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Foreword
This Service Publication provides information
covering normal service, maintenance and repair of
the BT Prime-Mover lift truck noted on the cover. It
has been specifically prepared to help owners and
service personnel maintain these trucks in efficient
and safe operating condition.
This Manual is intended for use by persons who are
trained and authorized to do lift truck maintenance.
It is designed to provide essential information about
the correct and safe service maintenance and repair
of the truck by trained mechanics or service
technicians.
The Pictorial Contents list components or systems
by Basic Group Number of Major Parts. Additional
content listings are placed at the beginning of each
Section in the manual.
General and detailed service and repair
procedures are outlined (as required) for each
component or subsystem. Some procedures include
explanations that are common to several
components or subsystems.
NOTICE
The descriptions and specifications included in this manual were in effect at the time of
printing. BT Prime-Mover reserves the right to discontinue models at any time, or make
improvements and changes in specifications or design without notice and without
incurring obligation. Specifications, torques, pressures, measurements, adjustments,
illustrations and other items may change at any time. Contact your authorized BT
Prime-Mover dealer for information on possible updates or revisions.
OCTOBER 1995
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Foreword-1
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CONTENTS
OCTOBER 1995
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Contents-1
Pictorial Contents
Group PS - Periodic Service
Group 12 - Battery
Group 13 - Electrical Control Handle
Group 16 - Electrical Motor
Group 17 - Electrical Schematics
Group 19 - Electrical Controls
Contents-2
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OCTOBER 1995
Pictorial Contents
OCTOBER 1995
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Contents-3
Pictorial Contents
Contents-4
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OCTOBER 1995
Group SA
SAFE MAINTENANCE
Safety........................................................................................... Section 1
Lifting, Jacking, and Blocking................................................... Section 2
OCTOBER 1995
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SA-00-1
SA-00-2
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OCTOBER 1995
Section 1.
Safety
OCTOBER 1995
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SA-01-1
NOTE
This message is used when special
information is required relating to
procedures,
equipment,
tools,
pressure, capacities, and other
special data.
IMPORTANT
This message is used when special
precautions should be taken to
ensure a correct action or to avoid
damage to, or malfunction of, the
truck or a component.
CAUTION
This message is used as a reminder
of safety hazards that can result in
personal
injury
if
proper
precautions are not taken.
WARNING
This message is used when a
hazard exists that can result in
injury or death if proper precautions
are not taken.
DANGER
This message is used when an
extreme hazard exists that can
result in injury or death or serious
injury if proper precautions are not
taken.
The above terms have been adopted by BT PRIMEMOVER Company. The same terms may be used in
different context in service literature supplied
directly or indirectly by vendors or truck
components.
SA-01-2
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OCTOBER 1995
NOTE
You should also be familiar with
additional
operating
and
maintenance safety instructions
contained
in
the
following
publications:
OCTOBER 1995
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SA-01-3
Service Electric Truck Batteries in a wellventilated area to avoid the danger of lighting
explosive gases.
Cautions
The following is a list of CAUTIONS connected with
the operation and maintenance of trucks equipped
with solid state control panels.
CAUTION
WELDING ON TRUCK
1.Make sure the truck has no grounds.
2.Disconnect truck battery.
3.Protect
electrical
wiring
and
components from weld spatter with a
shield.
4.Ventilate battery or remove battery
from truck.
If the above is not followed, damage
can result to wring and electrical
components on solid state control
truck.
SA-01-4
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CAUTION
WELDING ON TRUCK
Do not steam clean a solid state
controlled truck as excessive
moisture will interfere with proper
operation of the solid state
components.
CAUTION
CHECK POLARITY
Battery Polarity must be correct or
the truck will not operate.
CAUTION
USE TRUCK BATTERY ONLY
Do not use a motor generator unit
such as ready power or a battery
charger to move and/or check this
truck as serious damage may
occur.
IMPORTANT
SAFETY NOTICE
Read and understand all Safety
Precautions and Warning before
performing repairs on lift trucks.
OCTOBER 1995
OCTOBER 1995
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SA-01-5
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Section 2.
Machine Jacking and Blocking
IMPORTANT
BT Prime-Mover dose not recommend towing the RCX lift truck.
OCTOBER 1995
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SA-02-1
CAUTION
To perform these service procedures, first:
Park truck on a hard, level, and solid
surface, such as a concrete floor with no
gaps or breaks.
Put upright in vertical position and fully
lower the forks or attachment.
Turn key switch OFF.
WARNING
DEFECTIVE EQUIPMENT
CAN CAUSE ACCIDENTS
All tools and lifting equipment must be in
good condition, meet the load capacity
requirements and have OSHA labels
when required. Tools with defects can
have failures causing sever injury or
death.
SA-02-2
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OCTOBER 1995
Blocking
Position
the
Upright
in
Raised
WARNING
Do not stand under the forks when
blocks are put under the carriage
and rails. The forks can fall and
cause injury or death to personnel.
NOTE
When
convenient,
it
is
recommended to remove the
battery from truck, to reduce weight
for both safer and easier jacking.
NOTE
If there is insufficient clearance
under frame for your jack, the truck
may first be driven onto thin
platforms, such as 1in. x 6in. x 12in.
pieces of board (shims), to increase
the truck frame under-clearance.
NOTE
For STANDARD UPRIGHT, block
may be needed to be cut to suit.
TRIPLE STAGE UPRIGHT, the
carriage may be blocked as shown.
OCTOBER 1995
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SA-02-3
IMPORTANT
Lift only the front or the rear of the
truck at one time. Watch truck for
signs of lateral instability. It may tip
sideways. You may have to support
or guide the side of the truck or
overhead guard to prevent tipping.
1. Remove battery.
2.
3.
Remove forks.
SA-02-4
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OCTOBER 1995
Group PS
PERIODIC SERVICE
OCTOBER 1995
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PS-00-1
PS-00-2
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OCTOBER 1995
Section 1.
Maintenance Schedules
OCTOBER 1995
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PS-01-1
Maintenance Schedules
This Service Publication provides information
covering normal service, maintenance and repair of
the BT Prime-Mover lift truck noted on the cover. It
has been specifically prepared to help owners and
service personnel maintain these trucks in efficient
and safe operating condition.
Inspection Forms
To insure that the daily inspection and PM are
properly performed, we recommended the use of
inspection forms. Such forms not only provide a
guide for the inspections and maintenance
requirements for each vehicle, they will assist you in
determining when to schedule this vehicle for major
repair. Consequently these repairs can be done
without the disruptive effect of unscheduled down
time.
NOTE
PS-01-2
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OCTOBER 1995
OCTOBER 1995
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PS-01-3
L2
General Purpose
Grease
with EP additive
General Purpose
Grease
with EP additive
and Moly Additive
L3
80 W 90
L4
Chain Lube
L5
L6
PS-01-4
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Hydraulic Fluid
Gear Lubricant.
Hydraulic Fluid.
Use only high quality hydraulic fluid with Zinc
or equivalent Anti-Wear additive which meets
the requirements of ASTM
D-2882 pump wear test with 50 mg total
weight loss maximum.
Use only heavy-duty Hydraulic Brake Fluid
which meets or exceeds the requirements of
SAE J1703 Specification, or alternatively,
Type DOT Brake Fluid, Grade DOT 3, as
specified by Federal Motor Vehicle Safety
Standard No. (FMVSS 116).
Non-petroleum type.
OCTOBER 1995
Miscellaneous Lubricants
Miscellaneous Linkage
Corrosion Protection
Mechanical Lubricant
Apply to electrical connections any time they are disconnected. The lubricant should be reapplied before
making the connection.
Application Examples (Standard and Cold Storage Applications):
Corrosion Protection
Mechanical Paste Lubricant
Apply to electrical connections any time they are disconnected. The lubricant should be reapplied before
making the connection.
OCTOBER 1995
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PS-01-5
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Section 2.
Planned Maintenance
OCTOBER 1995
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PS-02-1
CAUTION
Do not operate a lift truck with damaged
or missing decals and nameplates.
Replace them immediately. They contain
important information.
DANGER
Do not operate a lift truck with damaged
or missing decals and nameplates.
Replace them immediately. They contain
important information.
PS-02-2
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OCTOBER 1995
DANGER
For trucks equipped with spark-enclosed
(EE) construction, or with polyurethane
tires, check the ground strap for wear and
secure attachment.
DANGER
Upright can drop suddenly. Look at the
upright, but keep hands out.
IMPORTANT
Uprights and lift chains require special
attention and maintenance to maintain them
in safe operating condition. Refer to Lift
Chain Maintenance in Group 34 for additional
information.
CAUTION
If load backrest has been removed, a bolt
and washer must be in place on each end of
the top fork bar to act as a fork stop.
OCTOBER 1995
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PS-02-3
FORKS
Inspect the load forks for cracks, breaks,
bending and wear. The fork top surfaces should
be level and even with each other. The height
difference between both fork tips should be no
more than 0.25 inch (6mm).
WARNING
If the fork blade at the heel is worn down by
more than 10%, the load capacity is
reduced and the fork must be replaced. Do
not attempt to fill with weld.
CAUTION
If the forks are obviously bent or damaged,
have them inspected by a trained
maintenance person before operating the
truck.
PS-02-4
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OCTOBER 1995
Damaged tire.
Damaged wheels or loosening of the locking
rings on multi-piece rims.
Missing bolt
CAUTION
Personnel working on wheels and tires
must be trained and qualified to do wheel
and tire maintenance.
DANGER
RIM SEPARATION
Remove the air from tires before doing
any work on tires or rims. Multi-piece
rims cans separate with enough force to
cause injury or death.
FUNCTIONAL CHECKS
Replace missing bolts and tighten loose bolts to the
correct torque before operating the truck.
PNEUMATIC TIRES
CAUTION
Check tire pressure from a position facing
the tread of the tire, not the side. Use a longhandle gauge to keep your body away from
the side. If tires are low, don't add air. The tire
may require removal and repair. Have the tire
and wheel inspected by a person trained and
authorized to do tire and wheel maintenance.
Low tire pressure can reduce the stability of
your lift truck and cause it to tip over.
OCTOBER 1995
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PS-02-5
IMPORTANT
NOTE
Fault Codes
Code
-01
-02
Condition
Brake switch open.
Truck in forward when the key is turned on
and accelerator is depressed.
-03
-04
-05
-06
PS-02-6
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OCTOBER 1995
LOWER
LIFT
5. Check Steering
REVERSE
6. Check Brakes
Move the truck forward at a slow speed. Slowly lift
foot brake pedal, truck should come to a smooth
stop.
Repeat above step in reverse.
Check braking lining wear by inspecting the brake
actuating spring length. See procedure in Group
23, Section 2.
OCTOBER 1995
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PS-02-7
NOTE
It is recommended that these
tests be conducted with a rated
capacity load, if possible.
WARNING
Make sure travel path is clear of obstacles
and personnel.
PS-02-8
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OCTOBER 1995
rated
NOTE
It is recommended that the
following tests also be conducted
with a rated capacity load, if
available.
CAUTION
Be sure there is adequate overhead
clearance before raising the upright.
Perform test on level, firm surface.
OCTOBER 1995
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PS-02-9
WARNING
FALLING FORKS
Do not walk or stand under raised forks. The
forks can fall and cause injury or death.
CAUTION
When
you
have
completed
the
operational tests, park and leave truck
according to standard shutdown
PS-02-10
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OCTOBER 1995
12,
Battery,
for
additional
Air Cleaning
Always maintain a lift truck in a clean condition. Do
not allow dirt, dust, lint, or other contaminants to
accumulate on the truck. Keep the truck free from
leaking oil and grease. Wipe up all oil spills. Keep
the controls and floorboard clean and dry. A clean
truck makes it easier to see leaks, loose, missing or
damaged parts, and will help prevent fires. Clean
truck will run cooler.
The environment in which a lift truck operates will
determine how often and to what extent cleaning is
necessary. For example, trucks operating in
manufacturing plants which have a high level of dirt
or lint (e.g., cotton fibers, paper dust, etc.) in the air
or on the floor, will require more frequent cleaning. If
air pressure does not remove heavy deposits of
grease, oil, etc., it may be necessary to use steam
or liquid spray cleaner. Do not clean electrical
components with steam.
LIFT TRUCKS SHOULD BE AIR CLEANED AT
EVERY PM INTERVAL, AND OTHERWISE AS
OFTEN AS REQUIRED.
OCTOBER 1995
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CAUTION
Use clean, dry, low-pressure compressed
air; restrict air pressure to 30 psi (207
kPa), maximum. Wear suitable eye
protection and protective clothing.
PS-02-11
Hydraulic Sump
Check the hydraulic sump tank fluid level. Correct
fluid level is important for proper hydraulic system
operation. Low Fluid level can cause pump damage.
