the forks all the way to the floor. 2. Turn the key switch OFF and disconnect the battery connector. 3. Remove the front covers. See “Front Covers” on page 7-16. 4. Wrap a chain or lifting strap around the top of the mast. Attach the chain or strap to a hoist or suitable lifting device with a 5-ton capacity. 5. Lift the hoist just enough to take slack out of the lifting chain and strap. 6. Note the number of threads showing on the tilt cylinder piston retaining nut. This will facilitate installation. Loosen the jam nut and unthread the piston from the mast pivot block. See Figure 7-164.

Tilt Cylinder Pivot Block

7. Cover the drive motor and brake assembly with shop rags to protect them from hydraulic fluid. Disconnect and cap the two hydraulic hoses from the tilt cylinder. Also cap the fittings on the cylinder itself.

Tilt Cylinder

8. Remove the pin from the clevis pin on the rear of the tilt ram. See Figure 7-165. 9. Support the rear end of the tilt cylinder. Push or tap the clevis pin out of the rear of the cylinder.

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Clevis Pin

Jam Nut 8D14034S.TIF

Figure 7-164: Tilt Cylinder Piston Removal

Prime-Mover CRX30/35/40/50 Service Manual

Component Procedures Hydraulic Components

Installation 1. Position the cylinder housing yoke in place and secure with the clevis pin and cotter pin. 2. Connect the hydraulic hoses to the cylinder.

Clevis Pin

Cylinder Housing

3. Thread the cylinder piston into the mast pivot block until the same number of threads shows as you counted earlier. 4. Tighten the retaining nut against the pivot block. 5. Remove protective rags from drive motor and brake assembly.

8D14048S.TIF

Figure 7-165: Tilt Cylinder Clevis Pin and Cotter Pin

6. Reconnect the battery connector and turn the key switch ON. 7. Test the mast tilt function. Check for leaks at the cylinder. 8. Turn the key switch OFF and disconnect the battery connector. 9. Reinstall front covers. See “Front Covers” on page 7-16.

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Quad Mast Hose Replacement This procedure provides the necessary steps to install replacement hydraulic hoses on the 35D Quad mast.

Installation See Figure 7-166. The numbered arrows in the figure correspond to the steps that follow. 1. Connect the short hoses to the carriage bracket fittings. Hand tighten the fittings. Double Function: The No. 4 hoses connect to the two left fittings (viewed from the operator’s seat). 2. Route the hoses over the crosshead pulleys. Tighten the cover capscrew and torque to 63 ft. lb. (85 Nm). 3. Route the hoses down between the freelift cylinder and cross member. Position the hoses in their natural curve over the crosshead pulleys. Tighten the hose ends at the carriage bracket. 4. Connect the long hoses to the short hoses behind the freelift cylinder. Double Function: The right side hoses (viewed from the operator’s seat) are approx. 14 in. (355 mm) longer than the left side hoses. 5. Pull down on the hoses with approx. 30 lb. (13.5 kg) force. Clamp the hoses to the lower bracket attached to the inner upright cross member. Tighten the clamp capscrew and torque to 11 ft. lb. (15 Nm). 6. Route hoses up to the left through the guide. Position the hoses in the guide as indicated. Reinstall the retainer bar with the end in the bracket slot. 7. Route hoses up and over the upper bracket pulleys, then down to the middle hose guide. 8. Pull down on the hoses with 40 lb. (18 kg) force. Clamp the hoses to the top of the middle hose guide. Tighten the clamp capscrews and torque to 11 ft. lb. (15 Nm).

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Component Procedures Hydraulic Components

7 21

14 12

4 3 34

Single Function

Double Function

8 2 15 12

3 41 2

3 412

24 21

4321 13

5 1 1

Single Function

4 2

Double Function

Single Function

Double Function

Figure 7-166: Quad Mast Hose Routing

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Hydraulic Components 9. Clamp the hoses to the lower location on the middle hose guide. Arrange the hoses in the clamp as shown. Tighten the capscrews and torque to 11 ft. lb. (15 Nm).

10. Reinstall the upper hose guide to the tapped bar on the outer upright. Leave the capscrews loose. 5

11. Loop the hoses 5 in. (125 mm) below the bottom of the middle hose guide and route upward into the upper hose guide. 12. Feed the hose ends up between the chain anchors. Install the hose retainer bar at the top of the upper hose guide. Tighten the capscrews and torque to 11 ft. lb. (15 Nm). 13. Reinstall the guide bar between the upper hose guide and tapped bar on the outer upright. Route the hoses to the right of the guide bar. Tighten the guide capscrews and torque to 36 ft. lb. (50 Nm).

5 3

14. Clamp the hoses to the guide bar. Tighten the capscrews and torque to 11 ft. lb. (15 Nm). 15. Clamp the hoses to the back side of the upper hose guide. Tighten the capscrews and torque to 11 ft. lb. (15 Nm). 2, 4

Hose and Bracket Adjustment See Figure 7-167. The numbered arrows in the figure correspond to the steps that follow. 1. Raise the mast slowly, checking all guides and brackets for proper clearances and alignment. 2. Check for a sufficient length of hose between the middle and upper hose guides at full extension. 3. Check the hoses for proper tracking over the sheaves.

4. Check the hoses for even tracking in the hose guides. 5. Raise and lower the mast slowly through several cycles for a final check. Check all clamp capscrews for proper torque and retighten if necessary.

Figure 7-167: Quad Mast Hose and Bracket Adjustment

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Component Procedures Mast, Chain, Hose, Cable

7167: Component Procedures

Mast, Chain, Hose, Cable

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Mast, Chain, Hose, Cable

Mast Complete Removal NOTE: See also “Partial Removal” procedure which follows for an alternative means of gaining access to motors and pumps. For this procedure, you will need a hoist or lift truck of suitable capacity. 1. Turn the key switch OFF and disconnect the battery connector. 2. Remove the console and front covers. See “Console Cover” on page 7-14 and "Front Covers" on page 7-16. 3. Remove the forks. See “Forks” on page 7-157. 4. Reconnect the battery connector and turn the key switch ON. Elevate the fork carriage about 18 in. (450 mm). Place blocks under the fork carriage. Lower the fork carriage onto the blocks. See Figure 7-168. 5. Turn the key switch OFF and disconnect the battery connector. 6. Remove the lower mounting bolt only from each mast bearing cap. Do not remove the upper bolt. See Figure 7-168. 7. Reconnect the battery connector and turn the key switch ON. Elevate the fork carriage, remove the blocking, and lower the fork carriage all the way to the floor. 8. Verify that the mast is in a vertical position. 9. Position the truck beneath the hoist or forks of a lift truck of suitable capacity. 10. Turn the key switch OFF and disconnect the battery connector. 11. Wrap a chain or lifting strap around the top of the mast. Attach the chains or straps to a hoist. 12. Lift the hoist just enough to take the slack out the chain or strap.

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Lower Bearing Bolt 8D14030S.TIF

Figure 7-168: Mast Pivot Bearing Caps

Prime-Mover CRX30/35/40/50 Service Manual

Component Procedures Mast, Chain, Hose, Cable

13. Count the number of threads visible in back of the retaining nut for reference in re-assembly. Loosen tilt cylinder retaining nuts. Remove piston from mast pivot block. See Figure 7-169.

Tilt Cylinder Pivot Block

Clevis Pin

14. Reconnect the battery connector and turn the key switch ON. Actuate the tilt control and retract the tilt rams.

Tilt Cylinder

15. Turn the key switch OFF and disconnect the battery connector.

Jam Nut 8D14034S.TIF

Figure 7-169: Tilt Cylinder Removed from Mast

16. Carefully lay the tilt cylinder down on the brake assembly. 17. Disconnect hose from the lift/lower manifold being careful not to spill hydraulic fluid. Plug/cap each fitting to prevent contamination from entering the hydraulic system. See Figure 7-170. 18. Remove the upper mounting bolt securing the mast bearing cap on each drive unit. Remove the mast bearing cap. 19. Use the hoist or another lift truck to lift the mast just enough to allow it to be moved away from the tractor. 20. Using tie wraps, attach hose to lift chain to keep in place.

8D14033S.TIF

Figure 7-170: Mast Hydraulic Hose Disconnection

Shims

Drive Wheel

Drive Unit

21. Have wood blocks positioned so that the mast can be properly supported off the floor. 22. Carefully lower the mast onto the support blocks with the fork carriage facing down.

Mast

23. Note the number of shims between the OilLite bearings and mast. See Figure 7-171. OilLite Bearing

Pivot Bearing Cap 8D14035S.TIF

Figure 7-171: Mast Pivot Bearing Parts

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Installation NOTE: For this procedure, you will need a hoist or lift truck of suitable capacity. 1. Ensure that the pivot bearings are shimmed as they were when the mast was removed. 2. Wrap a chain or lifting strap around the top of the mast. Attach the chains or straps to the lifting device. 3. Slowly lift the mast up and off the wooden blocks. 4. Slowly move the mast towards the truck. 5. Position the lower pivot bearings on the mast at the same height of the pivot yokes on the drive units. 6. Carefully engage the mast pivot bearings with the yokes on the drive unit. 7. Install the upper screw in both mast bearing caps. 8. Attach the tilt cylinder to the pivot points on the mast. 9. Reconnect the battery connector and turn the key switch ON. 10. Slowly, extend the tilt rams until you are able to thread the piston into the pivot block. Screw the retaining nut snug against the pivot block. Adjust so the number of threads showing behind the jam nut is the same as before removal. 11. Remove the lifting device and any chains/straps used to lift the mast. 12. Reconnect the hydraulic hose at the main manifold. 13. Reconnect the battery connector and turn the key switch ON. 14. Slowly elevate and tilt the mast. Check for any hydraulic leaks. 15. Elevate the fork carriage about 18 in. (450 mm). Place blocks under the fork carriage. Lower the fork carriage onto the blocks. 16. Turn the key switch OFF and disconnect the battery.

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Component Procedures Mast, Chain, Hose, Cable

17. Apply Loctite 242 (Blue) to the lower mast bearing cap screws and torque them to 43 ft. lb. (60 Nm). 18. Remove the upper mast bearing cap screws. Apply Loctite 242 (Blue) to the screws and torque them to 43 ft. lb. (60 Nm). 19. Reconnect the battery connector and turn the key switch ON. 20. Elevate the fork carriage and remove any blocking. 21. Install the forks. 22. Bleed the hydraulic system. See “Bleeding the Hydraulic System” on page 7-128. 23. Install the covers. See “Covers and Accessories” on page 7-13.

Partial Removal NOTE: See also “Partial Removal” procedure which follows for an alternative means of gaining access to motors and pumps.

Tilt Cylinder Pivot Block

Clevis Pin

NOTE: For this procedure, you will need a hoist or lift truck of suitable capacity. 1. Turn the key switch OFF and disconnect the battery connector. 2. Remove the console and front covers. See “Console Cover” on page 7-14 and "Front Covers" on page 7-16.

Tilt Cylinder

3. Remove the forks. See page 7-157.

Jam Nut

4. Verify that the mast is in a vertical position. 5. Position the truck beneath the hoist or lift truck.

8D14034S.TIF

Figure 7-172: Tilt Cylinder Removed from Mast

6. Turn the key switch OFF and disconnect the battery connector. 7. Wrap a chain or lifting strap around the top of the mast. Attach the chains or straps to a hoist or lift truck. 8. Lift the hoist just enough to take the slack out the chain or strap. 9. Count the number of threads visible in back of the retaining nut for reference in re-assembly. Loosen tilt cylinder retaining nuts. Remove piston from mast pivot block. See Figure 7-172.

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Component Procedures

Prime-Mover CRX30/35/40/50 Service Manual

Mast, Chain, Hose, Cable 10. Reconnect the battery connector and turn the key switch ON. Actuate the tilt control and retract the tilt rams. 11. Turn the key switch OFF and disconnect the battery connector. 12. Carefully lay the tilt cylinder down on the brake assembly.

! CAUTION Tilting the mast too far forward will cause the bottom of the mast upright to gouge the drive unit cover. See Figure 7-173. 13. Using the hoist or lift truck, carefully tilt the mast forward until it is no more than 45°.

Installation after Partial Removal NOTE: For this procedure, you will need a hoist or lift truck of suitable capacity.

Mast

Drive Unit

Drive Wheel

1. With the mast securely held by a strap and chain, carefully raise the mast until it is vertical. 2. Attach the tilt cylinder to the pivot points on the mast. 3. Reconnect the battery connector and turn the key switch ON. 4. Slowly, extend the tilt rams until you are able to thread the piston into the pivot block. Screw the retaining nut snug against the pivot block. Adjust so the number of threads showing behind the jam nut is the same as before removal. 5. Remove the lifting device and any chains/straps used to lift the mast. 6. Install the forks. See page 7-157. 7. Install the covers. See page 7-13.

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Avoid Contact Between Mast and Drive Unit Plate 8D14108S.TIF

Figure 7-173: Mast Partial Removal (Detail)

Prime-Mover CRX30/35/40/50 Service Manual

Component Procedures Mast, Chain, Hose, Cable

Lift Chains Inspection Inspect the chains for: • Damage • Excessive corrosion • Lack of lubrication • Stretch or excessive wear

Main Lift Chain Trucks with a two-stage or three-stage mast will have two main lift chains. On either type of mast, the free lift chains are the ones that are closest to the forks and are directly hooked to the carriage. The main lift chains are located on the back side of the mast uprights.

Removal Main Lift Chain

1. Lower the forks all the way down. 2. Turn the key switch OFF and disconnect the battery connector. NOTE: Before you remove the main lift chain anchor nut, note how many threads on the chain anchor are visible above the anchor block. This will give you a good starting point when you reinstall the lift chain.

Adjustment Nut

Main Lift Chain Anchor

3. Remove the locknut from the threaded chain anchor. See Figure 7-174.

Lock Nut 8D14012S.TIF

Figure 7-174: Main Lift Chain Anchor

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Component Procedures

Prime-Mover CRX30/35/40/50 Service Manual

Mast, Chain, Hose, Cable 4. At the lower end of the lift chain, remove the cotter pin from the chain’s master link. See Figure 7-175.

Cotter Pin

5. Drive the pin out of the master link.

Installation 1. Place the lower end of the lift chain on its attachment point. 2. Align the holes and insert the master link pin through them. Secure the pin in place with a new cotter pin. Be sure to spread the legs of this cotter pin so that it does not fall out. 3. Bring the chain up over the sprocket, making sure that the chain is not twisted. 4. Insert the threaded end of the chain anchor into its attachment point. 5. Place a new adjustment nut and locknut on the chain anchor. Adjust the nut to the approximate position before it was removed making sure that both chain tensions are equal.

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8D14063S.TIF

Figure 7-175: Remove Lower Cotter Pin

Prime-Mover CRX30/35/40/50 Service Manual

Component Procedures Mast, Chain, Hose, Cable

Free Lift Chains The lift truck has two free lift chains. The free lift chains are the ones closest to the forks and have one end attached to the fork carriage. The threaded chain anchor is located at the base of the mast weldment.

Free Lift Chains

Free Lift Chain Anchor

Removal 1. Lower the forks carriage onto wooden blocks. Continue to lower until the chains go slack.

Adjustment Nut Lock Nut

2. Turn the key switch OFF and disconnect the battery connector. NOTE: Before you remove the chain anchor nut, note how many threads on the chain anchor are visible above the anchor block. This will give you a good starting point when you reinstall the lift chain. See Figure 7-176.

8D14011S.TIF

Figure 7-176: Free Lift Chain Anchor

3. Remove the locknut and adjustment nut from the threaded chain anchor. 4. Remove the cotter pin from the pin that secures the lower end of the lift chain. See Figure 7-177.

Cotter Pin

5. Drive the pin out of the lower end of the lift chain.

Installation 1. Attach the chain to the backside of the fork carriage. 2. Align the holes and insert the pin through them. Secure the pin in place with a new cotter pin. Be sure to spread the legs of this cotter pin so that it does not fall out.

8D14014S.TIF

Figure 7-177: Free Lift Chain

3. Bring the lift chain up over the sprocket, making sure that the chain is not twisted. 4. Insert the threaded end of the chain anchor through the hole at the base of the mast. 5. Install a new adjustment nut and locknut on the chain anchor. Adjust the nut to the approximate position before it was removed. Readjust the locknut for proper fork height.

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Component Procedures

Prime-Mover CRX30/35/40/50 Service Manual

Mast, Chain, Hose, Cable

Lift Ram Seals Replacement 1. Remove the ram assembly from the truck. 2. Place the ram assembly on a workbench and secure the lift ram housing in a vice. 3. Loosen the gland nut at the top of the cylinder with the piston cap tool (Main cylinder use P/N 313666-466, Free Lift cylinder use P/N 313666-467). See Figure 7-178 and Figure 7-179. 4. Rotate the gland nut (the piston will rotate as well) until the gland nut is out of the cylinder.

2099_003.tif

Figure 7-178: Piston Cap Tool

5. Pull the piston out of the cylinder. NOTE: Watch for guides falling off of the end of the piston when you remove it from the cylinder. See Figure 7-180.

Gland Nut

6. Pull the gland nut off the piston. 7. Replace any seal necessary. All seals are on or in the gland nut. 8. Place the two guides around the groove at the bottom of the piston. 9. Hold the guides on the piston as you slide the piston, guides end first, in the cylinder. Stop when there is about one foot of piston outside the cylinder. 10. Slide the gland nut on the piston. NOTE: You may want to wrap a rag around the piston where it may contact the threads to avoid scratching the piston.

Piston Cap Tool

Piston

8a21016s

Figure 7-179: Loosening the Gland Nut

Guides

11. Push the gland nut toward the cylinder. It will be tight. When the gland nut is close enough, start threading it into the cylinder. 12. Raise the piston slightly with your hand and continue threading the gland nut into the cylinder.

Piston

13. Add Loctite 242 (Blue) on the last three threads of the gland nut. 14. Secure the gland nut on the lift ram with the piston cap tool or an appropriate tool. Torque to 160 ±5 ft. lb. (217 ±7 Nm).

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8a21017s

Figure 7-180: Pulling the Piston Out of the Cylinder

Prime-Mover CRX30/35/40/50 Service Manual

Component Procedures Mast, Chain, Hose, Cable

Forks Removal 1. Position the lift truck in an area with enough room for maneuvering.

! CAUTION The forks weigh approx. 100 lb. Use extreme caution when working with forks. 2. Lift the top clip on the fork to allow it to slide to the center of the carriage. 3. Line up the bottom of the fork with the cutout on the bottom of the carriage and pull the fork-bottom clear of the carriage. NOTE: Do not remove or lift forks yet. 4. Carefully raise the carriage just enough so that a wood block can be positioned approx. 3 in. (76 mm) in front of the fork heel. 5. Carefully lower the carriage until the top pin is clear of the carriage. 6. Lay the fork down in a safe area.

Installation 1. Place the fork on a wood block located in front of the fork loading notch in the center of the carriage bottom bar. Make sure the wood block is just high enough to elevate the top pin on the fork above the carriage. See Figure 7-181.

8d14009s.tif

2. Tilt the fork back slowly so that it is in position to hook over the top rail of the carriage.

! CAUTION Make sure the fork is in position to hook onto the top rail of the carriage before you proceed.

Figure 7-181: Fork Installation

3. Carefully lift the tip of the fork and remove the wood block.

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Component Procedures Mast, Chain, Hose, Cable 4. Lower the fork until the bottom hook falls into the cutout on the bottom of the carriage. 5. Slide the fork left or right to the desired width for the pallet being used. 6. Secure the top clip on the fork.

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Prime-Mover CRX30/35/40/50 Service Manual

Theory of Operation

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8-1

Theory of Operation

Prime-Mover CRX30/35/40/50 Service Manual

Traction System

Traction System Component

Location

Function

Traction Power Amplifiers

Accessed through the battery compartment. Mounted on hinged plates behind the traction motors.

Regulates current to the traction motors. There is one amplifier for each traction motor.

Steer Position Sensor

Located on a bracket above the steerable wheel assembly.

Sends feedback to the Interface Card regarding the position of the steer wheel. This is necessary to be able to rotate each drive wheel in the proper direction.

Multi Function Control Handle

Located on the top of the operator console in the center.

Interface between the operator and the Interface Card to execute operator requests.

Speed Sensors

Located on the side of the drive (traction) motors below the brake.

The speed sensors function as an interface between the traction motors and the Interface Card. They tell the Interface Card present speed. There is one sensor located on the side of each traction motor. This information is used to determine the speed of the vehicle and can also be viewed on the operator display.

Brake Assembly

Located directly on top of both drive motors.

The brakes are located on top of each traction motor. The brake stops the vehicle when the operator’s foot is removed from the deadman pedal. Each brake incorporates an electrical coil. The brake is spring applied and electrically released.

Horn

Located on the multi-function control handle.

The horn is an electrical warning device which is operated by a request from the operator. The horn button located in the multi-function control handle sends a signal to the Interface Card. The Interface Card processes this request and gives the horn its negative by way of an internally mounted coil driver.

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Prime-Mover CRX30/35/40/50 Service Manual

Theory of Operation Traction System

Component

Location

Function

Emergency Power Off (EPO)

Located on the left of the operator display interface.

The EPO disables all functions of the truck by removing B- from relay K3.

Operator Display Interface (ODI)

Located on the top of the operator console, in front of the multi-function control handle.

The ODI provides the operator with operational information of the vehicle. It also provides troubleshooting information to technicians.

Deadman Switch (S2)

Located under the deadman pedal in the operator compartment.

The deadman switch enables truck functions when the operator is in the operator compartment. The deadman switch is a micro-switch. Testing can be found in the electrical testing section.

Translator Card

Located under the Interface Card.

The Translator Card converts digital and analog inputs/outputs to satisfy simulated truck conditions.

Interface Card

Located on the left side of the tractor frame by the overhead guard mounting.

Receives inputs and sends output signals to the other components of the vehicle to initiate truck functions. NOTE: There are no serviceable parts or Firmware in the Interface Card.

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8-3

Theory of Operation

Prime-Mover CRX30/35/40/50 Service Manual

Example of Hall Effect Switch Schematic

Hall Effect Switches The limit switches and lift/lower switches used on this truck are Hall Effect switches. These switches consist of a transistor that is turned on when a magnet is positioned next to the transistor. (Keep in mind that the magnet is part of the switch assembly and can only be seen if the switch is disassembled). Refer to Figure 8-1 for a schematic representation of a Hall Effect switch.

+12VP

DGND Figure 8-2: Figure 8-1:

Example of Hall Effect Switch Schematic

The switch is powered as follows: • +6 to +12V is applied to the positive (+) terminal • battery negative is applied to the negative (-) terminal • When a magnet is not present, the transistor is in an OFF state and the output lead is in a high state. • When a magnet is present, the transistor is turned ON creating a path from the negative (-) terminal to the 0 terminal. Terminal “0” will now be a negative (-) potential. See Figure 8-2 for an example of a typical Hall Effect switch.

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Typical Hall Effect Switch

Contactor Coils The contactor coils used on this lift truck are all 36V coils (TPC, LPC, AUX, STR). These coils are turned on and off by coil drivers located within the Interface Card. The coil drivers are not replaceable singularly and must be replaced by way of the Interface Card.

Solenoids All of the solenoids used in the hydraulic system are 36V. The voltage of the solenoid coil can be verified by checking the metal tag on the end of the solenoid coil under the securing nut.

Prime-Mover CRX30/35/40/50 Service Manual

Theory of Operation Typical Hall Effect Switch

Torque On Demand

Proportional Plugging

Torque on demand allows the truck to smoothly climb out of potholes or other floor obstructions. For this situation, assume the truck is stopped with the drive tire resting in a depression in the floor. The following occurs:

When the truck is traveling in one direction and the control handle is moved through neutral to the opposite direction to stop the truck and/or change directions, the process of plugging occurs. “Proportional Plugging” means that the further the control handle is moved, the quicker the truck stops and changes direction. In this example, plugging occurs from the forks-first direction to tractor-first.

1. A travel request has been received from VR1, but the obstruction prevents the drive motor from turning. 2. The speed request remains constant. 3. The speed error signal increases the longer the truck does not move. 4. The Pulse Width Modulated (PWM) duty cycle increases (more ON time). This keeps the power transistor turned on for a longer period of time, increasing the current through the drive motor armature. 5. The Interface Card sends a communication signal to the traction power amplifier. The traction power amplifier controls current through the drive motor field windings. Drive motor torque is proportional to the current level in the field windings. More current gives greater torque. 6. The speed sensor can sense even the smallest amount of drive motor rotation. If the truck is driven against a solid object, the speed sensor will sense that the drive motor cannot rotate and will disable travel after a short time. The travel controller will have to be returned to neutral position before attempting to travel again.