Overfilling can cause loss of fluid or lift system
malfunction.
Hydraulic fluid expands as its temperature rises.
Therefore, it is preferable to check the fluid level at
operating temperature, after approximately 30
minutes of truck operation. To check the fluid level,
first park the truck on a level surface. Put the upright
in a vertical position and lower the fork carriage fully
down. KEEP DIRT OUT OF THE SUMP. Pull the
dipstick out, wipe it with a clean wiper and reinsert it
fully into the dipstick tube. Remove the dipstick and
check the oil level. Keep the oil level above the
LOW mark on the dipstick by adding recommended
hydraulic fluid only, as required. DO NOT
OVERFILL.
Check the condition of the hydraulic fluid for color,
clarity, and contamination. Change (replace) the oil
as necessary.
WARNING
An upright or carriage can unexpectedly.
Chain or block the carriage and rails.
Failure to follow this warning can result in
serious injury.
PS-02-12
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WARNING
Be sure to put blocking under the
frame to keep the truck safe.
Lift Chains
NOTE
OCTOBER 1995
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PS-02-13
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Group 12
BATTERY
OCTOBER 1995
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12-00-1
12-00-2
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OCTOBER 1995
Section 1.
Battery Handling
OCTOBER 1995
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12-01-1
12-01-2
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OCTOBER 1995
Battery Handling
WARNING
Electric truck batteries are heavy and awkward to handle. On
charge, they give off hydrogen and oxygen which, in certain
concentrations, are explosive. Electric truck batteries are also
costly, so before you remove, service, or install a truck
battery, consult BATTERY MANUFACTURER, for more
recommendations and instructions on handling and charging
batteries. Carefully read and follow recommendations and
instructions.
DANGER
Explosive gas is always present
around batteries, especially when
they are being charged. The
following should be adhered to:
OCTOBER 1995
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12-01-3
WARNING
SULFURIC ACID
The battery contains corrosive acid which can cause injury. If acid
contacts your eyes or skin, flush immediately with water and get
medical assistance.
12-01-4
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OCTOBER 1995
Battery Removal
1. Move truck to the designated battery service
area.
2. Turn key switch OFF and disconnect battery.
NOTE
Do not wash battery in truck.
OCTOBER 1995
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12-01-5
Battery Maintenance
Batteries are used to supply the electrical power to
operate an Electric Industrial Truck. Their voltage
depends on the number of individual cells they
contain. There are approximately 2 volts for each
cell in the commonly used lead-acid type battery.
Batteries normally range from 6 volts to 72 volts.
Their capacity varies depending on the application.
Only use batteries that comply with factory
specifications as to size and capacity.
Battery Maintenance
To obtain maximum performance and
battery life, the instructions supplied by
your Battery Vendor should be adhered to.
12-01-6
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OCTOBER 1995
Battery Vents
When Charging Batteries: The vent caps
must be kept in place to avoid electrolyte
spray. Care must be taken to assure that vent
caps are functioning. The cap vents must be
open to allow the battery to breath. The
battery cover must be removed/opened to
dissipate heat and explosive gas.
When Cleaning Batteries: The vents must be
tightly in place.
Battery Charging
Follow the instructions supplied by the Battery
Charger Vendor.
Battery Electrolyte
Always use a carboy tilter or siphon when
handling battery electrolyte.
When mixing electrolyte, always pour acid
into water ~ never pour water into acid.
Pouring water into acid will cause a dangerous
chemical action.
Replacement Batteries
CAUTION
IMPORTANT
Vent caps must be free of obstruction and in
good condition. Battery top should be clean and
free of cracks or breaks. Battery terminals must
be clean and solidly mounted. Damaged
batteries should be repair or replaced.your
battery vendor.
OCTOBER 1995
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12-01-7
Install Battery
If the battery is uncovered, cover the battery with a
non-conducting material (i.e., plywood, heavy
cardboard, etc.) prior to installation.
Push battery into battery compartment.
Install battery retainer.
Remove non-conductive material from battery.
Connect battery to truck.
12-01-8
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OCTOBER 1995
Group 13
ELECTRICAL HANDLE SWITCH
OCTOBER 1995
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13-00-1
13-00-2
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OCTOBER 1995
Section 1.
Control Handle Switch
OCTOBER 1995
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13-01-1
13-01-2
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OCTOBER 1995
OCTOBER 1995
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13-01-3
Remove Switch
1. Remove fasteners (2 and 3), refer to
opposite illustration.
2. Remove inner fasteners(4 and 5).
3. Pull harness wires free of their retainer slots
in handle (heel side).
4. Provide some wire slack in the housing
before removing a switch,
5. Pull switch from housing.
6. Remove wires from switch connections.
Install Switch
IMPORTANT
Connector plugs and receptacles are
permanently labeled with the proper PL
(Plug) and SO (Socket) number for easy
identification.
CAUTION
If disconnected, match plug number
with appropriate socket number before
making a connection, i.e., Plug #PL-9
plugs into pin Socket #SO-9, etc. If not,
electrical shorts and possible damage
to equipment may result.
13-01-4
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OCTOBER 1995
Remove Switch
1. Remove cam fastener, washer and cam.
Refer to illustration.
2. Disconnect switch assembly
removed) from the wire harness.
(to
be
Install Switch
1. Install new switch assembly.
2. Connect switch assembly to wire harness.
3. Adjust switch. Refer to Group 19, Section 5,
for switch adjustment procedures.
OCTOBER 1995
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13-01-5
13-01-6
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OCTOBER 1995
Group 16
ELECTRICAL MOTORS
OCTOBER 1995
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16-00-1
16-00-2
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OCTOBER 1995
Section 1.
General Information
Safety.................................................................................................. 2
Servicing Electric Motors.................................................................. 2
Electric Motor Maintenance .............................................................. 3
Inspection Procedures.................................................................... 3
Motor Cleanliness........................................................................... 3
Motor Inspection............................................................................. 3
Test for Motor Insulation Resistance to Ground......................... 4
Using a 500 Volt Megger................................................................ 4
Using a Simpson 260-6p Volt Ohmmeter or
Equivalent Calibrated on the Rx10,000 Scale................................ 4
Brush and Commutator Inspection.................................................. 5
Operating Conditions ........................................................................ 5
Brush and Commutator Inspection................................................. 5
Brush Inspection Chart ..................................................................... 7
OCTOBER 1995
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16-01-1
Safety
WARNING
Always wear safety glasses.
Remover covers.
Remove key.
Discharge capacitor.
3. Remove cover(s).
16-01-2
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OCTOBER 1995
Inspection Procedures
To perform these service
recommended that you first:
procedures,
it
is
Motor Insulation
contamination
mechanical Factors
high Temperatures
Motor Cleanliness
Electric motors should be kept clean at all times to
prevent shorting, minimize wear, and for best
cooling.
WARNING
Wear eye protection and protective
clothing when cleaning or drying with
compressed air. Reduce air pressure
to 30 psi (207 kPa). Debris removed
with air pressure can cause injury.
OCTOBER 1995
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16-01-3
power
cables
from
motor
NOTE
Test ALL terminals individually or by
interconnecting with jumper wires.
NOTE
Test all terminals individually, or
joined together, as noted.
at
least
16-01-4
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4. VOM
must
show
1,000,000
ohms
(1megohm) resistance or higher for a good
motor insulation.
5. If less than 1 megohm is measured, air
clean motor and repeat test. If air cleaning
does not make an improvement, the motor
will have to be removed from the truck and
disassembled for a closer inspection.
OCTOBER 1995
3. Clean
commutator
surface.
Wipe
commutator with a dry, lint-free cloth. DO
NOT use lubricant or solvent on
commutator.
Uneven film.
IMPORTANT
Operating Conditions
Operating environment of lift truck motors
varies widely: The following recommendations
should be applied as actual conditions dictate.
Normal Service: Basically an eight hour day of
mostly indoor or outdoor material
handling.
Severe Service:
Extended operating
constant usage.
hours,
or
OCTOBER 1995
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IMPORTANT
and
NOTE
16-01-5
16-01-6
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OCTOBER 1995
OCTOBER 1995
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16-01-7
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Section 2.
Drive Motors
Safety.................................................................................................. 2
General Information........................................................................... 3
Operating Conditions ........................................................................ 3
Drive Motor Description .................................................................... 4
Drive Motor Removal......................................................................... 4
Drive Motor......................................................................................... 5
Drive Motor......................................................................................... 6
Disassembly ................................................................................ 6
Component Inspection and Troubleshooting............................... 8
Testing......................................................................................... 9
Frame and Field Service notes.................................................... 9
Assembly ..................................................................................... 9
36-Volt Drive Motor Specifications ................................................. 11
Brush Inspection Chart .................................................................... 12
OCTOBER 1995
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16-02-1
Safety
WARNING
Wear eye protection and protective
clothing when cleaning or drying with
compressed air. Reduce air pressure
to 30 psi (207 kPa). Debris removed
with air pressure can cause injury.
16-02-2
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OCTOBER 1995
General Information
Operating Conditions
OCTOBER 1995
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Extended operating
constant usage.
hours,
or
Freezer operation
Processing plants (poultry, meat)
16-02-3
Drive Motor
Installation
1. Install service brake if removed. Refer to
service brake group for details.
2. Install new O-ring on drive motor flange pilot.
IMPORTANT
Coat spline shaft of motors with never
seize before installation.
WARNING
Use only approved hoist, chains, and
straps to lift drive motor. Be sure
hoist and accessories have correct
capacity to safely support the load.
16-02-4
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OCTOBER 1995
OCTOBER 1995
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16-02-5
Drive Motor
Disassembly
from
the
Remove Fan
A puller is installed and a slight pressure exerted
against the fan. Use a small propane torch to heat
the area of the fan around the shaft. When the fan
becomes loose on the shaft, as evidenced by the
puller becoming loose, it should be removed as
quickly as possible.
Remove Spline
Use a hammer and chisel or drift punch to drive
spline out of shaft.
16-02-6
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OCTOBER 1995
OCTOBER 1995
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16-02-7
Bearings
1. Check bearings by turning them with your
fingers. Feel for binding or gritty effects and
excessive looseness or wobble. A good
bearing should also have a small amount of
drag or stiffness caused by the lubrication
but should turn smoothly. If the bearing turns
very freely, it should be replaced. Bearings
should also be changed, if worn out,
damaged or removed from armature shaft.
Ball bearings that have been pulled off of
shafts, pressed out of end heads, or side
loaded in such a way as to apply pressure
on the balls and races must be replaced.
Although the bearing may appear or feel
good, the bearing races have been brinelled
and will fail within a relatively short period of
service.
Armature
1. Check security of fan.
2. Check for loose commutator bars. Loose
commutator bars will usually be indicated by
excessive wear or burning on one bar. The
commutator can be checked for loose bars
by lightly tapping all of the bars with the
handle of a plastic or wooden handled
screwdriver. A contrasting dull thud or
vibration will indicate a loose bar in which
case, the armature must be replaced.
3. Check for grounded circuits using a test
light. Most commercial growlers incorporate
a test light as shown in illustration below.
coloring
16-02-8
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OCTOBER 1995
Testing
Frame and Field Assembly
After thorough inspection, the Frame and Field
Assembly should be checked for grounded, open or
shorted circuits. Grounded and open circuits can be
checked using a test light. Most commercial
growlers incorporate a test light as shown in
opposite illustration.
Grounded Circuit
Touch one test lead to a clean bare metal
spot on the frame and check all terminals
with the other lead. If a grounded condition
exists, the test light will light.
Open Circuit
Check between all connecting terminals with
test leads. If the bulb fails to light, an open
circuit is indicated.
Shorted Circuit
Shorted windings in series coils are very
difficult to detect. Generally, if the coil
insulation is sound and these are no signs of
overheating, the coil can be presumed good.
OCTOBER 1995
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Assembly
Field Coil Installation
Good solder connections are important due to the
vibration characteristics encountered by these
motors which can cause cold or poorly soldered
connections to break.
16-02-9
NOTE
We do not recommend using a
soldering gun or torch. Soldering
gun cannot provide the heat
concentration
required
and
soldering torches can damage the
insulation.
16-02-10
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OCTOBER 1995
OCTOBER 1995
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16-02-11
16-02-12
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OCTOBER 1995
Section 3.
Hydraulic Pump Motors
Safety.................................................................................................. 2
General Information........................................................................... 3
Operating Conditions ........................................................................ 3
Hydraulic Pump Motor ...................................................................... 4
Disassembly ................................................................................ 4
Component Inspection and Troubleshooting............................... 6
Testing......................................................................................... 7
Frame and Field Service notes.................................................... 7
Assembly ..................................................................................... 7
36-Volt Drive Motor Specifications .................................................. 9
Brush Inspection Chart .................................................................... 10
OCTOBER 1995
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16-03-1
Safety
WARNING
Wear eye protection and protective
clothing when cleaning or drying with
compressed air. Reduce air pressure
to 30 psi (207 kPa). Debris removed
with air pressure can cause injury.