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1. The Interface Card senses that the truck is still moving in the forks-first direction because of the input from the traction power amplifiers. 2. The Interface Card senses the voltage from VR1 and recognizes this is a request for tractor-first travel. 3. The Interface Card will not change the polarity of the fields during plugging. 4. As the armature continues to rotate it will be turned into a generator. The generated voltage will be routed back to the battery which has now become the load. 5. This process will continue until the truck is almost stopped. After the truck has slowed almost to a stop, proportional plugging will stop and the traction system will be in drive mode. NOTE: If the EPO knob is depressed during travel, the truck will reverse the fields of the motor to stop the truck quickly.

8-5

Theory of Operation

Prime-Mover CRX30/35/40/50 Service Manual

Typical Hall Effect Switch

Regenerative Braking to Zero Speed 1. Slow down is accomplished when reversing direction by providing a small amount of retarding torque for deceleration. If the lift truck is moving and the control handle is moved from one direction to the other, the regen signal is initiated 2. Once the regen signal has been initiated, the field current is increased. Armature current is regulated to the regen current limit (adjustment of regen current limit is controlled by acceleration Configure settings). 3. As the lift truck slows down, the field current continues to increase and the armature begins to be pulsed more on-time. The field current will increase until it reaches 100% on-time. 4. Once both of the above conditions are met and the regen current can no longer be maintained, the braking function is cancelled. 5. The fields will then reverse and the control reverts back to motoring in the direction the operator requested. 6. Part of the energy produced by the motor during regen is returned to the battery and part is dumped in the motor as heat. The advantages of this system are less drive motor heat and longer brush life in the drive motors.

Battery Discharge Indicator The Battery Discharge Indicator (BDI), as displayed on the operator display, shows the amount of usable energy which remains in the battery. The value displayed is the percentage of energy in the battery available for use. The BDI uses battery voltage under load for this calculation. When 0% is displayed on the Operator’s Display, lift will be prevented until the battery is recharged or replaced with a fully charged battery. The battery should not be changed or charged until the operator display reads 0 to 5%. Recharging a battery that is not fully discharged will drastically shorten the life expectancy of the battery. After the battery is charged, it should also be given a period of time to cool down. Failure to allow sufficient cooling time may also destroy the battery prematurely due to overheating. If a battery is changed prior to this point, the display may not reset. If the display does not reset, it will continue to show the percentage of the battery removed. This percentage will stay on the display until the battery installed reaches the percentage on the display. At this point in time the display will start to count down as the battery discharges. NOTE: As a battery becomes older or is improperly maintained, it will not be able to accept a 100% charge. Therefore the operator display will show less than 100% even after a full recharging period.

Battery Maintenance Information The truck battery should only be changed or charged when the Specific Gravity (SG) reaches the point where the battery manufacturer recommends recharging. The cut-out should be configured so that the battery reaches this level when lift cut-out occurs. This can be adjusted in the Configure Mode on the operator display. See page 3-4. The cut-out setting may need to be changed, depending on the condition of the battery, so that lift cut-out will occur when the battery specific gravity is at the point recommended by the battery manufacturer.

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Prime-Mover CRX30/35/40/50 Service Manual

Theory of Operation Typical Hall Effect Switch

Current Limiting

Thermal Cut-Back

The power amplifier continually adjusts the PWM signal from commands given by the Interface Card, via the Translator Card, so current limit is never exceeded. The following process occurs many times per second:

Temperature sensors on the power amplifiers and drive motor monitor temperatures. The output of the drive temperature sensor is fed into the Interface Card. The output of the power amplifier temperature sensor is fed into the Interface Card via the Translator Card. As the temperature rises in the traction system, the Interface Card displays an over-temperature message. However, plugging strength (regenerative braking) is not reduced.

1. Drive motor armature current is monitored by the power amplifiers. 2. The “on time” of the PWM signal is reduced by the power amplifier and Interface Card as needed so that maximum current is never exceeded. 3. The lowered duty cycle causes the power amplifier to limit the current to the traction motor. The Interface Card monitors vehicle operation and will control performance as required to ensure safe vehicle operation and prevent damage to various systems of the truck. The following functions are monitored and truck performance adjusted to suit: • Thermal limitations • Elevated height limits

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NOTE: As the temperature of the drive motor and/or power amplifier increases, current will be reduced in a stepped manner. The Interface Card adjusts the current of the traction motor as follows: 1. The temperature sensor measures the traction motor temperature and sends the signal to the Interface Card at JPC10-3, JPC10-2 and JPC10-1. 2. A thermal switch prevents operation when the motors are overtemperature.

8-7

Theory of Operation

Prime-Mover CRX30/35/40/50 Service Manual

Typical Hall Effect Switch

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Prime-Mover CRX30/35/40/50 Service Manual

Theory of Operation Travel Functions

Travel Functions Battery Connected NOTE: All readings are wrt TP4 (B-) See Figure 8-3. • B+ is seen at FU2 (600A) and TPC-2 which is open. • B+ is seen at FU1 (40A) and at steer contactor STR-2 which is open. • B+ is seen at FU3 (500A), through it to lift contactor LPC-2 which is open. NOTE: All JPF connections are located on the Contactor Fuse Panel. • B+ is seen at auxiliary contactor AUX-2 which is open through FU4 (40A), JPF1-1, FU9 (5A) to TS1-1. • B+ is seen at JPF1-3 and JPF1-10 through FU7 (15A) to K1 which is open. • B+ is seen at JPF1-8 and JPF1-9 through FU5 (15A) out of the Contactor Fuse Panel at JPF3-4, to open key switch S1-1. • B+ is seen at JPF1-8 and JPF1-9 through FU5 (15A) to JPF2-1 and then at the Interface Card, JPC8-7 (Battery Sense In). • B+ is seen at the open tips of K2 and K3.

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8-9

Theory of Operation Battery Connected

Figure 8-3:

8-10

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Battery Connected

Prime-Mover CRX30/35/40/50 Service Manual

Theory of Operation Battery Connected

Legend

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Battery Positive

Activation

Battery Negative

Sense Wires

8-11

Theory of Operation

Prime-Mover CRX30/35/40/50 Service Manual

Battery Connected

Turning Key Switch (S1) ON

SelfTest Checks

Start-up Sequence

During the SelfTest portion of power up, the following components and circuits will be checked for correct operation.

When the key switch is turned from OFF to ON, the Interface Card performs a series of system self-tests. If you press the Enter button, the operator display will show the hour meters. During the start-up sequence, the following will be displayed in the order and the length of time indicated:

Identifier*

Meaning

Time Displayed (seconds)

Checks: 1. Voltage of the battery and whether or not it is within max./min. voltage range. 2. Calculates the battery state of charge. 3. Proper output of the Interface Card power supply voltage. 4. No fused contactor tips (LPC, TPC, STR, AUX). 5. Position of the Deadman Switch (S2); the PC contactor will not energize unless the deadman pedal is released.

xxxx.xHB

Hours on Deadman Pedal

xxxx.xHD

Hours Drive System Use

xxxx.xHL

Hours Lift System Use

7. Power amplifier and traction motor temperatures.

xxxx.xHS

Hours Steer System Use

If a problem is detected, SelfTest will stop at the point of the problem and display the appropriate fault code on the operator display.

SelfTest

System Testing

PASSED

SelfTest passed

Please complete daily checklist

Message to operator

6. Operation of the horn (audible test only).

-----

*The operator display will show the four hour meters if you press the Enter button.

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Prime-Mover CRX30/35/40/50 Service Manual

Theory of Operation Battery Connected

Key Switch Turned ON

Forward Travel Requested

NOTE: All readings are wrt TP4 (B-)

See Figure 8-6.

See Figure 8-4.

With the deadman depressed and the directional controller moved, the following happens:

• B+ is fed to the contactor fuse panel to JPF1-8 and JPF1-9 through FU5 (15A) through the closed tips of S1 (key switch) into the contactor fuse panel at JPF3-2. • Coils K1, K2, K3 and JPF2-6 to EPO Sense on the Interface Card will receive negative by way of TP4 through the contactor fuse panel. • B+Key is further seen at JPF2-5 (leaving the contactor fuse panel to the Interface Card at JPC 8-17 (B+Key). • B+Key enters the Interface Card at JPC8-17 and travels to the Interface Card power supply, and is made into 12VDC. 12V can be monitored at JPC7-1, JPC5-1, and JPC4-16. • B+KA enters the Interface Card at JPC8-4 and JPC8-5. After this, it can also be found at JPC8-15 (horn), JPC9-3 (which supplies SOL1,2,4,6,7,8,9) • B+KB enters the Interface Card at JPC10-19. After this, it can be found at: JPC10-20 and JPC10-21 (brakes) • B+KC enters the Interface Card at JPC8-13. After this, it can be found at JPC8-14 (which supplies STR, TPC, LPC, and AUX coils).

• As the control handle is moved, the Interface Card senses a voltage increase from VR1 (travel potentiometer). • The Interface Card prepares for travel by sending a signal to the traction power amplifiers (left and right) by way of the Translator Card. • This will send a signal to the transistors which control the armature and field, to choose the proper speed and direction. • The amount of current through each motor will be monitored by current sensing devices in the traction power amplifiers. • Speed will be monitored by the left and right speed sensors. • The Interface Card will then send a signal to the coil drivers, mounted inside the Interface Card, for the brakes (B1, B2) which will supply B- to the brake coils. This will release the brakes. • The EPO, when depressed, will remove Bfrom coil K3. This in turn will remove B+ from all of the power amplifiers and coil drivers for the contactors and brakes (located in the Interface Card).

Deadman Switch Closed See Figure 8-5. With the deadman pedal (S2) depressed, a circuit is completed to the Interface Card between JPC7-16 and JPC7-5. The Interface Card will energize the brake coil drivers (internally located) and will supply B- to the brake coils (B1 and B2) when travel is requested. At this point, the brakes will release.

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8-13

Theory of Operation Key Switch (S1) Turned ON

Figure 8-4:

8-14

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Key Switch (S1) Turned ON

Prime-Mover CRX30/35/40/50 Service Manual

Theory of Operation Key Switch (S1) Turned ON

Legend

Return

Battery Positive

Activation

Battery Negative

Sense Wires

8-15

Theory of Operation Deadman Switch (S2) Closed

Figure 8-5:

8-16

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Deadman Switch (S2) Closed

Prime-Mover CRX30/35/40/50 Service Manual

Theory of Operation Deadman Switch (S2) Closed

Legend

Return

Battery Positive

Activation

Battery Negative

Sense Wires

8-17

Theory of Operation Forward Travel Requested

Figure 8-6:

8-18

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Forward Travel Requested

Prime-Mover CRX30/35/40/50 Service Manual

Theory of Operation Forward Travel Requested

Legend

Return

Battery Positive

Activation

Battery Negative

Sense Wires

8-19

Theory of Operation Hydraulic Functions

Hydraulic Functions Lift/Lower System System Overview All inputs and outputs related to the lift/lower system are controlled by the Interface Card. The Interface Card determines what actions are required based on inputs from the operator and from system feedback.

Lifting Moving the handle in the lift direction energizes S13. The Interface Card recognizes this as a lifting instruction and energizes the lift pump: The farther the handle is moved, the more oil is distributed to the lift cylinder by the spool valve. See Figures 8-7 and 8-8.

Lowering Moving the handle in the lower direction energizes S14. The Interface Card recognizes this as a lowering instruction. This causes the Interface Card to energize the Load Holding (L/H) solenoid and allow the oil to be metered to the reservoir through the spool valve. See Figure 8-9.

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Prime-Mover CRX30/35/40/50 Service Manual

Theory of Operation Lift Requested

Legend Pressure Lines Return Lines Suction Lines

Figure 8-7:

Return

Lift Requested

8-21

Theory of Operation Request For Lift

Figure 8-8:

8-22

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Request For Lift

Prime-Mover CRX30/35/40/50 Service Manual

Theory of Operation Request For Lift

Legend

Return

Battery Positive

Activation

Battery Negative

Sense Wires

8-23

Theory of Operation

Prime-Mover CRX30/35/40/50 Service Manual

Lower Requested

Legend Pressure Lines Return Lines Suction Lines

Figure 8-9:

8-24

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Lower Requested

Prime-Mover CRX30/35/40/50 Service Manual

Theory of Operation Lower Requested

Tilt See Figures 8-10, 8-11 and 8-12. With the key switch ON and the deadman pedal depressed, the following will occur to activate the tilt function. • Depressing the tilt switch (S8) on the control handle sends an input to the Interface Card at JPC6-3. The Interface Card interprets this input and the following occurs;

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•

The aux. pump is energized by a coil driver inside the Interface Card.

•

The pump/motor rotates at a speed predetermined by the Interface Card/program.

•

SOL8 is energized by the Interface Card at JPC9-10 allowing regulated flow to SOL6 (aux dir.).

•

SOL6 is energized for one direction of each auxiliary function, due to the fact that it directs oil flow for tilt up or tilt down.

•

SOL4 (tilt) is a normally closed solenoid which is energized by the Interface Card at JPC9-1.

•

Oil flows through SOL4 allowing the tilt function to work.

•

For the tilt down function, switch S9 is used and SOL6 is positioned to allow oil to flow in the opposite direction.

8-25

Theory of Operation Request For Tilt Up (S8)

Figure 8-10: Request For Tilt Up (S8)

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Prime-Mover CRX30/35/40/50 Service Manual

Theory of Operation Request For Tilt Up (S8)

Legend

Return

Battery Positive

Activation

Battery Negative

Sense Wires

8-27

Theory of Operation

Prime-Mover CRX30/35/40/50 Service Manual

Tilt Up Requested (S8)

Legend Pressure Lines Return Lines Suction Lines

Figure 8-11: Tilt Up Requested (S8)

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Prime-Mover CRX30/35/40/50 Service Manual

Theory of Operation Tilt Down Requested

Legend Pressure Lines Return Lines Suction Lines

Figure 8-12: Tilt Down Requested

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8-29

Theory of Operation Sideshift

Sideshift With the key switch ON and the deadman pedal depressed, the following occur: NOTE: The lift/aux pump is used for all auxiliary functions. The steer pump is only used for the steer function. • When switch S6 is closed, an input is sent to the Interface Card at JPC6-6. This input in turn will be sent to the vehicle function controller located internally in the Interface Card. • The lift/aux pump will rotate at a speed predetermined by software. • SOL8 will be energized at JPC9-10. This will allow regulated flow to the auxiliary functions. • SOL6 (aux dir.) will be energized at JPC9-8 depending on the direction of sideshift requested. • SOL2 (sideshift) will be energized at JPC9-12. To sideshift in the opposite direction, switch S7 will be closed instead of S6. The aux dir. SOL (SOL6) will also be moved to the opposite direction. See Figure 8-13 on page 8-31 and Figure 8-14 on page 8-32.

8-30

Return

Prime-Mover CRX30/35/40/50 Service Manual

Theory of Operation Sideshift Request (Low Flow)

Legend Pressure Lines Return Lines Suction Lines

Figure 8-13: Sideshift Request (Low Flow)

Return

8-31

Theory of Operation

Prime-Mover CRX30/35/40/50 Service Manual

Sideshift Request (High Flow)

Legend Pressure Lines Return Lines Suction Lines

Figure 8-14: Sideshift Request (High Flow)

8-32

Return

Prime-Mover CRX30/35/40/50 Service Manual

Theory of Operation High Flow Auxiliary Pressure - Select Aux.

Legend Pressure Lines Return Lines Suction Lines

Figure 8-15: High Flow Auxiliary Pressure - Select Aux.

Return

8-33

Theory of Operation Steering

Steering See Figure 8-16. With the key switch turned ON and the deadman pedal depressed, the following happens: • The Interface Card supplies a negative to the steer contactor solenoid by way of the coil driver located internal to the Interface Card. When the coil driver is activated, the steer solenoid will be energized with voltage from B+KC to B-. This in turn will close the normally open tips of the steer contactor. • Once the contactor tips are closed, battery voltage will flow through the steer motor and back to TP4 (B-). At this point, the steer motor will rotate the steer pump, which will cause hydraulic pressure to turn the steering in the requested direction. • The steer motor is only used for steer. All other auxiliary functions are energized by the lift pump/motor.

8-34

Return

Prime-Mover CRX30/35/40/50 Service Manual

Theory of Operation Steering Request

Legend Pressure Lines Return Lines Suction Lines

Figure 8-16: Steering Request

Return

8-35

Theory of Operation Sense Wires

Sense Wires Figure 8-17 identifies the various sense wires that are used to monitor system feedback.

8-36

Return

Prime-Mover CRX30/35/40/50 Service Manual

Theory of Operation Sense Wires

This page intentionally left blank.

Return

8-37

Theory of Operation Sense Wires

Figure 8-17: Sense Wires

8-38

Return

Prime-Mover CRX30/35/40/50 Service Manual

Theory of Operation Sense Wires

Legend

Return

Battery Positive

Activation

Battery Negative

Sense Wires

8-39

Theory of Operation

Prime-Mover CRX30/35/40/50 Service Manual

Sense Wires

This page intentionally left blank.

8-40

Return

Prime-Mover CRX30/35/40/50 Service Manual

Appendix

Return

A-1

Appendix

Prime-Mover CRX30/35/40/50 Service Manual

Lubrication Equivalency Chart

Lubrication Equivalency Chart Approved Lubricants Where Used

Type

Drive Unit Gear Case (all applications)

Synthetic Gear Lubricant

Forsythe Ltd. 75W - 90 API Service GL-5 Shell Spirax S 75W - 90 API Service GL-5 Mobil 1 75W - 90 API Service GL-5

Lift Chains

Oil

Chevron Delco 400 15W-40 API Service SE Citgo C-6 10W-30 Motor Oil MIL-H-46152 Exxon Extra Motor Oil 10W-30 API Service SE Gulflube Motor Oil X.H.D. 10W-30 Mobil Delvac Special 10W-30 API Service SE Phillips Trop-Arctic All Season Motor Oil 10W-40 MIL-L-46152 Shell Rotella T 15W-40 API Service SE, CC and CD Sohio Multron 10W-30 MIL-L-46152 API Service SE Texaco URSATEX 10W-30 2166

Hydraulic Reservoir (non-cold storage trucks)

Hydraulic Fluid

Chevron AW ISO 46 Citgo 46 Exxon Nuto H 46 Forsythe AWTH215 ISO46 Mobil DTE-1B NOCO NOCOLUBE AW46 Texaco Cygnus 46 or HD 46 Ultramar Ultra Hydraulik AW46

Hydraulic Reservoir (cold storage trucks) (+40°F to -20°F) (4C to -29°C)

Hydraulic Fluid

Exxon Univis J13 (similiar to MIL-H-5606A) Mobil Aero HFA Texaco Aircraft Hydraulic Fluid 15

Hydraulic Reservoir (cold storage trucks) (20°F to 70°F) (-6°C to 21°C)

Hydraulic Fluid

NOCO NOC 1866 Shell Tellus T Oil 32 Texaco HD AZ 32 1627 Rando or Cygnus 32

Hydraulic Reservoir (for extreme heating conditions)

Hydraulic Fluid

Chevron AW-MV Mobil 423 or 424 NOCO Torque TDH

Mast Uprights, Bearings, (etc.)

Grease

Chevron Avi-Motive Grease Citgo HEP2 (above 30° F only) Exxon RONEX MP or UNIREX N2 Gulf Gulfcrown Grease No. 2 Mobil Grease 77 Phillips Philube 1B and RB Grease Shell Alvania Grease EP2 Sohio Bearing Guard “LT” Texaco Regal AFB 2 Grease MIL-G-18709A

A-2

Return

Approved Manufacturer

Prime-Mover CRX30/35/40/50 Service Manual

Appendix Lubrication Equivalency Chart

Approved Lubricants

Return

Where Used

Type

Hydraulic Brake

Brake Fluid

Approved Manufacturer Must conform to: SAE Standard J1705F Federal Motor Vehicle Standard No. 116, DOT-5

A-3

Appendix

Prime-Mover CRX30/35/40/50 Service Manual

Torque Chart - Standard (Ferrous)

Torque Chart - Standard (Ferrous) Grade Identification Marking

SAE Grade 2 Bolts Tightening Torque

SAE Grade 5 Bolts Tightening Torque

SAE Grade 8 Bolts Tightening Torque

Dry

Oiled*

Dry

Oiled*

Dry

Oiled*

4-40 4-48 6-32 8-32 8-36 10-24 10-32 1/4-20 1/4-28

in. lb. 5 6 10 19 20 27 31 66 78

in. lb. 4 5 8 14 15 21 23 49 56

in. lb. 8 9 16 30 31 43 49 96 120

in. lb. 6 7 12 22 23 32 36 75 86

in. lb. 12 13 23 41 43 60 68 144 168

in. lb. 9 10 17 31 32 45 51 108 120

5/16-18 5/16-24 3/8-16 3/8-24 7/16-14 7/16-20 1/2-13 1/2-20 9/16-12 9/16-18 5/8-11 5/8-18 3/4-10 3/4-16 7/8-9 7/8-14 1-8 1-12 1 1/8-7 1 1/8-12 1 1/4-7 1 1/4-12 1 3/8-6 1 3/8-12 1 1/2-6 1 1/2-12

ft. lb. 11 12 20 23 30 35 50 55 65 75 90 110 160 180 140 155 220 240 300 340 420 460 560 640 740 840

ft. lb. 8 9 15 17 24 25 35 40 50 55 70 85 120 140 110 120 160 170 220 260 320 360 420 460 560 620

ft. lb. 17 19 30 35 50 55 75 90 110 120 150 180 260 300 400 440 580 640 800 880 1120 1240 1460 1680 1940 2200

ft. lb. 13 14 23 25 35 40 55 65 80 90 110 130 200 220 300 320 440 480 600 660 840 920 1100 1260 1460 1640

ft. lb. 25 25 45 50 70 80 110 120 150 170 220 240 380 420 600 660 900 1000 1280 1440 1820 2000 2380 2720 3160 3560

ft. lb. 18 20 35 35 55 60 80 90 110 130 170 180 280 320 460 500 680 740 960 1080 1360 1500 1780 2040 2360 2660

Size

Figure A-1:

A-4

None

Return

Torque Chart - Standard * NOTE: Use ”oiled” values for bolts with thread locking compound

Prime-Mover CRX30/35/40/50 Service Manual

Appendix Torque Chart - Metric

Torque Chart - Metric Ferrous Metric Bolts, Coarse Thread (The grade rating is stamped on the head of the bolt.) Diameter (in millimeters)

Grade 8.8

Grade 10.9

Torque (with bolts oiled*)

Newton-meters

Foot-pounds

Newton-meters

Foot-pounds

8.6

101

174

130

245

181

340

255

475

350

580

435

820

605

Brass MS63 Metric Bolts, Coarse Thread

Return

Torque (with bolts oiled*)

Diameter (in millimeters)

Newton-meters

Inch-pounds

0.5

4.4

3.5

0.79

7.0

1.2

2.2

3.9

150

A-5

Appendix

Prime-Mover CRX30/35/40/50 Service Manual

Torque Chart - Standard (Brass)

Torque Chart - Standard (Brass) Brass MS63 Standard Bolts, Coarse Thread Size

A-6

Return

Torque (with bolts oiled*) Newton-meters

Inch-pounds

4-40

0.37

3.3

4-48

0.40

3.6

6-32

0.69

6.1

6-40

0.77

6.8

8-32

1.24

8-36

1.24

10-24

1.58

10-32

1.92

1/4-20

3.96

1/4-28

4.52

5/16-18

8.25

5/16-24

9.15

3/8-16

14.69

130

3/8-24

16.61

147

Prime-Mover CRX30/35/40/50 Service Manual

Appendix Decimal Equivalent Chart

Decimal Equivalent Chart

4ths

8ths

16ths

32nds

64ths

To 3 Places

To 2 Places

MM Equivalent

1/64

.016

.02

.397

.031

.03

.794

.047

.05

1.191

.062

.06

1.587

.078

.08

1.984

.094

.09

2.381

.109

.11

2.778

.125

.12

3.175

.141

.14

3.572

.156

.16

3.969

.172

.17

4.366

.188

.19

4.762

.203

.20

5.159

.219

.22

5.556

.234

.23

5.593

.250

.25

6.350

.266

.27

6.747

.281

.28

7.144

.297

.30

7.540

.312

.31

7.937

.328

.33

8.334

.344

.34

8.731

.359

.36

9.128

.375

.38

9.525

.391

.39

9.922

.406

.41

10.319

.422

.42

10.716

.438

.44

11.112

.453

.45

11.509

.469

.47

11.906

.484

.48

12.303

.500

.50

12.700

1/32 3/64 1/16 5/64 3/32 7/64 1/8 9/64 5/32 11/64 3/16 13/64 7/32 15/64 1/4 17/64 9/32 19/64 5/16 21/64 11/32 23/64 3/8 25/64 13/32 27/64 7/16 29/64 15/32 31/64 1/2 Figure A-2:

Return

Decimal Equivalent Chart

A-7

Appendix

Prime-Mover CRX30/35/40/50 Service Manual

Decimal Equivalent Chart 4ths

8ths

16ths

32nds

64ths

To 3 Places

To 2 Places

MM Equivalent

33/64

.516

.52

13.097

.531

.53

13.494

.547

.55

13.891

.562

.56

14.288

.578

.58

14.684

.594

.59

15.081

.609

.61

15.478

.625

.62

15.875

.641

.64

16.272

.665

.66

16.669

.672

.67

17.065

.688

.69

17.462

.703

.70

17.859

.719

.72

18.256

.734

.73

18.653

.750

.75

19.050

.766

.77

19.447

.781

.78

19.844

.797

.80

20.241

.812

.81

20.637

.828

.83

21.034

.844

.84

21.431

.859

.86

21.828

.875

.88

22.225

.891

.89

22.622

.906

.91

23.019

.922

.92

23.416

.938

.94

23.812

.953

.95

24.209

.969

.97

24.606

.984

.98

25.003

1.000

1.00

25.400

17/32 35/64 9/16 37/64 19/32 39/64 5/8 41/64 21/32 43/64 11/16 45/64 23/32 47/64 3/4 49/64 25/32 51/64 13/16 53/64 27/32 55/64 7/8 57/64 29/32 59/64 15/16 61/64 31/32 63/64 Figure A-2:

A-8

Return

Decimal Equivalent Chart

Prime-Mover CRX30/35/40/50 Service Manual

Appendix Standard/Metric Conversions

Standard/Metric Conversions To Convert...