16-03-2
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OCTOBER 1995
General Information
Operating Conditions
OCTOBER 1995
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Extended operating
constant usage.
hours,
or
Freezer operation
Processing plants (poultry, meat)
16-03-3
Coupling
16-03-4
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OCTOBER 1995
OCTOBER 1995
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16-03-5
Bearings
1. Check bearings by turning them with your
fingers. Feel for binding or gritty effects and
excessive looseness or wobble. A good
bearing should also have a small amount of
drag or stiffness caused by the lubrication
but should turn smoothly. If the bearing turns
very freely, it should be replaced. Bearings
should also be changed, if worn out,
damaged or removed from armature shaft.
Ball bearings that have been pulled off of
shafts, pressed out of end heads, or side
loaded in such a way as to apply pressure
on the balls and races must be replaced.
Although the bearing may appear or feel
good, the bearing races have been brinelled
and will fail within a relatively short period of
service.
Armature
1. Check security of fan.
2. Check for loose commutator bars. Loose
commutator bars will usually be indicated by
excessive wear or burning on one bar. The
commutator can be checked for loose bars
by lightly tapping all of the bars with the
handle of a plastic or wooden handled
screwdriver. A contrasting dull thud or
vibration will indicate a loose bar in which
case, the armature must be replaced.
3. Check for grounded circuits using a test
light. Most commercial growlers incorporate
a test light as shown in illustration below.
coloring
16-03-6
Return
OCTOBER 1995
Testing
Frame and Field Assembly
After thorough inspection, the Frame and Field
Assembly should be checked for grounded, open or
shorted circuits. Grounded and open circuits can be
checked using a test light. Most commercial
growlers incorporate a test light as shown in
opposite illustration.
Grounded Circuit
Touch one test lead to a clean bare metal
spot on the frame and check all terminals
with the other lead. If a grounded condition
exists, the test light will light.
Open Circuit
Check between all connecting terminals with
test leads. If the bulb fails to light, an open
circuit is indicated.
Shorted Circuit
Shorted windings in series coils are very
difficult to detect. Generally, if the coil
insulation is sound and these are no signs of
overheating, the coil can be presumed good.
OCTOBER 1995
Return
Assembly
Field Coil Installation
Good solder connections are important due to the
vibration characteristics encountered by these
motors which can cause cold or poorly soldered
connections to break.
16-03-7
NOTE
We do not recommend using a
soldering gun or torch. Soldering
gun cannot provide the heat
concentration
required
and
soldering torches can damage the
insulation.
16-03-8
Return
OCTOBER 1995
OCTOBER 1995
Return
16-03-9
16-03-10
Return
OCTOBER 1995
Section 4.
Steer Pump Motor
Safety.................................................................................................. 2
General Information........................................................................... 3
Operating Conditions ........................................................................ 3
Steer Pump Motor (permanent Magnet Type .................................. 4
Troubleshooting Prior to Disassembly......................................... 4
Disassembly ................................................................................ 6
Component Inspection and Troubleshooting............................... 8
Assembly ..................................................................................... 9
36-Volt Drive Motor Specifications ................................................. 10
Motor Specifications ................................................................... 10
Brush Inspection Chart .................................................................... 11
OCTOBER 1995
Return
16-04-1
Safety
WARNING
Wear eye protection and protective
clothing when cleaning or drying with
compressed air. Reduce air pressure
to 30 psi (207 kPa). Debris removed
with air pressure can cause injury.
16-04-2
Return
OCTOBER 1995
General Information
Operating Conditions
OCTOBER 1995
Return
Extended operating
constant usage.
hours,
or
16-04-3
16-04-4
Return
OCTOBER 1995
OCTOBER 1995
Return
16-04-5
Disassembly
CAUTION
Do not place the stator ring (motor
housing) in any mechanical holding
device (e.g., vise) during the
disassembly
or
assembly
operation. Permanent distortion or
other damage will result. With the
motor disassembled, care must
also be taken not to drop the stator
ring assembly, since it can be
distorted. Motor may be held by
clamping on the mounting bracket.
IMPORTANT
Before disassembling motor, note
that there are match marks on the
stator assembly housing the
commutator cover. If marks are not
visible, use a scribe tool to make
match mars. These marks will be
used at assembly:
WARNING
Wear eye protection and protective
clothing when cleaning or drying
with compressed air. Reduce air
pressure to 30psi (207 kPA). Debris
removed with air pressure can
cause injury.
NOTE
Observe
how
brushes
are
assembled in brush holders. Note
position of the brush lead (pigtail).
16-04-6
Return
end
bearing
may
now
be
CAUTION
It is important that the pulling
motion on the armature be
continuous. Do not pull part way
out and release. If this is done, the
magnets will pull the armature back
into the stator and cause severe
damage.
To avoid damage to either the
armature
or
the
permanent
magnets, it is recommended that
the armature be removed only with
the motor housing and armature
shaft positioned vertically.
OCTOBER 1995
CAUTION
Do not drop, hit or clamp motor
OCTOBER 1995
Return
16-04-7
Bearings
1. Check bearings by turning them with your
fingers. Feel for binding or gritty effects and
excessive looseness or wobble. A good
bearing should also have a small amount of
drag or stiffness caused by the lubrication
but should turn smoothly. If the bearing turns
very freely, it should be replaced. Bearings
should also be changed, if worn out,
damaged or removed from armature shaft.
Ball bearings that have been pulled off of
shafts, pressed out of end heads, or side
loaded in such a way as to apply pressure
on the balls and races must be replaced.
Although the bearing may appear or feel
good, the bearing races have been brinelled
and will fail within a relatively short period of
service.
Armature
1. Check security of fan.
2. Check for loose commutator bars. Loose
commutator bars will usually be indicated by
excessive wear or burning on one bar. The
commutator can be checked for loose bars
by lightly tapping all of the bars with the
handle of a plastic or wooden handled
screwdriver. A contrasting dull thud or
vibration will indicate a loose bar in which
case, the armature must be replaced.
3. Check for grounded circuits using a test
light. Most commercial growlers incorporate
a test light as shown in illustration below.
coloring
16-04-8
Return
OCTOBER 1995
Assembly
Continue assembly in the reverse of disassembly,
paying particular attention to the following points.
Bearing Installation
1. Whenever ball bearings are pressed into an
end head or onto a shaft, always press
against the race that is absorbing the
pressure.
Press on the outer race when installing into
end head.
Press against the inner race when installing
onto a shaft.
2. End Heads having slip-fit bearings are
normally retained by a snap ring. Always
install new snap ring(s).
After Assembly
NOTE
If the armature has been turned and
undercut prior to testing, check for
and remove any copper buildup or
filings between commutator bars
and at the commutator riser. This
condition will cause an armature to
check shorted and usually results
from a dull undercutting tool.
Stator
1. Check magnets to be sure they are securely
mounted.
OCTOBER 1995
Return
16-04-9
Motor Specifications
Motor Coupling
Insulation
Brush Data
Brush Drop
0.5 Volt @ 29 Amps
16-04-10
Return
OCTOBER 1995
OCTOBER 1995
Return
16-04-11
Return
Group 17
ELECTRICAL SCHEMATICS
OCTOBER 1995
Return
17-00-1
17-00-2
Return
OCTOBER 1995
Section 1.
Wiring Schematics and Diagrams
IMPORTANT
Schematic and diagrams subject to change. Call your BT PrimeMover dealer to make sure you have latest schematic or diagrams.
OCTOBER 1995
Return
17-01-1
17-01-2
Return
OCTOBER 1995
OCTOBER 1995
Return
17-01-3
17-01-4
Return
OCTOBER 1995
OCTOBER 1995
Return
17-01-5
17-01-6
Return
OCTOBER 1995
OCTOBER 1995
Return
17-01-7
17-01-8
Return
OCTOBER 1995
OCTOBER 1995
Return
17-01-9
Return
Group 19
ELECTRICAL CONTROLS
OCTOBER 1995
Return
19-00-1
19-00-2
Return
OCTOBER 1995
Section 1.
Control Panel
OCTOBER 1995
Return
19-01-1
19-01-2
Return
OCTOBER 1995
OCTOBER 1995
Return
19-01-3
Control Features
Oscillator - The oscillator section of card has two
adjustable features and one fixed feature. With
accelerator output voltage at maximum volts, creep
speed can be adjusted by CREEP trimpot on card.
Top speed is fixed by card design and is obtained
with accelerator output voltage at minimum.
The % ON-TIME has a range of approximately 595%.
The center (or mid) operating condition of oscillator
is at 50% ON-TIME with a nominal 1.8 milliseconds
ON-TIME and 1.8 milliseconds OFF-TIME. This
corresponds to maximum operating frequency of
about 300 Hertz.
At
CREEP,
ON-TIME
will
decrease
to
approximately 0.8 milliseconds while OFF-TIME will
rise to about 20 milliseconds. At full SCR operation,
this condition will be reversed (short OFF-TIME and
long ON-TIME).
This variation of ON/OFF-TIME of oscillator
produces optimum frequencies through SCR range.
The frequency curve of oscillator is shown in
illustration on opposite page.
The rate at which oscillator may increase its percent
ON-TIME
is
limited
by
CONTROLLED
ACCELERATION. The minimum time required to
go from creep speed to 80-85% ON-TIME point may
be varied by trimpot (C/A) on card. This is
adjustable from approximately 0.5 seconds to 3.54.5 seconds.
19-01-4
Return
OCTOBER 1995
Normal Cleaning
IMPORTANT
OCTOBER 1995
Return
19-01-5
IMPORTANT
ALL TESTING SHOULD BE DONE
WITH DRIVE WHEELS RAISED OFF
THE FLOOR. (Do not plug the truck
when it is jacked up and drive
wheels are in a free-wheeling
position. The high motor speeds
can create excessive voltages that
can be harmful to the control.)
TroubleShooting Notes
Troubleshooting is based on using a digital
voltmeter to determine if correct voltages are
available to permit control to operate correctly.
The pulsing of main SCR is too fast for conventional
instruments to measure. When control is functioning
properly, a low hum can be heard.
Before proceeding with any testing, visually check
for loose wiring, signs of overheating of
components, condition of battery and battery
receptacle, etc. Refer to Group 19, Section 8 in this
manual.
Discharge capacitor by using an insulated
screwdriver or similar device that is insulated to
short across terminals of capacitor (1C).
19-01-6
Return
PMT trips.
Disconnect
the
battery
and
discharge the capacitor(s) before
handling the control panel.
BREAKING THIS RULE CAN CAUSE
SERIOUS INJURY.
OCTOBER 1995
OCTOBER 1995
Return
19-01-7
19-01-8
Return
OCTOBER 1995
CONTROL PANEL
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
OCTOBER 1995
Return
19-01-9
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
19-01-10
Return
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
Lockwasher
Washer
Heat sink, voltage sensor
Fastener, #4 REC heat sink
Lockwasher
Washer, #4 REC heat sink
Insulator
Heat sink, #4 REC
Insulator
#5 REC, SCR panel
Conductor, #5 rectifier
Conductor, SCR control panel
Lockwasher
Fastener, SCR panel REC
#2 REC, SCR panel
Conductor
Transformer
Washer, transformer
Lockwasher
Fastener, SCR transformer
OCTOBER 1995
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
OCTOBER 1995
Return
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
Washer
Bracket
Capacitor
Base
Harness, wiring
Fastener
Lockwasher
Control unit
Insulator
#1 REC
Block, terminal
Washer
Lockwasher
Filter, pump SCR panel #2 REC
Filter, SCR panel #4 REC
19-01-11
Contactor Inspection
Before attempting to disassemble a contactor to
install a new contact tip set, carefully observe
location and orientation of each part.
19-01-12
Return
OCTOBER 1995
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Base, magnet
Coil, field
Frame, magnet
Spring
Armature
Base, buss
Tip, contact
Bushing
Carrier
Tip, movable
Cap
Spring
Washer, flat
Nut, lock
Clamp
Lockwasher
Screw, machine
Suppression, pump contactor
Seat
OCTOBER 1995
Return
19-01-13
1
2
3
4
5
6
7
8
9
10
11
12
13
19-01-14
Return
OCTOBER 1995
IMPORTANT
OCTOBER 1995
Return
wiring
from
contactor
coil
(reverse)
Replace
19-01-15
19-01-16
Return
OCTOBER 1995
IMPORTANT
OCTOBER 1995
Return
IMPORTANT
movable
contact
IMPORTANT
19-01-17
19-01-18
Return
OCTOBER 1995
Oscillator Card
IMPORTANT
When removing connectors: To
prevent damage to the oscillator
card, always remove the connector
by pressing down on center tab
of connector with a wide blade
screwdriver,
then
rotate
screwdriver 90 (while continuing to
press down) to pry the connector
out of its socket.
When installing connectors: Be
sure the connectors are pressed
fully into socket and the locking tab
is fully engaged.
Removal
1. Remove two six-conductor plug connectors
from left hand side of card marked (A & B).
2. Remove two fourteen-conductor plug
connectors from right hand side of card
marked (Y & Z) in a similar manner
described above.
3. Remove control wires from six screw
terminals on top surface of card.
4. Remove two card retainer screws and
remove card.
Installation
1. Install card on SCR panel base plate and
tighten retainer screws.
2. Install control wires to terminals top surface
of card.
OCTOBER 1995
Return
19-01-19
Control and
Contactor Panel Installation
1. Before attempting to install control in truck,
make sure truck is correctly blocked and
battery is disconnected.
2. Clean area where control panel is to be
mounted. Make sure surface is free from
dirt, dust, rust, etc., which would not permit
panel base to make good contact with
mounting surface.
3. Apply an even, thin film (0.20 (5mm) max.)
of Thermal Joint Compound milled portion of
control base plate.
4. Install control panel on mounting plate and
tighten fasteners to specifications specified
in opposite illustration.
5. Connect wiring harness sections by joining
wiring couplers.
6. Connect power cables to correct terminals
on control panel. Make sure all connections
are tightened firmly.
7. Install top compartment covers.
8. Remove blocks from drive wheels.
9. Connect battery and test control panel
operation.
19-01-20
Return
OCTOBER 1995
OCTOBER 1995
Return
19-01-21
19-01-22
Return
OCTOBER 1995
CAUTION
Make connections as shown
here or you may experience
electrical
shorts
and
component damage.
OCTOBER 1995
Return
19-01-23
Return
Section 2.
EV-100MK Troubleshooting
NOTE
Refer to Supplements in Group 14,15, and 16 for additional information.
OCTOBER 1995
Return
19-02-1
Set meter to R X 10,000 and calibrate. Connect positive meter lead to anode of SCR. Connect
negative meter lead to cathode of SCR. Results should be above 100,000 ohms.
STEP 2:
With meter set as in Step 1, connect the meter positive to the cathode of SCR. Connect the
meter negative to the anode of the SCR. Again, the results should be above 100,000 ohms.
STEP 3:
Set the meter to R X 1 and calibrate. Connect positive meter lead to the gate terminal. Connect
the negative meter lead to the cathode. Results should be from 10 to 200 ohms.
STEP 4:
With the meter set as in Step 3, connect the meter positive to the cathode of the SCR. Connect
the negative lead to the gate terminal. Results should be from 5 ohms to infinity.
IMPORTANT
ON EV-100 PANELS, THE #2 AND #5 RECTIFIERS
(PRESS PACK DESIGN) USE A PACKAGING
ENCLOSURE THAT HAS THE POLARITY SYMBOLS
MIS-MARKED. ON THE SIDE OF THE PACKAGE, YOU
WILL SEE THE SCHEMATIC SYMBOL. USE THE
SCHEMATIC SYMBOL AND NOT THE POLARITY
SYMBOLS TO DETERMINE POLARITY!
19-02-2
Return
OCTOBER 1995
OCTOBER 1995
Return
19-02-3
19-02-4
Return
OCTOBER 1995
OCTOBER 1995
Return
19-02-5
19-02-6
Return
OCTOBER 1995
OCTOBER 1995
Return
19-02-7
19-02-8
Return
OCTOBER 1995
OCTOBER 1995
Return
19-02-9
19-02-10
Return
OCTOBER 1995
OCTOBER 1995
Return
19-02-11
Disconnect battery and discharge capacitor. Remove wires and buss bars
from connection points. Be sure to mark leads for proper reinstallation.
NOTE:
STEP 1:
STEP 2:
19-02-12
Return
OCTOBER 1995
Factory
Setting
Actual
Value
F1
-----------
-----------
F2
018-022
5.5-5.7%
F2
145-155
9.35-9.5%
F3
004-006
0.4-0.6 Sec.
F3
013-015
1.3-1.4 Sec.
F4
Current Limit
250-255
Max. Current
F5
148-152*
665-677 A
F6
1A Drop Out
250-255
Function Disabled
F6
106-110
793-807A
F7
001-003
Function Activated
F8
Not Applicable
NA
NA
F9
Not Applicable
NA
NA
F10
Not Applicable
NA
NA
F11
Speed Limit 1
052-055
F12
Speed Limit 2
000-001
Function Disabled
F13
Speed Limit 3
000-001
Function Disabled
F14
014
F15
Battery Volts
032-044
36 Volts
F16
038-042
222-234A
F17
000-004
Standard C/L
F18
175-177
23.5-24.5 Sec.
Function No.
*NOTE
This factory setting will provide
approximately 22 ft. (6.7 m) of
plugging distance.
OCTOBER 1995
Return
19-02-13
Condition
Voltage Reading
TB1
TB2
TB3
TB4
TB5
TB6
B+=Battery Voltage
19-02-14
Return
OCTOBER 1995
OCTOBER 1995
Return
19-02-15
Condition
Voltage Reading
TB1
TB2
TB3
TB4
TB5
TB6
TB7
TB8
TB9
Not Applicable
TB10
TB11
TB12
TB13
TB14
TB15
B+=Battery Voltage
19-02-16
Return
OCTOBER 1995
OCTOBER 1995
Return
19-02-17
19-02-18
Return
OCTOBER 1995
Section 3.
Recommended Tests, Equipment, and Procedures
Recommended Tests......................................................................... 2
Test Equipment ........................................................................... 2
Test Procedures .......................................................................... 2
Test Procedures................................................................................. 2
Ground Fault Condition ............................................................... 2
Power Steer Idle Current ............................................................. 3
SCR Current Limit ....................................................................... 3
1A Free-Wheeling Current........................................................... 3
1A Time Delay ............................................................................. 4
Creep Speed Motor Volts ............................................................ 4
Pugging ....................................................................................... 5
OCTOBER 1995
Return
19-03-1
Recommended Tests
1. Ground Fault Condition
2. Power Steer Idle Current
3. SCR Current Limit
STEP #3:
Read and record voltage reading displayed.
This is OPEN CIRCUIT BATTERY
VOLTAGE.
6. Always have key switch turned OFF and
parking brake SET before connecting
battery to truck.
4. 1A Free-Wheeling Current
5. 1A Time Delay
6. Creep Speed Motor Volts
7. Plugging Function
Test Equipment
1. Current Monitoring Shunt, 500 Amps, 50mV.
2. Digital Multi-Meter - Recommend "Simpson
D.M.M. Model #461" or equivalent.
3. Digital stop watch.
Test Procedures
PRELIMINARY PRECAUTIONS: The following
precautions must be adhered to while preparing for
and/or conducting above tests:
1. Tests #1 through #6 require drive wheels be
raised off floor.
2. Always inspect condition of battery cables
and connector of battery being used for test.
If battery cables are worn out, cable ends at
terminations cracked, or cable insulation
broken/cracked, battery should not be used
for test but should be sent for repair or
maintenance.
3. No extension cables should be used to
connect battery to truck for test. It is
recommended to install battery in truck for
test whenever possible. When such
installation is not practical, battery should be
set on floor close to truck battery receptacle,
to eliminate need for extension cable.
4. Always inspect condition of battery cells for
proper water level.
5. Before conducting any test, measure open
circuit voltage of battery. Record measured
value, nominal rating of battery volts, and
battery type number on test sheet. Open
circuit battery voltage is measured as
follows:
STEP #1:
Turn Digital Multi-meter ON Select 200 volts,
DC scale.
STEP #2:
Connect red lead to POSITIVE (+) terminal
on battery. Connect black lead to
NEGATIVE (-) terminal on battery.
19-03-2
Return
Test Procedures
Ground Fault Condition
NOTE
It is recommended that if ground
fault is detected on truck, tests for
other
parameters
should
be
conducted
ONLY
AFTER
ELIMINATING CAUSE OF AND
THEREBY GROUND FAULT.
STEP #1:
Disconnect battery from truck receptacle
and turn key switch OFF.
STEP #2:
Turn ON Digital Multi-meter; select
resistance measurement function, 20,000
Ohm scale.
STEP #3:
Connect Red lead of Multi-meter to
POSITIVE (+) terminal of truck receptacle
and connect BLACK lead of Multi-meter to
an unpainted surface (e.g., bolt, etc.) of truck
frame. Record resistance.
OCTOBER 1995
STEP #4:
Connect red lead of Multi-meter to
NEGATIVE (-) lead of truck receptacle and
leave BLACK lead of Multi-meter connected
as in Step #3. Record resistance.
STEP #5:
Compare values obtained in Steps #3 and
#4 against specification to determine
PRESENCE/ABSENCE
of
GROUND
FAULT. Refer to Group 40, Section 1, for
specification.
STEP #4:
Measure and record voltage across shunt
sensor wires (or terminals).
STEP #5:
The voltage reading obtained in Step #4 is a
direct reading of POWER STEER IDLE
CURRENT using conversion of 1mV equal
10 Amps. Refer to Group 40, Section 1, for
acceptable current range.
OCTOBER 1995
Return
STEP #3:
Install jumper wire on foot brake switch to
defeat its operation.
STEP #4:
Disconnect control wire #34 from 1A
contactor coil negative terminal and tape up.
STEP #5:
Connect battery to truck receptacle, turn key
switch ON.
IMPORTANT
Precautions should be taken not to
stall traction motors more than 20
seconds during Step #6.
STEP #6:
To obtain a HARD STALL condition of the
motor, do not depress foot brake pedal,
gradually rotate the multi-function control
handle to the FULLY FORWARD position.
Measure and record highest current reading
(voltage across shunt) obtained.
STEP #7:
Subtract power steer idle current from
reading obtained in Step #6 to obtain SCR
CURRENT LIMIT FOR DRIVE SYSTEM.
NOTE
There should be wait (idle) period
minimum
of
two(2)
minutes
between Steps #6 and #8.
Drive wheels should be allowed to
turn between Step #6 and #8.
STEP #8:
Repeat Steps #6 and #7. Take average of
two (2) readings and compare average
value to specifications. Refer to Group 40,
Section 1 for acceptable current range.
1A Free-Wheeling Current
STEP #1:
Raise drive wheels off floor. Turn key switch
to OFF and disconnect battery cables.
STEP #2:
Install jumper wire on foot brake switch to
defeat its operation.
STEP #3:
Connect control wire #34 to 1A contactor coil
negative terminal.
19-03-3
STEP #4:
Connect shunt to measure battery current.
STEP #5:
Connect battery to truck receptacle. Turn
key switch ON.
STEP #6:
Depress the foot brake pedal, rotate the
multi-function control handle to the FULLY
FORWARD position.
STEP #7:
Gradually release the brake pedal until the
battery current reading is between 100-200
Amps. Hold brake and control handle in
these positions for a minimum of ten (10)
minutes.
STEP #8:
After ten (10) minutes, depress the brake
pedal completely while still holding the
control handle fully rotated. After current
reading has stabilized, measure and record
it.
STEP #9:
Release the control handle completely. After
current reading has stabilized, measure and
record it as POWER STEER IDLE
CURRENT.
STEP #10:
The difference of current readings obtained
in Steps #8 and #9 is 1A FREE-WHEELING
CURRENT and must be used to compare
against specifications. Refer to Group 40,
Section 1, for free-wheeling current
specification.
1A Time Delay
STEP #1:
Raise drive wheels off floor. Turn key switch
to OFF and disconnect battery cables.
STEP #2:
Install jumper wire on foot brake switch to
defeat its operation.
STEP #3:
Connect battery to truck receptacle, turn key
switch ON.
STEP #4:
To obtain a HARD STALL condition of the
motor, do not depress foot brake pedal.
19-03-4
Return
STEP #5:
Rotate the multi-function control handle to
the FULLY FORWARD position as fast as
possible and start Digital Stop Watch the
moment control handle stops.
STEP #6:
Stop the stop watch the moment any motion
or movement of 1A (bypass) contactor tip is
detected.
STEP #7:
Stop Watch reading is 1A TIME DELAY.
Repeat Steps #5 and #7 at least four (4)
times. Take average of all readings as 1A
TIME
DELAY
to
compare
against
specifications.Refer to Group 40, Section 1,
for time specification.
OCTOBER 1995
Plugging
STEP #1:
Lower drive wheels to floor, remove jumper
wire from foot brake switch. Turn key switch
to OFF and disconnect battery cables.