Return

Multiply...

Inches to Millimeters

Inches x 25.4

Millimeters to Inches

Millimeters x 0.039

Inches to Centimeters

Inches x 2.54

Centimeters to Inches

Centimeters x 0.394

Feet to Meters

Feet x 0.305

Meters to Feet

Meters x 3.281

Yards to Meters

Yards x 0.914

Meters to Yards

Meters x 1.094

Miles to Kilometers

Miles x 1.609

Kilometers to Miles

Kilometers x 0.621

Square Inches to Square Centimeters

Square Inches x 6.452

Square Centimeters to Square Inches

Square Centimeters x 0.155

Square Feet to Square Meters

Square Feet x 0.093

Square Meters to Square Feet

Square Meters x 10.753

Square Yards to Square Meters

Square Yards x 0.836

Square Meters to Square Yards

Square Meters x 1.196

Pints to Liters

Pints x 0.473

Liters to Pints

Liters x 2.113

Quarts to Liters

Quarts x 0.946

Liters to Quarts

Liters x 1.057

Gallons to Liters

Gallons x 3.785

Liters to Gallons

Liters x 0.26

Ounces to grams

Ounces x 28.35

Grams to ounces

Ounces x 0.035

Ounces to kilograms

Ounces x 0.028

Kilograms to ounces

Kilograms x 35.27

A-9

Appendix

Prime-Mover CRX30/35/40/50 Service Manual

Standard/Metric Conversions To Convert...

Multiply...

Pounds to Kilograms

Pounds x 0.454

Kilograms to pounds

Kilograms x 2.2

Pounds per Square Inch (PSI) to Kilopascals (kPa)

Pounds per Square Inch x 6.894

Kilopascals to Pounds per Square Inch

Kilopascals x 0.145

Pounds per Square Inch (PSI) to Kilograms per square centimeter (kg/cm2)

Pounds per Square Inch (PSI) x 0.0704

Kilograms per square centimeter (kg/cm2) to Pounds per Square Inch (PSI)

Kilograms per square centimeter (kg/cm2) x 14.2

Inch Pounds (in. lb.) to Newton Meters (Nm)

Inch Pounds x 0.113

Newton Meters (Nm) to Inch Pounds (in. lb.)

Newton Meters x 8.85

Foot Pounds (ft. lb.) to Newton Meters (Nm)

Foot Pounds x 1.3568

Newton Meters (Nm) to Foot Pounds (ft. lb.)

Newton Meters x 0.737

Miles per hour to kilometers per hour

Miles per hour x 1.609

Kilometers per hour to miles per hour

Kilometers per hour x 0.6214

Fahrenheit to Celsius

(°F - 32) x 0.555

Celsius to Fahrenheit

(°C x 1.8) + 32

A-10

Return

Prime-Mover CRX30/35/40/50 Service Manual

Appendix Schematics

7:snAppendix

Return

Schematics

A-11

Appendix

Prime-Mover CRX30/35/40/50 Service Manual

Schematics JPC7

FU3_SENSE FU2_SENSE FU1_SENSE

DGND

-16 ON_DEADMAN

MOTOR SENSORS

-2

-17

-3

-18

-4

-8

STEER_CHA

BLU

-2

JPC10 -8

-4

-9

JPS11

M1 t

B+KB

STEER_CHB STEER_CHC

B+KEY B+KC

LEFT_TRAC_BWI1

B+KA

LEFT_TRAC_BWI2

B+KA BATTERY_SENSE_IN

-3

MUX_TEMP1_LTM

EPO_SENSE

-24

-1

JPC10 -19

+12VP

JPC8 -17 -13 -4 -5 -7 -11

DGND_P

-2

-1

-23

RIGHT_TRAC_BWI2

FWD_L REV_L EPO

MUX_TEMP2_RTM DGND_P

MULTI-FUNCTION CONTROL HANDLE TRAVEL VR1

JPH3 -9

JPC6 -15

-14

-10

-11

-13

POT_SUP (TRAVEL) TRAVEL_POT_INPUT

-8 HORN

S3 1

TILT UP

S8 1

TILT DN

-2

-7

-6

-3

S9 1

-5

HORN_INPUT

-4 TILT_ DN_INPUT

S6 1

-3

-6

S7 1

-4

-5

OPTION A

S4 1

-8

-1

OPTION B

S5 1

-7

-2

-10

-14

S/S LEFT

POT_SUP (LIFT)

TILT_ UP_INPUT

S/S RIGHT

TRAVEL RETURN N/C

S/S_ RIGHT_INPUT

CONTROL HANDLE

-9

TPC_L JPC4 -1 TRAC1_AMP_GND TRAC1_HEATSINK_IN -2 -3 TRAC1_ARMATURE_IN -4 TRAC1_B+SENSE_IN -5 TRAC1 MISO -6 TRAC1 MOSI -7 TRAC1 SCLK TRAC1_AMP_SELECT -8 -9 BUS+ -10 BUS-11 TRAC1_FIELD_IN -12 TRAC1_B+ -13 TRAC1_AMP_ENABLE -14 READY -15 DGND -16 +12VP -17 N/C -18 N/C

-5 -6 -7 -8

B+KEY_ON KEY_ON DEADMAN FWD_R REV_R EPO THROTTLE PGND_R TXD_R

-4 -3 -2 -1

RXD_R TPC_R

S/S_ LEFT_INPUT

JPX2 -1 -2 -3 -4 -5 -6 -7 -8 -9

JPTL1 -1 -2 -3 -4 -5 -6 -7 -8 -22

-11

-23

-13

-17

JPX1 -1 -2 -3 -4 -5 -6 -12 -8 -9

JPTR1 -1 -2 -3 -4 -5 -6 -7 -8 -22

-11

-23

-13

-17

TRANSLATOR ASSEMBLY

JPX3

+12VP

DGND_P

-19

MUX_TEMP3_LM

B+KEY_ON

-22

SW1

-1

RXD_L

DGND

-1

-15

-3

LIFT_BWI1 LIFT_BWI2

-11

-15

JPX3

-4

-10

JPC10 -14

POWER AMPLIFIERS

-2

MOTOR SENSORS

JPS8

THROTTLE PGND_L TXD_L

+12VP

-10

-20

-4 -3

DGND

-12

B+KEY_ON KEY_ON DEADMAN

RIGHT_TRAC_BWI1

SW2

JPC10 -13

-16

-2

JPS12

OPTION_ A_INPUT OPTION_ B_INPUT DGND_P -12 N/C JPC8 -19

AUX

AUX_CONTACTOR

-18

STR

STR_CONTACTOR

-20

TPC

TPC_CONTACTOR

-21 LPC_CONTACTOR

LPC -14

-12

HE_SUPPLY1 GEAR_SENSE1

RIGHT SPEED SENSOR

(MD2)

JPC10 -4

-2 -3

-6

JPS4 -1

JPC10 -5

-2

-11

-3

-7

HE_DGND

HE_SUPPLY2 GEAR_SENSE2

+12 VP ADDR_LATCH DATA_LATCH DISP_MISO ALARM_PWM SHIFT_CLOCK DATA_OUT DGND

SPEED FEEDBACK

(MD1)

JPS3 -1

B-F

SPEED FEEDBACK

B+ KC

LEFT SPEED SENSOR

JPC8 -6 DGND

B+KA

-1 -2 -3 -12

JPC5 -1 -2 -3 -4

JPD1 -1 -2 -3 -4 -5 -6 -7 -8

-5 -6 -7 -8 JPC9 -3 -6

HE_DGND JPC10 -17

-1

-20

SS_SOL

LEFT_BRAKE1

(RIGHT)

JPB2 -2

-16

-1

-21

RIGHT_BRAKE2 B+KB 1

JPC8 -15

-16

B+KA

HORN & BRAKES

B+KB

SOL1

TILT_SOL SOL5_OUT SOL6_OUT SOL7_OUT

HORN ENABLE

-12

1 SOL2

JPH1-2

SOLENOID CONTROL

JPB1 -2

SOL8_OUT

LOAD_HLD_SOL (LEFT)

DISPLAY/INPUT KEYS

DISPLAY

CONTACTOR PANEL

-1

JPH1-1 2

1 SOL4 2

-7 AUX_PSI_SELECT_SOL -8 (DIRA_SOL)

1 SOL5

OPT.

2 SOL6

-9 (EQUAL_SOL) -10 (DIRB_SOL)

OPT.

SOL7 1

SOL8

2 SOL9

D 80855AL.EPS 838-010-855 1 of 6

Figure A-3:

A-12

Return

Electrical Schematic, Sheet 1 of 2 Scale=94.5

12V BRN A WHT B BLK

JPC7 -1

TRACTION POWER AMPLFIER (LEFT)

STEER POSITION SENSOR

JPS2 -1

JPC8-8 -10 -9

INTERFACE CARD

TRACTION POWER AMPLFIER (RIGHT)

-5

STEER POSITION SENSOR

COM

DEADMAN SWITCH

S2 NC

Prime-Mover CRX30/35/40/50 Service Manual

Appendix Schematics

JPF1-1

FU9 (5A) TS1-1

KEYSWITCH

TS1-3

S1 2

TS1-2

FU5 (15A) 1

FU7 (15A)

-10

-3

JPF3-4

JPF2-5

-8 -9

JPF3-2 K2

JPF2-7 T-1

JPF2-2 JPF2-8 JPF2-1 JPF2-6 JPF4-1

FU2 600A

TPC

B+ 1

B+ TP1

TRACTION POWER AMPLFIER (LEFT)

(LSFF)

FU1 40A

FU3 500A

FU4 40A

A1 M1

STR

LPC

AUX 1

A2 BJP B+

B+ D

+ JP B-

A1 MP F1

A E1

TRACTION POWER AMPLFIER (RIGHT)

4 -

A1 CONTACTOR FUSE PANEL

(RSFF)

A2 E2

RA F2 A2 B-

+ MS

S13 -1

+VS

-2 -3

OUT GND

S14 -1

+VS

S2A

JPF5 -1

S13 LIFT

-2

-2 OUT GND

-3

S2A

S14 LOWER

PART OF HYDRAULIC CONTROL JPF3 -1 1 S21 EPO

-3 2 JPF1-5

JPF5-6

JPF2 -4

DISPLAY/INPUT KEYS

-2 -3

-12

-10 -11 -12

ENTER

-6 -7

-11 1

-9

-4 -5

FU10 15A

TP4

JPD3 -1

MODE JPF4-2

-8

JPF1-13 -9 -12 -10 -11

L1 L2

JPD2 -6 -5 -1 -2 -3 -4 -7 -8 -9 -10 -11 -12 -13 -14 -15 -16 -17

TS2-1

P/O OVERLAY

TS2-2

TS2-3

L3 L4 L5 L6 L7 L8 L9 L10 L11 L12 L13 L14 L15 L16 L17 L18 L19

FU6 2 15A

-14

FU8 5A

-7

H S80855AR.EPS 838-010-855 1 of 6

Return

A-13

Appendix

Prime-Mover CRX30/35/40/50 Service Manual

Schematics

NOTES: 1. CONNECTORS PC2 & PC4 ON THE INTERFACE CARD ARE NOT USED. 2. THE TERMS "LEFT" AND " RIGHT" REFERENCE FROM THE OPERATOR'S POSITION FACING THE FORKS. 3. FORWARD MEANS FORKS FIRST DIRECTION.