STEP #2:
Connect battery to truck receptacle, turn key
switch ON, drive truck to open space or aisle
where at least 250 feet (76 m) of running
space is available.
STEP #3:
Drive in the FORWARD direction at top
speed. After the 1A contactor has picked up
(closed) and truck has traveled in top speed
mode at least 75 feet (23 m), change
direction of travel to FULL REVERSE.
STEP #4:
If truck continues to travel forward with
continuously decreasing speed until truck
stops and smoothly accelerates in reverse
direction, PLUGGING function is correct.
OCTOBER 1995
Return
STEP #5:
Repeat Steps #3 and #4 starting out with
reverse travel, then changing to forward
travel. The PLUGGING function should
operate same way.
NOTE:
Measurements made in step #6
should only be compared to
specifications,
if
test
was
conducted after truck was operated
for a minimum of 50 hours.
STEP #6:
Measure distance from point on travel path
where direction change was initiated to point
where truck actually started moving in
reverse direction. This measurement is
PLUGGING DISTANCE. Factory set
plugging distance is approximately 22 ft. (6.7
m).
The plugging distance is adjustable by
means of a trim pot on the oscillator card
and may be adjusted to suit the customer's
needs. Refer to Section 14 in this group for
procedures on adjusting plugging distance.
19-03-5
Return
Section 4.
Drive Motor Cut-Out Switch Check and Adjustment
OCTOBER 1995
Return
19-04-1
on
solid,
level
19-04-2
Return
OCTOBER 1995
OCTOBER 1995
Return
19-04-3
Return
Section 5.
Forward and Reverse Switches, Up and Down
Switches, and Transducer Adjustments
OCTOBER 1995
Return
19-05-1
19-05-2
Return
OCTOBER 1995
OCTOBER 1995
Return
19-05-3
Step 1
19-05-4
Return
OCTOBER 1995
Step 2
Forward, Reverse, Up & Down Switch Adjustment
Each switch must be adjusted so the switch arm just
touches the switch plunger with the arm roller in
contact with the cam surface, refer to example.
The adjustment is made with the adjusting screw of
each Do not over adjust. Slowly rotate adjusting
screw until the above conditions are met.
OCTOBER 1995
Return
19-05-5
Step 3
Step 4
IMPORTANT
To prevent damage to wiring: Loosen wires #29 & #13 by pulling them part way throw cam "slot".
Holding the body of the transducer, slowly rotate body clockwise and then counterclockwise by hand
(Voltage will increase and decrease as the body is rotated). Do not rotate the body to the extent that
wires are pulled out (or damaged).
Stop rotation when voltage registers between 3.50 and 3.75 volts. This is know as the "neutral point" or
maximum accelerator voltage position. Note when in this position the wire harness will be on the body
as shown here.
19-05-6
Return
OCTOBER 1995
Step 5
With transducer at the "neutral point", tighten Lock Nut securing transducer in position.
Verify accelerator voltage is between 3.50 and 3.75 volts and, any handle movement (in either
direction) results in reducing accelerator volts.
Step 6
Move handle to maximum forward and maximum reverse direction positions. Verify
accelerator volts are less then 0.20 volts.
OCTOBER 1995
Return
19-05-7
Step 7
19-05-8
Return
OCTOBER 1995
Step 8
Step on brake pedal. Measure directional switches and accelerator voltages at wire #6, wire #8
and wire #29 with respect to battery negative (wire #13).
Step 9
NOTE
Adjusting
the
screw
counterclockwise will operate the
switch closer to neutral position
of the control handle.
OCTOBER 1995
Return
19-05-9
Step 10
Step 11
19-05-10
Return
OCTOBER 1995
Step 12
To adjust actuation (operating) positions of Forward and /or Reverse Switches:
Rotate the adjustment screw(s), as required to obtain "specific accelerator voltage" of 3.40 to 3.60
volts corresponding to the actuation positions of both switches.
The voltage measure at the "actuation moment" of each switch must be 3.40 - 3.60 volts
(+0.05 volts apart maximum).
OCTOBER 1995
Return
19-05-11
Return
Section 6.
Periodic Electrical Checks
OCTOBER 1995
Return
19-06-1
Truck Preparation
WARNING
Always wear safety glasses.
Remover covers.
Remove key.
Discharge capacitor.
3.Remove cover(s).
19-06-2
Return
OCTOBER 1995
Electrical Connectors
Connector
plugs
and
receptacles
are
permanently labeled with the proper PL (Plug) and
SO (Socket/Receptacle) number for easy
identification.
IMPORTANT
Match the plug number with the
appropriate
receptacle
number
before making a connection. If you
do not, electrical shorts and
possible damage to the equipment
may result, i.e., plug #PL-10 plugs
into pin socket #SO-10, etc.
IMPORTANT
Be sure to follow the instructions,
where noted in this manual, when
installing a wire harness or
electrical cables. If you do not,
possible shorts and equipment
OCTOBER 1995
Return
19-06-3
19-06-4
Return
OCTOBER 1995
Electrical Tape
POWER CABLES
IMPORTANT
Every cable and wiring harness on
this truck is manufactured to an
exact specification. A shorter cable
or harness will not fit. If either a
harness or cable is routed
improperly
it
will
not
fit.
Subsequently, electrical shorts and
damaged components may result if
the replacement part is the wrong
one, or if it is routed incorrectly.
OCTOBER 1995
Return
19-06-5
Fasteners
IMPORTANT
Improperly Torqued Fasteners Can
Cause Damage!
Use an appropriate wrench and
tighten all fasteners to the torque
specified
in
the
following
inspection procedures.
19-06-6
Return
OCTOBER 1995
OCTOBER 1995
Return
19-06-7
NOTE
1.Inner nut must be supported during
torque operation.
2.Torque outer jam nut of terminal to
135-165 lbs./in. (15-19 Nm.
3.Torque outer jam nut of terminal to
90-110 lbs./in.(10.0-12.5 N m).
4.Torque outer jam nut of terminal to
68-83 lbs./in. (7.5-9.5 Nm).
19-06-8
Return
OCTOBER 1995
OCTOBER 1995
Return
19-06-9
19-06-10
Return
OCTOBER 1995
NOTE
1.Inner nut must be supported during
torque operation.
2.Torque outer jam nut of terminal to
135-165 lbs./in. (15-19 Nm.
3.Torque outer jam nut of terminal to
90-110 lbs./in.(10.0-12.5 N m).
4.Torque outer jam nut of terminal to
68-83 lbs./in. (7.5-9.5 Nm).
OCTOBER 1995
Return
19-06-11
NOTE
1.Inner nut must be supported during
torque operation.
2.Torque outer jam nut of terminal to
135-165 lbs./in. (15-19 Nm.
19-06-12
Return
OCTOBER 1995
OCTOBER 1995
Return
19-06-13
19-06-14
Return
OCTOBER 1995
Section 7.
Battery Tests
OCTOBER 1995
Return
19-07-1
Battery Tests
NOTE
Use both tests described here.
STATE OF CHANGE
100% CHANGE
75% CHANGE
50% CHANGE
25% CHANGE
VERY WEAK
DISCHARGED
Load Test
Put the main hydraulic system into by-pass while
reading battery volts with a voltmeter.
Minimum acceptable voltage
drop for 36 volt battery............................. 28.8 volts
Battery needs rechange or repair if voltage drops below
80% of the rated voltage of the battery.
19-07-2
Return
OCTOBER 1995
Section 8.
Solenoid Control Card Troubleshooting
Indicator Lights.................................................................................. 2
Troubleshooting Solenoid Control Card ......................................... 3
Lift Function ONLY Disabled ............................................................ 5
Install New Solenoid Control Card................................................... 7
OCTOBER 1995
Return
19-08-1
Indicator Lights
19-08-2
Return
OCTOBER 1995
Troubleshooting Solenoid
Control Card
IMPORTANT
It is normal for the Indicator Lights (LEDs) to "flicker" when any
part of the hydraulic system is put into use. This does not indicate a
problem. There is a problem, however, when one or both lights
illuminate with "no flicker".
Both Lights ON (RH4 & RH5) (key switch ON and all hydraulic switches open.)
If both lights are illuminated, the Solenoid Card is defective and should be replaced with a new one.
RH4 Light ON (Key Switch "ON" and all hydraulic switches Open.)
Check for shorted switch or wire to corresponding terminal with a volt-ohm meter, see opposite
illustration. Connect black (-) lead to ground and check each one of the following using red (+) meter
lead [Meter should be set on the 50V + DC Scale):
0V
0V
0V
0V
TB14 - Wire #5
0V
RH5 Light ON (Key Switch "ON" and all hydraulic switches Open.)
*only when truck is equipped with second auxiliary function, otherwise meter should register: - 0 volts
OCTOBER 1995
Return
19-08-3
19-08-4
Return
OCTOBER 1995
Battery Charged
RH5 Lights ON (Key Switch "ON" and all hydraulic switches Open.)
OCTOBER 1995
Return
19-08-5
19-08-6
Return
OCTOBER 1995
IMPORTANT
OCTOBER 1995
Return
19-08-7
Return
Section 14.
EV100LXT Control Panel
General ............................................................................................... 2
Operation............................................................................................ 2
Function Set-up Procedures............................................................. 3
Description of Function Numbers for:
IC3645EVLXCDI1TT................................................................. 4
IC3645EVLXCDI1TX ................................................................ 4
IC3645EVLXCDI1TK ................................................................ 4
IC3645EVLXCDI1MT................................................................ 7
IC3645EVLXCDI1MX................................................................ 7
IC3645EVLXCDI1MK................................................................ 7
IC3645EVLXCDI1PX ............................................................... 10
OCTOBER 1995
Return
19-14-1
General
The Handset is a multi-functional tool to be used
with the EV100/200 LX and LXT SCR controls. The
Handset consist of a Light Emitting Diode (LED)
display and a keyboard for data entry.
Purpose
The purpose of the Handset is to allow authorized
personal to perform the following functions:
Key Switch
Verify Display Segments
for
one second
BDI Display
or
Blank Display
Diagnostics
override
with fault
Run Mode
Diagnostics
override
with fault
BDI Display
or
Blank Display
Key Switch OFF
Display traction
hourmeter for
four seconds
Display pump
hourmeter for
four seconds
or
Blank
NOTE
Operation
WARNING
Before connecting or disconnecting
the handset tool, jack up the drive
wheels of the truck, turn off the key
switch, unplug the battery and
discharge the capacitors.
19-14-2
Return
OCTOBER 1995
WARNING
Before making any adjustments to
the control you must consult the
operating
and
maintenance
instructions supplied by the vehicle
manufacturer. Failure to follow
proper set up instructions could
result in misoperation or damage to
the control system.
NOTE
The term push, means to depress
key for approximately one second.
SET UP MODE
Action
Display shows
Remarks
turn on key
8888
Segment check
displayed
Push function
number
U888
Selected
function number
is displayed
_085
_088
Displayed valve
will blink
_125
Value changes
while blinking
Push CONT.
Charge value with
adjustment knob
Push STORE
Push ESC
_125
New valve
stored and
blinking stops
8888
Segment check
displayed
OCTOBER 1995
Return
19-14-3
Set
Control Cards
Example:
Function 1
IC3645EVLXCD1TT
IC3645EVLXCD1TX
IC3645EVLXCD1TK
Creep Speed
(Push2)
Function 5
5% to 15% on time
0 to 255
.03% per set unit
Example:
Function 3
Controlled Acceleration
and 1A Time
(Push 3)
.1 to 22.0 seconds
0 to 255
.084 seconds per set unit
Example:
Function 4
Current Limit
(Push 4)
19-14-4
Return
WARNING
0 to 255
Plug
settings
must
be
in
accordance with control operating
instructions. An excessively high
setting could cause damage to
control system or drive motor.
Function 6
OCTOBER 1995
Function 8
Example:
Function 9
75 to 630 amps
0 to 255
2.2 amps per set unit
Example:
Function 10
Regen Start
(Push 10)
0 to 95% on time
0 to 255
.37% per set unit
Example:
Function 11
OCTOBER 1995
Return
Function 12
Internal Resistance
Compensation
(Push 14)
EV100
VD
11.44
07.60
05.72
04.57
03.81
03.27
02.86
02.54
02.28
02.08
01.90
01.76
01.63
01.52
01.43
EV200
EV100
VD
Setting
VD
07.63
17
01.34
05.07
18
01.27
03.81
19
01.20
03.05
20
01.14
02.54
21
01.09
02.18
22
01.04
01.91
23
00.99
01.69
24
00.95
01.52
25
00.91
01.39
26
00.88
01.27
27
00.85
01.17
28
00.82
01.08
29
00.79
01.01
30
00.76
00.95
31
00.74
EV200
VD
00.80
00.85
00.80
00.78
00.73
00.69
00.66
00.63
0061
00.59
0057
00.55
00.53
00.51
00.49
19-14-5
Function 15
Battery Volts
(Push 15)
Set units
24 volts
36 volts
48 volts
72 volts
84 volts
36/48 volts
No BDI
Between 0 and 31
Between 32 and 44
Between 45 and 69
Between 70 and 80
Between 81 and 183
Between 184 and 250
Between 251 and 255
19-14-6
Return
EV100
Function
Standard
with FW
Speed
Limit
Regen/FW
STD C/L
High C/L
STD C/L
(Auto plug)
High C/L
(Auto plug)
0 to 4
5 to 9
20 to 24
25 to 29
40 to 44
45 to 49
10 to 14
30 to 34
50 to 54
15 to 19
35 to 39
55 to 59
EV200
Function
Standard
with FW
Speed
Limit
Regen/FW
STD C/L
STD C/L
(Auto plug)
64 to 68
84 to 88
104 to 108
74 to 78
94 to 98
114 to 118
WARNING
These settings must be changed by
authorized
personnel
only,
following instructions supplied by
the
manufacturer.
Card
type
selection must be made within the
capabilities of the SCR control
panel used and the supporting
electro-mechanical devices. Failure
to comply with proper application
standards
could
result
in
misoperation or damage to the
control and/or motors.
Function 18
1.5 to 65 seconds
Between 0 and 128
.5 seconds per set unit
Example:
.5 to 63 seconds
129 to 255
.5 seconds per set unit
Setting of 149 = 10.5 seconds
OCTOBER 1995
Set
Control Cards
Example:
Function 1
IC3645EVLXCD1MT
IC3645EVLXCD1MX
IC3645EVLXCD1MK
Creep Speed
(Push2)
0 to 255
Function 5
5% to 15% on time
0 to 255
.03% per set unit
Example:
Function 3
Controlled Acceleration
and 1A Time
(Push 3)
WARNING
Plug
settings
must
be
in
accordance with control operating
instructions. An excessively high
setting could cause damage to
control system or drive motor.
Function 6
Set
Resolution
Range
Set
Resolution
.1 to 22.0 seconds
0 to 255
.084 seconds per set unit
Function 7
Example:
Function 4
Current Limit
(Push 4)
OCTOBER 1995
Return
19-14-7
Function 11
Speed Limit 3
(Push 13)
Internal Resistance
Compensation
(Push 14)
Setting
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
EV100
VD
11.44
07.60
05.72
04.57
03.81
03.27
02.86
02.54
02.28
02.08
01.90
01.76
01.63
01.52
01.43
Function 15
EV200
VD
00.80
00.85
00.80
00.78
00.73
00.69
00.66
00.63
0061
00.59
0057
00.55
00.53
00.51
00.49
Battery Volts
(Push 15)
Set units
24 volts
36 volts
48 volts
72 volts
84 volts
36/48 volts
No BDI
Between 0 and 31
Between 32 and 44
Between 45 and 69
Between 70 and 80
Between 81 and 183
Between 184 and 250
Between 251 and 255
Range
Set
Resolution
Example
19-14-8
Return
EV200
EV100
VD
Setting
VD
07.63
17
01.34
05.07
18
01.27
03.81
19
01.20
03.05
20
01.14
02.54
21
01.09
02.18
22
01.04
01.91
23
00.99
01.69
24
00.95
01.52
25
00.91
01.39
26
00.88
01.27
27
00.85
01.17
28
00.82
01.08
29
00.79
01.01
30
00.76
00.95
31
00.74
OCTOBER 1995
Standard
with FW
STD C/L
High C/L
STD C/L
(Auto plug)
High C/L
(Auto plug)
0 to 4
5 to 9
1.5 to 65 seconds
Between 0 and 128
.5 seconds per set unit
Example:
.5 to 63 seconds
129 to 255
.5 seconds per set unit
Setting of 149 = 10.5 seconds
10 to 14
15 to 19
EV200
Function
Standard
with FW
STD C/L
STD C/L
(Auto plug)
64 to 68
74 to 78
WARNING
These settings must be changed by
authorized
personnel
only,
following instructions supplied by
the
manufacturer.
Card
type
selection must be made within the
capabilities of the SCR control
panel used and the supporting
electro-mechanical devices. Failure
to comply with proper application
standards
could
result
in
misoperation or damage to the
control and/or motors.
Function 18
OCTOBER 1995
Return
19-14-9
Function 1
IC3645EVLXCD1PX
Internal Resistance
Compensation State
(Push2)
0 to 1325 amps
52 to 255
6.5 amps per set unit
Example:
Function 3
Controlled Acceleration
and 1A Time
(Push 3)
(Push 11)
This function allows for the adjustment of the speed
limit (maximum battery volts to motor) when the SL1
limit switch is normally closed switch connected to
battery negative, the switch opening enables speed
limit.
Range
Set
Resolution
Example:
Function 12
Range
Set
Resolution
.1 to 5.5 seconds
0 to 255
.021 seconds per set unit
Function 16
Example:
Function 4
Current Limit
(Push 4)
Example:
0 = min. current, 255 = max. current
Function 11
Speed Limit 1 (SL1)
19-14-10
Return
Internal Resistance
Compensation
(Push CONT and 1)
Voltage Drop
11.44
07.60
05.72
04.57
03.81
03.27
02.86
Setting
17
18
19
20
21
22
23
Voltage Drop
01.34
01.27
01.20
01.14
01.09
01.04
00.99
OCTOBER 1995
Setting
9
10
11
12
13
14
15
16
Voltage Drop
02.54
02.28
02.08
01.90
01.76
01.63
01.52
01.43
Function 17
Setting
24
25
26
27
28
29
30
31
Voltage Drop
00.95
00.91
00.88
00.85
00.82
00.79
00.76
00.74
Function
STD C/L
High C/L
STD C/L
BDI (Lockout)
High C/L
BDI (Lockout)
with Pump
Ctr/PMT
Without Pump
Ctr/PMT
0 to 8
9 to 17
36 to 44
45 to 53
18 to 26
54 to 62
27 to 35
63 to 71
WARNING
These settings must be changed by
authorized
personnel
only,
following instructions supplied by
the
manufacturer.
Card
type
selection must be made within the
capabilities of the SCR control
panel used and the supporting
electro-mechanical devices. Failure
to comply with proper application
standards
could
result
in
misoperation or damage to the
control and/or motors.
OCTOBER 1995
Return
19-14-11
Return
Section 15.
EV100LXT Control Panel Status Codes
OCTOBER 1995
Return
19-15-1
19-15-2
Return
OCTOBER 1995
OCTOBER 1995
Return
19-15-3
19-15-4
Return
OCTOBER 1995
OCTOBER 1995
Return
19-15-5
19-15-6
Return
OCTOBER 1995
OCTOBER 1995
Return
19-15-7
19-15-8
Return
OCTOBER 1995
OCTOBER 1995
Return
19-15-9
19-15-10
Return
OCTOBER 1995
OCTOBER 1995
Return
19-15-11
19-15-12
Return
OCTOBER 1995
OCTOBER 1995
Return
19-15-13
19-15-14
Return
OCTOBER 1995
OCTOBER 1995
Return
19-15-15
19-15-16
Return
OCTOBER 1995
OCTOBER 1995
Return
19-15-17
19-15-18
Return
OCTOBER 1995
OCTOBER 1995
Return
19-15-19
19-15-20
Return
OCTOBER 1995
OCTOBER 1995
Return
19-15-21
19-15-22
Return
OCTOBER 1995
OCTOBER 1995
Return
19-15-23
19-15-24
Return
OCTOBER 1995
OCTOBER 1995
Return
19-15-25
19-15-26
Return
OCTOBER 1995
OCTOBER 1995
Return
19-15-27
19-15-28
Return
OCTOBER 1995
OCTOBER 1995
Return
19-15-29
19-15-30
Return
OCTOBER 1995
OCTOBER 1995
Return
19-15-31
19-15-32
Return
OCTOBER 1995
OCTOBER 1995
Return
19-15-33
Return
Section 16.
Checking Components
OCTOBER 1995
Return
19-16-1
screw
NOTE
Do not attempt to remove circuit
broad from card box.
19-16-2
Return
OCTOBER 1995
Capacitor 1C
Contactors F,R,1A,SP,FW,D,REGEN
and P
150 ampere contactors instruction sheets.
300 ampere contactors instruction sheets.
NOTE
Control is arranged so that the F
and R contactors do not break
current. Check to see that the 1A
contactor drops before the F and R
contactor.
Most contactor coils are polarity
sensitive. The left-hand terminal
must be connected to positive.
Potentiometer in Accelerator
To check operation of potentiometer, disconnect the
battery and disconnect the wire at control card TB1.
Connect a VOM to the wire that was removed from
TB1 and to negative. Place the VOM on the R x 100
scale. With the accelerator in the creep speed
position, the ohms reading should be 4800 to 6000
ohms. With the accelerator in the top speed
position, the ohm reading should be 50 ohms or
less. With the wire disconnected as above, check
for resistance of 1 megohm or higher from pot wire
to the truck frame.
OCTOBER 1995
Return
NOTE
If you
check
above,
shorts
VOM.
19-16-3
19-16-4
Return
OCTOBER 1995
IMPORTANT
The use of heat-transfer grease
(such as GE Versilube G-350-M or
equivalent) is recommended.
Capacitor
Remove all
required)
module
connections.
(As
NOTE
When replacing these devices, use
the original hardware in the same
holes, as the insert are used for
electrical connections.
NOTE
Insulator not required for 2REC and
5REC.
OCTOBER 1995
Return
19-16-5
Return
Group 20
DRIVE AXLE
OCTOBER 1995
Return
20-00-1
20-00-2
Return
OCTOBER 1995
Section 1.
Drive Axle
General Description........................................................................... 2
Service Notes ..................................................................................... 2
Drive Axle Maintenance .................................................................... 2
Fluid Level Checks ...................................................................... 2
Fluid Change Procedure.............................................................. 2
Drive Axle Removal ........................................................................... 3
Drive Axle Special Tools ................................................................... 4
Drive Axle Disassembly .................................................................... 8
Drive Axle Assembly ........................................................................ 11
Assembly Notes.......................................................................... 11
Assembly .................................................................................... 11
Drive Axle Installation ...................................................................... 14
OCTOBER 1995
Return
20-01-1
General Description
The drive axle consists of right hand and left hand
axle end assemblies. The two axle ends are
fastened together to form the drive axle assembly.
Each axle end half contains a ring gear and pinion
and final drive gearing. The drive motors are
mounted directly to the axle ends.
Refer to Group
recommended
specification.
40 Specifications, for
transmission
fluid
Service Notes
The drive axle contains metric fasteners. Use only
metric tools to service unit.
WARNING
Make certain blocks are secure and
installed under carriage so that
carriage can not fall.
20-01-2
Return
OCTOBER 1995
WARNING
3. Remove forks.
4. Turn key switch OFF and disconnect
battery.
5. Remove battery.
WARNING
CAUTION
To avoid injury, remove all the axle
fasteners in the order listed.
to
Group
34
OCTOBER 1995
Return
20-01-3
20-01-4
Return
OCTOBER 1995
OCTOBER 1995
Return
20-01-5
20-01-6
Return
OCTOBER 1995
OCTOBER 1995
Return
20-01-7
NOTE
Sealant was applied to the axle end
housing flanges at assembly. Force
may be required to separate the two
housings.
Note
In order to remove lock nut, it will
be necessary to fabricate a tools to
keep the output shaft from turning.
Refer to Drive Axle Special Tools.
20-01-8
Return
OCTOBER 1995
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
OCTOBER 1995
Return
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
20-01-9
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
20-01-10
Return
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
OCTOBER 1995
Assembly
1. Install pinion bearing cups into axle end
housing.
2. Press outer bearing cone onto output gear
pinion.
3. Slide spring bushing onto output gear pinion.
Install pinion into axle end housing.
4. Install inner bearing cone onto pinion. Install
spacer, bevel gear, apply Threadlocker to a
new bevel gear nut and install. Tighten bevel
gear nut to give a running torque of [0.7
Nm] 6.2 lb./in on the pinion bearing.
5. Install pinion bearing cups into motor
mounting flange.
6. Press inner bearing cone onto pinion and
insert pinion into motor mounting flange.
7. Slide backing washer, spring bushing,
backing washer, and outer bearing cone
onto pinion.
8. Apply Threadlocker to pinion shaft lock nut
and install on pinion. Tighten nut to give a
rolling torque of [0.5 Nm] 4.4 lbs/in on the
pinion bearing. Use special tool to torque
nut.