FU7

RIGHT DRIVE MOTOR LIFT PUMP MOTOR

STEER PUMP MOTOR

AUXILIARY PUMP MOTOR

LPC

CONTACTOR POWER DISCONNECT- LIFT

FUSE 15 AMP ON FUSE/RELAY PCB FUSE 5 AMP ON FUSE/RELAY PCB

FU9

FUSE 5 AMP ON FUSE/RELAY PCB

STR

FUSE 100 AMP MOTOR FUSE ON CONTACTOR PANEL

TPC

CONTACTOR POWER DISCONNECT- TRACTION

FU5

FUSE 15 AMP ON FUSE/RELAY PCB

AUX

CONTACTOR POWER DISCONNECT- AUXILIARY

FU6

FUSE 15 AMP ON FUSE/RELAY PCB

FU10

FUSE 15 AMP ON FUSE/RELAY PCB

KEYSWITCH

FU2

FUSE 600 AMP DRIVE MOTOR FUSE ON CONTACTOR PANEL

DEADMAN

FU3

FUSE 500 AMP LIFT MOTOR FUSE ON CONTACTOR PANEL

SWITCH HORN

FU1

FUSE 40 AMP STR MOTOR FUSE ON CONTACTOR PANEL

SWITCH OPTION A (OPT.)

FU12

FUSE 1.5 AMP STROBE OR ROTATING LIGHT

SWITCH OPTION B (OPT.)

FU13

FUSE 1.5 AMP FAN - OPERATOR COMPARTMENT (OPT.)

SWITCH SIDE SHIFT RIGHT (OPT.)

HORN

SWITCH SIDE SHIFT LEFT (OPT.)

TRAVEL ALARM (OPT.)

SWITCH TILT UP

SWITCH TILT DOWN

CONTACTOR POWER DISCONNECT- STEER

CONTROL HANDLE

CONNECTOR ON STROBE LIGHTS (OPT.)

S10 & S15

SWITCH FOR WORKING LIGHTS (OPT.)

JP48

CONNECTOR OVER-MAST CABLE-CARRIAGE SIDE (OPT.)

S11

SWITCH HIGH SPEED/MAST LIMIT (OPT.)

JPA1

CONNECTOR ON ATTACHMENT CARD TO I.C. (OPT.)

S12

SWITCH LIFT LIMIT (OPT.)

JPA2

CONNECTOR ON ATTACHMENT CARD TO SOLENOIDS (OPT.)

S13

SWITCH LIFT

JPA3

CONNECTOR ON ATTACHMENT CARD TO CONTROL SWITCHES (OPT.)

S14

SWITCH LOWER

JPA4

CONNECTOR ON ATTACHMENT HANDLE WIRE ASSEMBLY (OPT.)

S16

ATTACHMENT SPOOL VALUE SWITCH (A) (OPT.)

JPB+

CONNECTOR ON BATTERY

S17

ATTACHMENT CONTROL HANDLE SWITCH (B) (OPT.)

JPB-

CONNECTOR ON BATTERY

JP3

JPB2

S21

CONNECTOR ON RIGHT BRAKE

SWITCH EPO

S18

SWITCH TILT LIMIT (OPT.)

S36

SWITCH - OPERATOR FAN (OPT.) LOAD HOLDING SOLENOID

JPB3

CONNECTOR ON LEFT BRAKE

JPC1

CONNECTOR IC TO LOADER

SOL1

JPC4

CONNECTOR IC TO TRACTION TRANSLATOR CARD

SOL2

CONNECTOR IC TO DISPLAY

SOL4

TILT SOLENOID

CONNECTOR IC TO MULTI-FUNCTION CONTROL HANDLE

SOL5

AUX PSI SELECT SOLENOID (OPT.)

JPC7

CONNECTOR IC TO OPTIONAL FEATURES, DEADMAN, & STEER POSITION SENSOR

SOL6

DIRECTION A SOLENOID

JPC8

CONNECTOR IC TO CONTACTOR PANEL & HORN

SOL7

EQUALIZATION SOLENOID

JPC9

CONNECTOR IC TO HYD. MANIFOLD

SOL8

DIRECTION B SOLENOID

JPC10

CONNECTOR IC TO BRAKES, MOTOR SENSORS

SOL9

HIGH FLOW AUX SELECT SOLENOID (OPT.)

JPC11

CONNECTOR IC TO OPTIONAL WEIGHT SENSOR (OPT.)

JPC12

CONNECTOR IC TO LIFT LIMIT & SPEED LIMIT SWITCHES (OPT.)

SOL11

HIGH FLOW AUX 2 (OPT.)

CONNECTOR ON OPERATOR DISPLAY

SPL1 THRU 4

SPLICES FOR WORKING LIGHTS (OPT.)

TP1,TP4

TY-POINTS

JPC5 JPC6

JPD1 JPD2

CONNECTOR ON OPERATOR DISPLAY TO OVERLAY

JPF1

CONNECTOR ON FUSE/RELAY CARD TO B+/B-

JPF2

CONNECTOR ON FUSE/RELAY CARD TO IC

JPF3

CONNECTOR ON FUSE/RELAY CARD TO S1, EPO

JPF4

CONNECTOR ON FUSE/RELAY CARD TO ATTACHMENT CARD (OPT.)

JPF5

CONNECTOR ON FUSE/RELAY CARD TO TRANSLATOR CARD

JPF6

CONNECTOR "EE" CONTACTOR PANEL ENCLOSURE

JPF7

CONNECTOR "EE" CONTACTOR PANEL ENCLOSURE

JPH1

CONNECTOR TO SIDESHIFT SOL (SOL2)

JPH2

CONNECTOR OVER-MAST CABLE-TRACTOR SIDE (OPT.)

JPH3

CONNECTOR ON MULTI-FUNCTION CONTROL HANDLE

JPS1

CONNECTOR LIFT/LOWER SWITCH CONTROL

JPS2

CONNECTOR ON STEER POSITION SENSOR

JPS3

CONNECTOR LIFT SPEED SENSOR

JPS4

CONNECTOR RIGHT SPEED SENSOR

JPS5

CONNECTOR HIGH SPEED LIMIT SWITCH (OPT.)

JPS6

CONNECTOR LIFT LIMIT SWITCH (OPT.)

JPS8

CONNECTOR LIFT MOTOR BWI & TEMP SENSOR

JPS11

CONNECTOR TRACTION MOTOR (LEFT) BWI & TEMP SENSOR

JPS12

CONNECTOR TRACTION MOTOR (RIGHT) BWI & TEMP SENSOR

JPTL1

CONNECTOR ON TRACTION POWER AMP (LEFT)

JPTR1

CONNECTOR ON TRACTION POWER AMP (RIGHT)

JPWL1

CONNECTOR ON RIGHT WORKING LIGHT

JPWL2

CONNECTOR ON LEFT WORKING LIGHT

SOL10

SIDE SHIFT SOLENOID

HIGH FLOW AUX 1 (OPT.)

2 SPEED ATTACHMENT & 1 LOW SPEED MOUNTED ON CARRIAGE OR ATTACHMENT 1

B+KA FROM SOL8

2 SOL9

CONNECTOR ON REV. WORKING LIGHT

JPWL4

INTERCONNECT TO JPWL2 (OPT.)

JPWL5

INTERCONNECT TO JPWL1 (OPT.)

JPX1

CONNECTOR ON TRANSLATOR CARD TO RIGHT TRACTION MOTOR

JPX2

CONNECTOR ON TRANSLATOR CARD TO LEFT TRACTION MOTOR

JPX3

CONNECTOR ON TRANSLATOR CARD TO INTERFACE CARD (IC)

WORN BRUSH LED

LIFT MOTOR LED POWER PANEL LED

HOURMETER LED

SCHEDULE SERVICE LED

SERVICE REQUIRED LED

OVER TEMPERATURE LED

TRUCK LED

L10-L19

BATTERY DISCHARGE LED'S

A Figure A-4:

JPH2

-1

-2

-3

-4

-5

2 SOL10

2 SOL2

OVER-THE-MAST CABLE ASSEMBLY

CARRIAGE OR ATTACHMENT

JP3

K-1

TS1-2 -1 3

STROBE OR ROTATING LIGHT

FU12 1.5A

JP3 -2

TS2-2

FU13 1.5A

TS1-2

ACCESSORY CIRCUIT

TS2-1

FAN

TRACTION MOTOR LED

L3 L4

JP48

SOL11

JPWL3

A-14

LEFT DRIVE MOTOR

FU8

FU4

Return

K-1

2 S36

B Electrical Schematic, Sheet 2 of 2cale=94.5

Prime-Mover CRX30/35/40/50 Service Manual

Appendix Schematics

JPWL3

-1 1 2 S10

FU9 5A TS1-1

1 B+

JPWL5 -1

JPWL1 -1

JPWL4 -1

JPWL2 -1

FU6 15A

TS2-2

FWD (LEFT)

1 2 S15

B-

JPWL4 -2

JPWL2 -2

JPWL5

JPWL1

-2

WORK LIGHTS (RIGHT)

REV

TS2-1

JPWL3 -2

3 JPC1 -1

BUS-

B+KA

-2 -3

-5

BUS+

LOADER COMM PORT

-4

DGND

-6 -7

(+)

JPC8 -22

ATTACHMENT CONTROL HANDLE SWITCH

S17

-9

JPA4

JPA3

-1

-6

-2

(-)

+12V +

ATTACHMENT CARD (OPTIONAL)

OUT -

JPC12

-15 -4

-3

-13

JPA2

-4

-14

-8

-5

-12 -9

-6

B+KA

-7

-20

-8

-10

-9

-7

SOL9_EN SOL10_EN SOL11_EN DGND

-3

JPC12

JPS5

-1

-6

-2

HI_SPEED_LIMIT

-3

B+KA B-F JPH1

JPC12 -4

JPS6 -1

-5

-2

-3

DGND

LIFT_LIMIT

-1

-3

-2

-12

B+KA

JPC11

-3

PRES. SENSOR #1

FU6 2 15A

DGND

-1

B+

B-

Return

WEIGHT SENSOR

-2

STROBE OR ROTATING LIGHT

LIFT LIMIT SWITCH

GND

+12VP

PRESSURE IN

FU6 15A

S12

+VS

-4

SIDE_SHIFT_OUT

B+ 1

S11

HIGH SPEED LIMIT SWITCH

GND

OUT

DGND

+VS

JPC9

FU7 15A

MAST LIMIT SWITCH

GND

OUT

+12 VP LIFT LIMIT SWITCH

JPF4-2

-3

+VS

+12VP

H/F AUX2_SOL

-5

ATTACH_SWB

H/F AUX1_SOL

-4

-2

PRESS_OPT_IN

-10

JPF4-1

JPS5 -1

-6

OUT

ATTACH_SWA

-9

S11

GND

+12VP

ATTACHMENTS

-2

-3

-1 JPC7

HIGH SPEED LIMIT SWITCH

JPA1 -1

H/F_AUX_SEL

S18

TILT LIMIT SWITCH

-4

ATTACHMENT SPOOL VALUE SWITCH

+VS

BOTTLER'S TILT OPTION

INTERFACE CARD (OPTIONAL FEATURES)

-7 S16

TRAVEL ALARM/LIGHT

-8

A-15

Appendix

Prime-Mover CRX30/35/40/50 Service Manual

Schematics

Figure A-5:

A-16

Return

Hydraulic Schematic, Sheet 1 of 3

Prime-Mover CRX30/35/40/50 Service Manual

Appendix Schematics

Figure A-6:

Return

Hydraulic Schematic, Sheet 2 of 3

A-17

Appendix

Prime-Mover CRX30/35/40/50 Service Manual

Schematics

Figure A-7:

A-18

Return

Hydraulic Schematic, Sheet 3 of 3

Prime-Mover CRX30/35/40/50 Service Manual

Index

Return

I-1

Index

Prime-Mover CRX30/35/40/50 Service Manual

Abbreviations List . . . . . . . . . . . . . . . . . . . 1-5 Adjusting Control Handle. . . . . . . . . . . . . 7-38 Air Gap Adjustment, Brake . . . . . . . . . . . 7-76 Analog Tests . . . . . . . . . . . . . . . . . . . . . . 6-85 Antistatic Bag . . . . . . . . . . . . . . . . . . . . . 2-12 Antistatic Kit . . . . . . . . . . . . . . . . . . . . . . 2-13 Antistatic Mat . . . . . . . . . . . . . . . . . . . . . 2-12 Antistatic Wrist Strap. . . . . . . . . . . . . . . . 2-12 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 Assembly Axle Shaft . . . . . . . . . . . . . . . . . . . . . 7-71 Bearings. . . . . . . . . . . . . . . . . . . . . . . 7-67 Bevel Gear . . . . . . . . . . . . . . . . . . . . . 7-66 Cover, Inspection . . . . . . . . . . . . . . . . 7-74 Helical Gear . . . . . . . . . . . . . . . . . . . . 7-68 Shims . . . . . . . . . . . . . . . . . . . . . . . . 7-67 Spiral Pinion Gear . . . . . . . . . . . 7-66, 7-68 Assembly Procedures . . . . . . . . . . 7-66 to 7-75 Auxiliary Motor . . . . . . . . . . . . . . . . . . . .7-117 Auxiliary Pump . . . . . . . . . . . . . . . . . . . .7-141 Axle Seal . . . . . . . . . . . . . . . . . . . . . . . . . 7-49

Cards Interface Card . . . . . . . . . . . . . . . . . . . 7-88 Translator Card . . . . . . . . . . . . . . . . . . 7-90 Caution, Safety Definition . . . . . . . . . . . . . . 2-2 Chains Free Lift. . . . . . . . . . . . . . . . . . . . . . . 7-153 Free Lift Chains. . . . . . . . . . . . . . . . . 7-155 Main Lift . . . . . . . . . . . . . . . . . . . . . . 7-153 Main Lift Chains . . . . . . . . . . . . . . . . 7-153 Changing Hydraulic Fluid . . . . . . . . . . . . 7-126 Changing Hydraulic Oil . . . . . . . . . . . . . . 7-126 Checking Hydraulic Oil Level. . . . . . . . . . 7-126 Cleaning, Motor . . . . . . . . . . . . . . . . . . . 7-102 Codes Summary Tables . . . . . . . . . . . . . . . . . . 6-5 Commutator, Motor. . . . . . . . . . . . . . . . . 7-106 Component Locator Photos . . . . . . . . . . . . . 7-5 Configure Mode. . . . . . . . . . . . . . . . . . 3-4, 3-6 Connector, Battery . . . . . . . . . . . . . . . . . . 7-91 Contactor Coils . . . . . . . . . . . . . . . . . . . . . . 8-4 Contactor Fuse Panel . . . . . . . . . . . . . . . . 7-83 Contactors . . . . . . . . . . . . . . . . . . . . . . . . 7-84 Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-84 Steer . . . . . . . . . . . . . . . . . . . . . . . . . . 7-84 Testing Resistance. . . . . . . . . . . . . . . . 7-84 Tip Inspection . . . . . . . . . . . . . . . . . . . 7-85 Tip Replacement . . . . . . . . . . . . . . . . . 7-86 Traction. . . . . . . . . . . . . . . . . . . . . . . . 7-84 Control Handle . . . . . . . . . . . . . . . . . . . . . 7-37 Assembly. . . . . . . . . . . . . . . . . . . . . . . 7-40 Installation . . . . . . . . . . . . . . . . . . . . . 7-42 Linkage Adjustment. . . . . . . . . . . . . . . 7-38 Removal . . . . . . . . . . . . . . . . . . . . . . . 7-40 Switch Replacement . . . . . . . . . . . . . . 7-41 Conversions, Standard/Metric . . . . A-9 to A-10 Covers Console . . . . . . . . . . . . . . . . . . . . . . . . 7-13 Front . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16 Front Covers . . . . . . . . . . . . . . . . . . . . 7-16 Seat Pad . . . . . . . . . . . . . . . . . . . . . . . 7-19 Steer Compartment . . . . . . . . . . . . . . . 7-18

B Backlash, Measuring . . . . . . . . . . 7-73 to 7-74 Bag, Antistatic . . . . . . . . . . . . . . . . . . . . . 2-12 Battery Charging, general . . . . . . . . . . . . . . . . 4-11 Cleaning Exterior . . . . . . . . . . . . . . . . 7-93 Connector . . . . . . . . . . . . . . . . . . . . . 7-91 Discharge Indicator (BDI), Theory. . . . . 8-6 Gates . . . . . . . . . . . . . . . . . . . . . . . . . 7-93 Inspection . . . . . . . . . . . . . . . . . . . . . 4-11 Installation. . . . . . . . . . . . . . . . . . . . . 7-92 Maintenance . . . . . . . . . . . . . . . . . . . 4-11 Removal . . . . . . . . . . . . . . . . . . . . . . . 7-92 Rollers . . . . . . . . . . . . . . . . . . . . . . . . 7-93 Safety. . . . . . . . . . . . . . . . . . . . 2-7 to 2-11 Troubleshooting . . . . . . . . . . . . . . . . . 7-96 Weight . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Battery Connector Inspection and Replacement. . . . . . . . 7-91 Bearings, Motor Checking . . . . . . . . . . . . . . . . . . . . . . 5-24 Bleeding Hydraulic System . . . . . . . . . . .7-128 Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-76 Air Gap Adjustment . . . . . . . . . . . . . . 7-76 Assembly . . . . . . . . . . . . . . . . . . . . . . 7-78 Removal and Installation . . . . . . . . . . 7-78 Brake Air Gap Adjustment . . . . . . . . . . . . 7-76 Brake Assembly . . . . . . . . . . . . . . . . . . . . 7-78 Brush Spring Tension, Motor . . . . . . . . . .7-105 Brushes, Motor . . . . . . . . . . . . . . . . . . . .7-102

I-2

Return

D Deadman Pedal . . . . . . . . . . . . . . . . . . . . . 7-43 Decimal to Fraction Conversion. . . . . . . . . . A-7 Default Passwords . . . . . . . . . . . . . . . . . . . 3-5 Design, Manual. . . . . . . . . . . . . . . . . . . . . . 1-4 Digital Output Tests . . . . . . . . . . . . . . . . 6-123 Disassembly Axle Shaft . . . . . . . . . . . . . . . . . 7-59, 7-64 Bearings . . . . . . . . . . . . . . . . . . . . . . . 7-62 Bevel Gear. . . . . . . . . . . . . . . . . . . . . . 7-59

Prime-Mover CRX30/35/40/50 Service Manual

Helical Gear . . . . . . . . . . . . . . . . . . . . 7-60 Shims. . . . . . . . . . . . . . . . . . . . . . . . . 7-62 Spiral Gear . . . . . . . . . . . . . . . . . . . . . 7-60 Spiral Pinion Gear . . . . . . . . . . . . . . . 7-65 Disassembly Procedures. . . . . . . . 7-58 to 7-65 Drive Unit Housing . . . . . . . . . 7-58 to 7-63 Drive Motor . . . . . . . . . . . . . . . . . . . . . . 7-111 Drive Unit Replacement. . . . . . . . . . . . . . . . . . . . 7-47 Drive Units. . . . . . . . . . . . . . . . . . . . . . . . 7-46 Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-46 Oil Level, Checking . . . . . . . . . . . . . . . 7-46 Drive Wheel/Tire . . . . . . . . . . . . . . . . . . . 7-27 E Electric Motor Tests . . . . . . . . . . . . . . . . 7-108 Electrical Components . . . . . . . . . . . . . . . 7-81 Electrical Connections Locator Chart . . . . . . . . . . . . . . . . . . . . 5-9 Electrostatic Discharge Precautions . . . . . 2-12 Elevating Section . . . . . . . . . . . . . . . . . . 7-148 Emergency Power Off Switch . . . . . . . . . 7-121 Entering a Password . . . . . . . . . . . . . . . . . 3-5 EPO (Emergency Power Off) Switch. . . . . 7-121 ESD Precautions . . . . . . . . . . . . . . . . . . . 2-12 F Fault Codes Summary Tables. . . . . . . . . . . . . . . . . . 6-5 Filter, Hydraulic . . . . . . . . . . . . . . . . . . . 7-126 Firmware . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Flash Loader . . . . . . . . . . . . . . . . . . . . . . 3-15 Fluids Bleeding Hydraulic System . . . . . . . . 7-128 Changing Hydraulic Fluid . . . . . . . . . 7-126 Hydraulic . . . . . . . . . . . . . . . . . . . . . 7-126 Setting Hydraulic Pressure . . . . . . . . 7-135 Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-157 Fraction to Decimal Conversion . . . . . . . . . A-7 Free Lift Chains . . . . . . . . . . . . . . . . . . . 7-153 Fuse Panel . . . . . . . . . . . . . . . . . . . . . . . . 7-83 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-82 Removal, Testing, and Replacement . . 7-82

Index

H Hall Effect Switches. . . . . . . . . . . . . . . . . . . 8-4 Harness, Wiring. . . . . . . . . . . . . . . . . . . . . 7-98 Helical Gear Assembly . . . . . . . . . . . . . . . . 7-68 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-101 Housing Assembly Axle Shaft . . . . . . . . . . . . . . . . . . . . . . 7-71 Bearings . . . . . . . . . . . . . . . . . . . . . . . 7-67 Bevel Gear . . . . . . . . . . . . . . . . . . . . . . 7-66 Shims . . . . . . . . . . . . . . . . . . . . . . . . . 7-67 Spiral Pinion Gear . . . . . . . . . . . . . . . . 7-66 Housing Disassembly . . . . . . . . . . 7-58 to 7-63 Axle Shaft . . . . . . . . . . . . . . . . . 7-59, 7-64 Bearings . . . . . . . . . . . . . . . . . . . . . . . 7-62 Bevel Gear . . . . . . . . . . . . . . . . . . . . . . 7-59 Helical Gear . . . . . . . . . . . . . . . . . . . . . 7-60 Shims . . . . . . . . . . . . . . . . . . . . . . . . . 7-62 Spiral Gear . . . . . . . . . . . . . . . . . . . . . 7-60 Spiral Pinion Gear . . . . . . . . . . . . . . . . 7-65 Hydraulic Components . . . . . . . . . . . . 7-125 to 7-146 Filter . . . . . . . . . . . . . . . . . . . . . . . . . 7-126 Fluid . . . . . . . . . . . . . . . . . . . . . . . . . 7-126 Functions . . . . . . . . . . . . . . . . . . . . . . 8-20 Oil, Selecting . . . . . . . . . . . . . . . . . . . 7-126 Pressure Adjustments . . . . . . . . . . . . 7-135 Reservoir . . . . . . . . . . . . . . . . . . . . . . 7-137 Schematics . . . . . . . . . . . . . . . . . . . . .A-16 Steer Motor . . . . . . . . . . . . . . . . . . . . 7-133 System, Bleeding . . . . . . . . . . . . . . . . 7-128 I Inspection, Battery . . . . . . . . . . . . . . . . . . 4-11 Interface Card . . . . . . . . . . . . . . . . . . . . . . 7-88 J Jacking Safety . . . . . . . . . . . . . . . . . . . . . . 2-14 K Key Switch . . . . . . . . . . . . . . . . . . . . . . . 7-119 Kit Options . . . . . . . . . . . . . . . . . . . 7-56, 7-57

Gates, Battery . . . . . . . . . . . . . . . . . . . . . 7-93 Grounded Motor Tests . . . . . . . . . . . . . . 7-109 Guidelines Electrical Troubleshooting . . . . . . . . . . 5-8 Hydraulic Troubleshooting . . . . . . . . . 5-25

Learn Mode . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Lift Contactor . . . . . . . . . . . . . . . . . . . . . . 7-84 Lift Motor . . . . . . . . . . . . . . . . . . . . . . . . 7-114 Lift Pump . . . . . . . . . . . . . . . . . . . . . . . . 7-140 Lift Ram Seals . . . . . . . . . . . . . . . . . . . . . . . . . 7-156 Lists Abbreviations. . . . . . . . . . . . . . . . . . . . . 1-5

Return

I-3

Index

Prime-Mover CRX30/35/40/50 Service Manual

Symbols . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Loading Software . . . . . . . . . . . . . . . . . . . 3-15 Locator Photos, Components . . . . . . . . . . . 7-5 Lubrication Equivalency Chart. . . . . . . . . . A-2