9. Check motor pinion and bevel gear mesh
adjustment.
NOTE
Mesh adjustment is made with
motor mounting flange shims and
bevel gear spacer. Mark teeth of
motor pinion and bevel gear with
gear checking compound.
OCTOBER 1995
Return
20-01-11
20-01-12
Return
OCTOBER 1995
OCTOBER 1995
Return
20-01-13
NOTE
Do not install O ring (item # 10 on
right hand drive axle) at this time.
WARNING
Use only approved hoist, chains,
and straps to lift the drive axle and
motors.
Be
sure
hoist
and
accessories have correct capacity
to safely support the load.
20-01-14
Return
CAUTION
To avoid injury, install all the axle
mounting bolts in the order
indicated.
OCTOBER 1995
NOTE
Coat spline shaft of motors with
Anti-Seize, before installation.
OCTOBER 1995
Return
20-01-15
Return
Group 22
WHEELS AND TIRES
OCTOBER 1995
Return
22-00-1
22-00-2
Return
OCTOBER 1995
Section 1.
Cushion Wheels and Tires
OCTOBER 1995
Return
22-01-1
NOTE
The cushion drive and steering tires
specified for this series forklift
trucks were chosen after extensive
testing as the best combination of
tread and shape design and
material compounding, including
hardness, to provide the required
wear and handling characteristics.
18 x 7 x 12.12
18 x 8 x 12.12
18 x 9 x 12.12
9x5
IMPORTANT
The
user
is
advised
that
replacement
of
the
original
equipment tires with tires other
than those recommended by BT
Prime-Mover
may
result
in
decreased operating performance
and stability.
22-01-2
Return
OCTOBER 1995
OCTOBER 1995
Return
22-01-3
22-01-4
Return
OCTOBER 1995
OCTOBER 1995
Return
22-01-5
Return
Section 2.
Pneumatic Drive Tire and Wheel Maintenance
OCTOBER 1995
Return
22-02-1
WARNING
For your safety and the safety of others!
Before you do tire or rim maintenance:
Read the OSHA rules regarding owner. DO
NOT work on tires or rims you have been
trained in the correct. Read and understand
all and repair procedures on tires and rims.
Serious injury or death can result if the
safety messages are ignored.
22-02-2
Return
OCTOBER 1995
Safety Procedures
1. Do not fill a tire with air that has been run flat
without first inspecting the tire, rim and
wheel assembly. Double check the lock ring
for damage. Make sure that it is secure in
the gutter before filling the tire with air.
OCTOBER 1995
Return
22-02-3
CAUTION
Check tire pressure from a position
facing the tread of the tire, not the
side. Use a long-handled gauge to
keep your body away from the side.
If tires are low, don't add air. Have
the tire and wheel inspected by a
person trained and authorized to do
tire and wheel maintenance. The tire
may require removal and repair.
Incorrect (low) tire pressure can
reduce the stability of your lift truck
and cause it to tip over.
18 x 7 x 8 16 PR
18 x 9 x 8 16 PR
Not Available
IMPORTANT
Check wheels and tires for damage
every
time
you
check
tire
pressure.repairs when needed. Dirt
can into cuts and cause damage to
the tire cord and thread. Remove
debris all cuts.
22-02-4
Return
OCTOBER 1995
WARNING
Before you loosen the wheel
mounting bolts, remove the air from
the tire. Failure to remove the air
from the tire can result in injury.
CAUTION
To perform these service procedures, first:
22-02-5
22-02-6
Return
OCTOBER 1995
Clean the tire bead seat area. Remove all rust and
rubber.
OCTOBER 1995
Return
22-02-7
IMPORTANT
Install washer on tube over valve
stem before flap is installed, if
specified.
Put the side ring over the rim and install the lock ring
as shown.
Install the tire onto the wheel rim, against the bead
seat area.
Connect air chuck and put (21 kPa) 3 psi of air into
the tire.
22-02-8
Return
OCTOBER 1995
WARNING
Make sure all items of equipment
use (nitrogen cylinder, regulator,
gauges, hoses) are UL approved
and in good condition. Use the
correct regulator and hose for the
pressures that are necessary.
WARNING
Use nitrogen only. DO NOT use
oxygen or any other gas to fill your
tires.
NOTE
If your air supply does not have
enough pressure to fill the tire, you
can use a pressurized cylinder of
commercial nitrogen gas to get the
correct tire pressure. Connect the
nitrogen cylinder to the valve stem
with the use of an air chuck. BE
SURE TIRE IS STILL IN SAFETY
CAGE! Refer to How to adjust the
regulator on the nitrogen cylinder".
OCTOBER 1995
Return
22-02-9
CAUTION
Put equal air pressure in both tires
of assembly. Do not put air into a
tire is flat without first inspecting it
and the wheel for damage.
CAUTION
Put equal nitrogen pressure in both
tires of assembly. Do not put air
into a tire is flat without first
inspecting it and the wheel for
damage.
22-02-10
Return
OCTOBER 1995
OCTOBER 1995
Return
22-02-11
CAUTION
Use a long-handled gauge so that
your hand does not go inside the
cage, or in front of any component
of a multi-piece wheel.
WARNING
Before you add air pressure to the
tire, make sure the lock ring is
correctly positioned in the rim and
side ring. The lock ring can
separate from the rim with enough
force to cause injury or death.
WARNING
Use compressed air or nitrogen
only to fill your tires. DO NOT use
oxygen or any other gas.
22-02-12
Return
OCTOBER 1995
Adding Nitrogen
OCTOBER 1995
Return
22-02-13
Return
Group 23
BRAKE SYSTEM
OCTOBER 1995
Return
23-00-1
23-00-2
Return
OCTOBER 1995
Section 1.
Brake System and Bleeding
OCTOBER 1995
Return
23-01-1
23-01-2
Return
OCTOBER 1995
IMPORTANT
Reservoir should be
approximately 1/4 full
before you begin to
bleed the system.
OCTOBER 1995
Return
IMPORTANT
Check reservoir often during the
bleeding operation
to prevent overflowing of hydraulic fluid.
23-01-3
Return
Section 2.
Brake Adjustment
OCTOBER 1995
Return
23-02-1
23-02-2
Return
OCTOBER 1995
OCTOBER 1995
Return
23-02-3
23-02-4
Return
OCTOBER 1995
OCTOBER 1995
Return
23-02-5
NOTE
Spray threads of nuts and bolts
with "Primer T" five(5) minutes
before applying General Purpose
Threadlocker at time of installation.
23-02-6
Return
OCTOBER 1995
Section 3.
Brake Slave Cylinder
OCTOBER 1995
Return
23-03-1
CAUTION
To perform these service procedures, first:
IMPORTANT
When
removing
or
installing
hydraulic lines and components, it
is necessary to prevent any dirt
particles
from
entering
the
hydraulic system. The smallest
particles are capable of severely
damaging the system.
23-03-2
Return
OCTOBER 1995
IMPORTANT
CLEANLINESS!
Perform
procedures in a clean environment.
Make sure all parts are cleaned
before disassembly and kept clean
during assembly.
Disassembly
1.Remove rubber boot, bleeder screw and filling.
2.Remove retainer ring and internal components.
Inspection
Clean the cylinder body and other metal parts in a
Stoddard type cleaner solvent and thoroughly rinse
with clean brake fluid. Clean rubber parts in
Stoddard type solvent and rinse in clean brake fluid.
Use only low pressure compressed air or a lint-free
cloth to dry parts. Lay the cleaned parts on a clean
sheet of paper and protect from contamination until
reassembly.
Inspect the piston and cylinder bore for visible score
marks, ridges, and corrosion. Check that the
cylinder bore is smooth to the touch. Replace the
slave cylinder if there is any doubt about its
serviceability.
Assembly
Use all parts from the service kit.
1. Fit spring seat and spring into cylinder bore.
2. Lubricate new piston cup with clean brake
fluid and install. Install piston, retaining ring,
and rubber boot.
3. Reinstall bleeder screw and fitting.
OCTOBER 1995
Return
23-03-3
Installation
1. Fit push rod into seat of slave cylinder
piston. Mount slave cylinder to mounting
bracket with fasteners. Torque fasteners to
(9.4-10.6 Nm) 83-94 lb./in.
2. Connect line to brake slave cylinder.
23-03-4
Return
and
test
truck
brake
OCTOBER 1995
Group 25
STEERING GEAR
OCTOBER 1995
Return
25-00-1
25-00-2
Return
OCTOBER 1995
Section 1.
Steering Gear
OCTOBER 1995
Return
25-01-1
1. Dust Seal
2. Retaining Ring
3. Seal Gland Bushing
4. Seal, 2-1/8"OD
5. Quad Ring Seal
6. Needle Bearing Kit
7. Bearing Race
8. Needle Thrust Bearing
9. Set Screw
25-01-2
Return
OCTOBER 1995
OCTOBER 1995
Return
25-01-3
8. Remove drive.
9. Remove spacer plate.
10. Remove seal from housing.
25-01-4
Return
OCTOBER 1995
IMPORTANT
Be careful not to bind spool and
sleeve in housing. Rotating spool
and sleeve slowly while removing
will help prevent binding.
OCTOBER 1995
Return
25-01-5
25-01-6
Return
IMPORTANT
Do not insert assembly beyond
flush position. This will prevent pin
from dropping into discharge
groove of housing.
OCTOBER 1995
Return
25-01-7
25-01-8
Return
OCTOBER 1995
OCTOBER 1995
Return
25-01-9
Return
Group 26
STEERING AXLE
OCTOBER 1995
Return
26-00-1
26-00-2
Return
OCTOBER 1995
Section 1.
Steering Axle Repair
OCTOBER 1995
Return
26-01-1
WARNING
All lifting components used in this
procedure must be in good
condition,
meet
the
lifting
requirements, and have OSHA
approval labels when required.
26-01-2
Return
OCTOBER 1995
OCTOBER 1995
Return
26-01-3
NOTE
Tighten upper bearing retainer to
75 lb./ft. (100 Nm) to remove free
play.
resistance
of
fork
assembly should be no more then
27 lb./in. (3 Nm).
26-01-4
Return
OCTOBER 1995
Section 2.
Power Steering Pump
OCTOBER 1995
Return
26-02-1
See 1a,b,c,d
Air in fluid.
c)
See 2b
Relief valve leakage or valve set too low.
Before
steer
pump
is
removed
and/or
disassembled, check the following list of problems
and solutions. It could save cost, time, and effort.
d)
1. Noisy Pump.
a)
Low supply of oil.
See 3 a, b, c, d, e, f.
5. Shaft Seal Leakage.
a)
Damaged or worn seal.
b)
Fill reservoir.
Oil too heavy.
b)
Replace seal.
Front cover bearing out position.
c)
c)
d)
See 5b
Improper fit of shaft.
d)
See 5b.
a)
O ring damaged.
See 1a,b,c, d
Wrong fluid.
b)
Replace O ring.
Damaged surfaces in O Ring groove.
b)
c)
d)
See 1a,b,c,d
Drive shaft not aligned.
e)
f)
26-02-2
Return
OCTOBER 1995
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
OCTOBER 1995
Return
14.
14.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
26-02-3
IMPORTANT
CLEANLINESS!
Perform
procedures in a clean environment.
Make sure all parts are cleaned
before disassembly and kept clean
during assembly.
assembly together.
26-02-4
Return
OCTOBER 1995
IMPORTANT
Be careful not to damage the shaft
seal bore in end cover. Nicks or
scratches in the surface where seal
is press fitted will result in leakage.
NOTE
NOTE
Slight lapped condition of gear
bores
will
neither
harm
performance
nor
require
replacement.
OCTOBER 1995
Return
26-02-5
IMPORTANT
A shoulder is machined in bearing
bore to ensure correct depth of
bearing seating. Press bearing fully
against this shoulder.
Dimension B
0.045-0.050 in.
0.058-0.063 in.
26-02-6
Return
OCTOBER 1995
OCTOBER 1995
Return
NOTE
When installing pump to motor,
install the rubber coupling insert
(cross) into either the motor or
pump half of coupling, with slots in
the insert over the tangs of
coupling half.
26-02-7
26-02-8
Return
OCTOBER 1995
OCTOBER 1995
Return
26-02-9
26-02-10
Return
OCTOBER 1995
OCTOBER 1995
Return
26-02-11
Return
Section 3.
Steering Torque Generator
OCTOBER 1995
Return
26-03-1
26-03-2
Return
2.
OCTOBER 1995
NOTE
Position lifting straps as close to
center of torque generator as
possible.
around
torque
OCTOBER 1995
Return
26-03-3
Steering Torque
Generator Disassembly
NOTE
1. Remove Allen-head
generator housing.