Open Circuit Motor Test . . . . . . . . . . . . . 7-108 Operator Display . . . . . . . . . . . . . . . . . . . . 7-36 Orbitrol (Steer Valve) . . . . . . . . . . . . . . . . 7-129 Overhead Guard . . . . . . . . . . . . . . . . . . . . 7-20 Overheating, Motors . . . . . . . . . . . . . . . . . 5-24

M Main Lift Chains . . . . . . . . . . . . . . . . . . .7-153 Maintenance . . . . . . . . . . . . . . . . . 4-1 to 4-10 Maintenance Mode. . . . . . . . . . . . . . . 3-4, 3-11 Manual Design. . . . . . . . . . . . . . . . . . . . . . 1-4 Map, Navigating the Manual . . . . . . . . . . . 1-2 Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-148 Complete Removal . . . . . . . . . . . . . . .7-148 Installation. . . . . . . . . . . . . . . . . . . . .7-150 Partial Removal . . . . . . . . . . . . . . . . .7-151 Quad Hose and Bracket Adjustment . . .7-146 Hose Replacement . . . . . . . . . . . .7-144 Mat, Antistatic . . . . . . . . . . . . . . . . . . . . . 2-12 Measuring Backlash . . . . . . . . . . 7-73 to 7-74 Message and Code Summary Tables . . . . . 6-5 Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Configure . . . . . . . . . . . . . . . . . . . . 3-4, 3-6 Learn . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Maintenance . . . . . . . . . . . . . . . . 3-4, 3-11 Performance . . . . . . . . . . . . . . . . . . . . . 3-9 Motor Brush Spring Tension . . . . . . . . . . . .7-105 Brushes . . . . . . . . . . . . . . . . . . . . . . .7-102 Cleaning. . . . . . . . . . . . . . . . . . . . . . .7-102 Commutator. . . . . . . . . . . . . . . . . . . .7-106 Grounded Tests . . . . . . . . . . . . . . . . .7-109 Open Circuit Tests . . . . . . . . . . . . . . .7-108 Short Circuit Test. . . . . . . . . . . . . . . .7-110 Terminal Nuts . . . . . . . . . . . . . . . . . .7-107 Tests . . . . . . . . . . . . . . . . . . . . . . . . .7-108 Motor Bearings Checking . . . . . . . . . . . . . . . . . . . . . . 5-24 Motors . . . . . . . . . . . . . . . . . . . . . . . . . . .7-102 Auxiliary . . . . . . . . . . . . . . . . . . . . . .7-117 Drive . . . . . . . . . . . . . . . . . . . . . . . . .7-111 Hydraulic Steer . . . . . . . . . . . . . . . . .7-133 Lift . . . . . . . . . . . . . . . . . . . . . . . . . . .7-114 Steer . . . . . . . . . . . . . . . . . . . . . . . . . 7-24 See also Drive Motor See also Lift/Aux Motor O Oil Changing Hydraulic Fluid . . . . . . . . .7-126 Checking Hydraulic Oil Level . . . . . . .7-126 Hydraulic Fluid . . . . . . . . . . . . . . . . .7-126 Selecting Hydraulic Oil . . . . . . . . . . . .7-126

I-4

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P Passwords. . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Default . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Entering a Password . . . . . . . . . . . . . . . 3-5 PC Loader Program . . . . . . . . . . . . . . . . . . 3-15 Pedal, Deadman . . . . . . . . . . . . . . . . . . . . 7-43 Performance Mode #1 . . . . . . . . . . . . . . . . . 3-9 Performance Mode #2 . . . . . . . . . . . . . . . . . 3-9 Performance Mode #3 . . . . . . . . . . . . . . . . . 3-9 Performance Mode #4 . . . . . . . . . . . . . . . . . 3-9 Planned Maintenance . . . . . . . . . . . 4-1 to 4-10 3 Months/250 Hours. . . . . . . . . . . . . . . 4-6 6 Months/500 Hours. . . . . . . . . . . . . . . 4-6 90-Day Inspection . . . . . . . . . . . . . . . . . 4-5 Annual/1500 Hours . . . . . . . . . . . . . . 4-10 Guidelines . . . . . . . . . . . . . . . . . . . . . . . 4-2 Operator’s Daily Checklist . . . . . . . . . . . 4-3 Power Amplifiers Traction. . . . . . . . . . . . . . . . . . . . . . . . 7-99 Pressure Adjustments . . . . . . . . . . . . . . . 7-135 Pumps Auxiliary . . . . . . . . . . . . . . . . . . . . . . 7-141 Lift . . . . . . . . . . . . . . . . . . . . . . . . . . 7-140 Steer . . . . . . . . . . . . . . . . . . . . . . . . . 7-139 Q Quad Mast Hose and Bracket Adjustment . . . . . . 7-146 Hose Replacement . . . . . . . . . . . . . . . 7-144 R Ram Seals . . . . . . . . . . . . . . . . . . . . . . . . . 7-156 Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . 7-142 Reservoir, Hydraulic . . . . . . . . . . . . . . . . 7-137 Reversing Steering Action . . . . . . . . . . . . 7-134 Rollers, Battery . . . . . . . . . . . . . . . . . . . . . 7-93 S Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Battery Safety . . . . . . . . . . . . . . 2-7 to 2-11 Definitions. . . . . . . . . . . . . . . . . . . . . . . 2-2 General Safety Rules . . . . . . . . . . 2-3 to 2-7 Jacking Safety . . . . . . . . . . . . . . . . . . . 2-14 Static Precautions . . . . . . . . . . . . . . . . 2-12 Towing . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Prime-Mover CRX30/35/40/50 Service Manual

Index

Welding Safety . . . . . . . . . . . . . . . . . . 2-16 Schematics Electrical . . . . . . . . . . . . . . . . A-12 to A-15 Hydraulic . . . . . . . . . . . . . . . . . . . . . . A-16 Seals Axle . . . . . . . . . . . . . . . . . . . . . . . . . . 7-49 Lift Ram . . . . . . . . . . . . . . . . . . . . . . 7-156 Seat Pad. . . . . . . . . . . . . . . . . . . . . . . . . . 7-19 Sensors Speed Feedback . . . . . . . . . . . . . . . . 7-122 Steer Position Proximity . . . . . . . . . . 7-123 Short Circuited Armature or Field Winding . . . . . . . . . . . . . . . . . . 7-110 Shorts to Frame Test . . . . . . . . . . . . . . . . 5-14 Software Configuration. . . . . . . . . . . . . . . 3-15 Solenoids . . . . . . . . . . . . . . . . . . . . . . . . 7-131 Specifications, Vehicle . . . . . . . . . . . . . . . . 3-2 Speed Feedback Sensor . . . . . . . . . . . . . 7-122 Spiral Pinion Assembly. . . . . . . . . . . 7-68, 7-69 Standard/Metric Conversions. . . . . A-9 to A-10 Static Precautions . . . . . . . . . . . . . . . . . . 2-12 Steer Contactor . . . . . . . . . . . . . . . . . . . . 7-84 Steer Motor . . . . . . . . . . . . . . . . . . . . . . . 7-24 Steer Position Proximity Sensor . . . . . . . 7-123 Steer Pump . . . . . . . . . . . . . . . . . . . . . . 7-139 Steer Valve (Orbitrol) . . . . . . . . . . . . . . . 7-129 Steerable Wheel/Tire . . . . . . . . . . . . . . . . 7-28 Steerable Wheel/Tire Assembly . . . . . . . . 7-31 Steering Reversing . . . . . . . . . . . . . . . . . . . . . 7-134 Summary Tables, Messages and Codes. . . . 6-5 Switches Deadman Switch . . . . . . . . . . . . . . . . 7-43 Emergency Power Off Switch. . . . . . . 7-121 EPO (Emergency Power Off) . . . . . . . 7-121 Hall Effect . . . . . . . . . . . . . . . . . . . . . . 8-4 Key Switch . . . . . . . . . . . . . . . . . . . . 7-119 Symbols List . . . . . . . . . . . . . . . . . . . . . . . 1-5 Systems Overview . . . . . . . . . . . . . . . . . . . 3-1

Deadman Switch Closed . . . . . . . . . . . 8-13 Forward Travel Requested . . . . . . . . . . 8-13 Hall Effect Switches . . . . . . . . . . . . . . . . 8-4 Hydraulic Functions . . . . . . . . . . . . . . 8-20 Key Switch ON . . . . . . . . . . . . . . . . . . . 8-12 Lift/Lower System . . . . . . . . . . . . . . . . 8-20 Proportional Plugging. . . . . . . . . . . . . . . 8-5 Regenerative Braking . . . . . . . . . . . . . . . 8-6 SelfTest . . . . . . . . . . . . . . . . . . . . . . . . 8-12 Sense Wires . . . . . . . . . . . . . . . . . . . . . 8-36 Solenoids . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Steering . . . . . . . . . . . . . . . . . . . . . . . . 8-34 Thermal Cut-Back . . . . . . . . . . . . . . . . . 8-7 Torque on Demand . . . . . . . . . . . . . . . . 8-5 Traction System. . . . . . . . . . . . . . . . . . . 8-2 Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . 7-142 Tire/Wheel Assemblies . . . . . . . . . . . . . . . 7-27 Tires/Wheels Tires . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27 Torque Chart. . . . . . . . . . . . . . . . . . . . . . . .A-4 Metric . . . . . . . . . . . . . . . . . . . . . . . . . .A-5 Standard . . . . . . . . . . . . . . . . . . . . . . . .A-4 Standard (Brass) . . . . . . . . . . . . . . . . . .A-6 Standard (Ferrous). . . . . . . . . . . . . . . . .A-4 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Traction Contactor . . . . . . . . . . . . . . . . . . 7-84 Traction Power Amplifiers . . . . . . . . . . . . . 7-99 Traction System . . . . . . . . . . . . . . . . . . . . . 8-2 Translator Card. . . . . . . . . . . . . . . . . . . . . 7-90 Translator Card LEDs . . . . . . . . . . . . . . . . 5-12 Troubleshooting . . . . . . . . . . . . . . . . 5-1, 7-56 Battery . . . . . . . . . . . . . . . . . . . . . . . . 7-96 Electrical Guidelines . . . . . . . . . . . . . . . 5-8 Hydraulic Guidelines . . . . . . . . . . . . . . 5-25 Motor Overheating . . . . . . . . . . . . . . . . 5-24 Shorts to Frame Test . . . . . . . . . . . . . . 5-14 Translator Card LEDs . . . . . . . . . . . . . 5-12 Waiting for Precharge. . . . . . . . . . . . . . . 5-3 Wiring Problems . . . . . . . . . . . . . . . . . 5-18

T Terminal Nuts, Motors . . . . . . . . . . . . . . 7-107 Tests Analog . . . . . . . . . . . . . . . . . . . . . . . . 6-85 Digital Output Tests . . . . . . . . . . . . . 6-123 Tests, Electric Motor . . . . . . . . . . . . . . . 7-108 Theory of Operation Aux Functions Sideshift . . . . . . . . . . . . . . . . . . . . 8-30 Tilt . . . . . . . . . . . . . . . . . . . . . . . . 8-25 Battery Connected . . . . . . . . . . . . . . . . 8-9 Battery Discharge Indicator (BDI) . . . . . 8-6 Contactor Coils. . . . . . . . . . . . . . . . . . . 8-4 Current Limiting. . . . . . . . . . . . . . . . . . 8-7

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V Vehicle Specifications . . . . . . . . . . . . . . . . . 3-2 VR1 Replacement . . . . . . . . . . . . . . . . . . . 7-40 W Waiting for Precharge. . . . . . . . . . . . . . . . . . 5-3 Warning, Safety Definition . . . . . . . . . . . . . . 2-2 Welding Safety . . . . . . . . . . . . . . . . . . . . . . 2-16 Wheel Tire Assemblies . . . . . . . . . . . . . . . . 7-27 Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27 Wiring General . . . . . . . . . . . . . . . . . . . . . . . . 7-97 Inspection . . . . . . . . . . . . . . . . . . . . . . 7-97

I-5

Index

Repair . . . . . . . . . . . . . . . . . . . . . . . . 7-97 Wiring Harness . . . . . . . . . . . . . . . . . . . . 7-98 Wiring Problems, Troubleshooting . . . . . . 5-18 Wrist Strap, Antistatic . . . . . . . . . . . . . . . 2-12

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Prime-Mover CRX30/35/40/50 Service Manual

Back Cover

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

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