26-03-4
Return
set
screws
OCTOBER 1995
OCTOBER 1995
Return
Steering Torque
Generator Parts Inspection
1. Clean all torque generator components and
lay on a clean sheet of paper. Protect parts
from dirt and contamination before
reassembly.
2. Inspect all parts for wear or damage.
Replace parts as required.
26-03-5
26-03-6
Return
OCTOBER 1995
Steering Torque
Generator Installation
1. If installing replacement steering torque
generator, install motor cut-out cam locating
roll pin as shown below.
2. Coat pinion shaft with Anti-Seize Lubricant
before installation.
3. Position locating key in generator pinion key
way. Position torque generator on steering
axle, align generator pinion key with steering
axle and install. Seat torque generator by
carefully tapping on top surface of generator
housing with a block of wood and hammer.
OCTOBER 1995
Return
torque
26-03-7
NOTE
Apply
lubricant
to
terminals
before
connection.
push-on
making
26-03-8
Return
OCTOBER 1995
Steering Torque
Generator Assembly Specifications
OCTOBER 1995
Return
26-03-9
26-03-10
Return
OCTOBER 1995
Group 29
HYDRAULIC PUMP, SUMP AND FILTER
OCTOBER 1995
Return
29-00-1
29-00-2
Return
OCTOBER 1995
Section 1.
Hydraulic Pump
OCTOBER 1995
Return
29-01-1
Disassembly
NOTE
All reference numbers refer to items
shown in the illustrations on the
next page.
NOTE
During disassembly, take special
note of the wear patterns on the
wear plate (8), thrust plate (6) and
body (14). The large port in the rear
cover (3) always corresponds to the
inlet side of the pump. The inlet side
can be further identified by the gear
contact pattern in the body (gear)
bore. The wear plate (8) will have a
somewhat heavier wear pattern on
the inlet side. The thrust plate (6)
will also have a pattern than can be
established for reassembly. Also
note that the long journal of the
driven gear (13) is toward the front
of the pump.
29-01-2
Return
NOTE
Cover seal (5) and thrust plate (6)
may or may not remain with rear
cover. Should they remain with the
body, remove seal and lift out thrust
plate before proceeding.
IMPORTANT
Care should be taken not to damage
(gouge) the shaft seal bore,
because this will result in shaft seal
leakage.
Parts Inspection
1. Wash all parts and dry thoroughly with a
clean lint free cloth.
2. Inspect wear plate (8) and thrust plate (6).
Replace if scoring or uneven wear is
observed.
NOTE
Somewhat heavier wear pattern is
normal on the low pressure (inlet)
side of the plates (6& 8). However,
there should be no heavy scoring in
this area.
OCTOBER 1995
OCTOBER 1995
Return
29-01-3
Assembly
1. Place body (14) on flat plate with shaft seal
bore up. Install new shaft seal (10). Press
seal into bore until it is to approximate depth
shown below. (The outside diameter of the
sleeve should be slightly smaller the outside
diameter of the shaft seal.)
Pack the area between the double lip of the
seal with Lubriplate or equivalent grease.
2. Invert body so that gear bores are up. Install
wear plate (8) in bottom of bore, making
29-01-4
Return
OCTOBER 1995
OCTOBER 1995
Return
29-01-5
29-01-6
Return
OCTOBER 1995
Section 2.
OCTOBER 1995
Return
29-02-1
29-02-2
Return
OCTOBER 1995
Section 3.
Hydraulic Schematics
OCTOBER 1995
Return
29-03-1
Hydraulic Diagram
29-03-2
Return
OCTOBER 1995
Group 30
HYDRAULIC CONTROL VALVES
OCTOBER 1995
Return
30-00-1
30-00-2
Return
OCTOBER 1995
Section 1.
OCTOBER 1995
Return
30-01-1
WARNING
Always wear safety glasses.
Remover covers.
Remove key.
Discharge capacitor.
3. Remove cover(s).
30-01-2
Return
OCTOBER 1995
IMPORTANT
When
removing
or
installing
hydraulic lines and components, it
is necessary to avoid any dirt
particles
from
entering
the
hydraulic system. The smallest
particles are capable of severely
damaging the system.
OCTOBER 1995
Return
30-01-3
30-01-4
Return
OCTOBER 1995
CAUTION
Do not attempt setting relief valve
without proper test equipment.
Refer to Section 3 for adjustment
procedures.
OCTOBER 1995
Return
30-01-5
Disassembly
Assembly
Inspection
30-01-6
Return
OCTOBER 1995
Assembly
1. If removed, install new O rings and valve
spool in valve body.
IMPORTANT
Threads should be free of dirt and
grease, in both the detent spool and
valve spool.
Disassembly
Required Tools
Standard Screwdriver
Phillips Screwdriver
IMPORTANT
Excessive valve spool travel into
valve body will possibly damage Orings.
NOTE
Detent spool removal may require
greater then normal forces since
this part is liquid locked in place.
IMPORTANT
Movement of valve spool in or out
of the valve body can damage the O
ring.
30-01-7
30-01-8
Return
OCTOBER 1995
Disassembly
End Cap Removal
NOTE
Refer to the previous control valve
end cap disassembly procedure.
NOTE
This may require heavier than
normal forces since the screw has
been installed using loctite.
CAUTION
Be
extremely
careful
when
removing spool and O rings from
the valve body. Do not scratch, nick
or mar the spool or the body bore.
To do so, will make the valve unfit
for further service.
WARNING
Wear eye protection and protective
clothing when cleaning or drying
with air pressure. Reduce air
pressure to 30 PSI (207 kPa). Debris
removed with air pressure can
cause injury.
OCTOBER 1995
Return
30-01-9
Assembly
Spool and Seals
1. Lubricate valve spool and new O ring with
clean hydraulic fluid.
2. Carefully insert spool into the bore at the cap
end of the valve body. Continue to push the
spool inward until the front (clevis) end of
spool is flush with the inward side of the front
O ring groove as shown here.
3. Next, pinch (as shown) a lubricated O ring
so it can be partially inserted into the groove.
4. Using a brass tool, completely push the O
ring into the groove. Be extremely careful
that you do not damage (cut or nick) the O
ring during installation. Be extremely careful
that you do not damage the body bore. To
do so will make the assembly unfit for
service.
5. Now, slowly rotate the spool while gently
moving it on through the front O ring.
Continue to push the spool inward until the
end of the spool is flush with the inside edge
of the groove located at the cap end of the
valve.
6. Lubricate and install a new O ring into this
groove. Follow the same procedure
described in Steps 3 and 4.
7. After the O ring is installed, use the
procedure previously described in step 5
and push the spool back through the valve
and the newly installed O ring. Continue this
process until the end of the spool is flush
with the casting at cap end of body.
End Cap Assembly (Refer to Control Valve End Cap
procedures.)
IMPORTANT
30-01-10
Return
OCTOBER 1995
Section 2.
OCTOBER 1995
Return
30-02-1
30-02-2
Return
OCTOBER 1995
Assembly Suggestions
IMPORTANT
Check to be sure the O ring face
seal is lubricated, seated and
properly retained in fitting groove.
See below. If the seal is missing or
not fitting properly in its groove, the
connection will leak.
OCTOBER 1995
Return
30-02-3
30-02-4
Return
OCTOBER 1995
Section 3.
NOTE
Refer to Section 4 Steering Circuit.
Refer to Section 5 for Auxiliary and Tilt Circuits.
OCTOBER 1995
Return
30-03-1
Test Ports
IMPORTANT
Check system pressure with the
hydraulic
fluid
at
operating
temperature: 110-130F (43-54C)
30-03-2
Return
OCTOBER 1995
NOTE
The relief valve is located at the end
the lift control valve. Refer to
illustration.
IMPORTANT
Check system pressure with the
hydraulic
fluid
at
operating
temperature: 110-130F (43-54C)
NOTE
The hydraulic relief valve setting
may be checked with a Mico
Quadrigage or with a conventional
pressure gauge having a scale of 04000 psi. (0-27,580 kPa).
OCTOBER 1995
Return
30-03-3
Return
Section 4.
NOTE
Refer to Section 3 Lift Circuit.
Refer to Section 5 for Auxiliary and Tilt Circuits.
OCTOBER 1995
Return
30-04-1
Test Ports
IMPORTANT
Check system pressure with the
hydraulic
fluid
at
operating
temperature: 110-130F (43-54C)
30-04-2
Return
OCTOBER 1995
NOTE
The relief valve is located in the
steering pump. Refer to illustration
on next page.
IMPORTANT
Check system pressure with the
hydraulic
fluid
at
operating
temperature: 110-130F (43-54C)
NOTE
IMPORTANT
on
OCTOBER 1995
Return
30-04-3
30-04-4
Return
OCTOBER 1995
Section 5.
NOTE
Refer to Section 3 Lift Circuit.
Refer to Section 4 for Steering Circuit.
OCTOBER 1995
Return
30-05-1
Test Ports
IMPORTANT
Check system pressure with the
hydraulic
fluid
at
operating
temperature: 110-130F (43-54C)
30-05-2
Return
OCTOBER 1995
NOTE
The relief valve RV1, RV2, are
located on the solenoid control
valve. Refer to illustration on next
page.
IMPORTANT
Check system pressure with the
hydraulic
fluid
at
operating
temperature: 110-130F (43-54C)
NOTE
The hydraulic relief valve setting
may be checked with a Mico
Quadrigage or with a conventional
pressure gauge having a scale of 04000 psi. (0-27,580 kPa).
on
OCTOBER 1995
Return
30-05-3
30-05-4
Return
OCTOBER 1995
Section 6.
OCTOBER 1995
Return
30-06-1
Valve Identification
NOTE
Selector solenoid valve shown with
device selector solenoid valve
attached. If device selector solenoid
valve is not used, an end plate is
attached to selector solenoid valve
instead.
30-06-2
Return
OCTOBER 1995
3. Assembly
OCTOBER 1995
Return
30-06-3
30-06-4
Return
OCTOBER 1995
OCTOBER 1995
Return
30-06-5
Return
Group 31
HYDRAULIC SUPPLY SYSTEM
OCTOBER 1995
Return
31-00-1
31-00-2
Return
OCTOBER 1995
Section 1.
Hydraulic System
General Description........................................................................... 2
Hydraulic Fluid and Filter Change ................................................... 2
Remote Pump Method .............................................................. 2
Truck Pump Method.................................................................. 3
Hydraulic Sump Tank ........................................................................ 5
OCTOBER 1995
Return
31-01-1
General Description
The parts of the main hydraulic system are the
hydraulic sump tank, main hydraulic pump, main
hydraulic valve, selector solenoid valve, and
associated hydraulic lines and hoses.
The parts of the hydraulic steering system are the
steering pump, steering gear, and steering torque
generator.
The hydraulic sump is a separate, removable tank.
NOTE
If sump tank must be removed for
service, hose at the bottom of sump
can be disconnected and oil
allowed to drain. There is no access
to this hose unless drive axle is
removed.
CAUTION
To perform this service procedure, first:
31-01-2
Return
OCTOBER 1995
CAUTION
To perform this service procedure, first:
NOTE
If battery is removed, use an
adapter cable connected between
battery and truck receptacle to
power hydraulic system.
IMPORTANT
Be careful when sump is nearly
emptied. Listen and watch for signs
of pump cavitation. DO NOT operate
pump after cavitation occurs.
Severe damage to pump gear, plate,
and housing will occur!
NOTE
If old oil is excessively dirty or
hydraulic system contaminated, it
is recommended that the sump tank
be completely drained by removing
the pump suction line from the
sump outlet, and flushed with clean
oil.
NOTE
Use quick-disconnect adapter fitting.
OCTOBER 1995
Return
IMPORTANT
Discard old oil
environmentally
manner.
and
filter in
acceptable
31-01-3
IMPORTANT
Always use genuine Prime-Mover
parts. Use recommended fluid only.
CAUTION
Be sure there is adequate overhead
clearance before raising upright.
WARNING
NOTE
Remove sump filler cap adapter to
clean sump pre-filter screen, if
necessary.
31-01-4
Return
tank
fluid
OCTOBER 1995
OCTOBER 1995
Return
31-01-5
Return
Group 32
CYLINDERS
OCTOBER 1995
Return
32-00-1
32-00-2
Return
OCTOBER 1995
Section 1.
Tilt Cylinder
OCTOBER 1995
Return
32-01-1
32-01-2
Return
OCTOBER 1995
OCTOBER 1995
Return
32-01-3
CAUTION
IMPORTANT
When
removing
or
installing
hydraulic lines and components, it
is necessary to prevent any dirt
particles
from
entering
the
hydraulic system. The smallest
particles are capable of severely
damaging the system.
WARNING
If both tilt cylinders are to be
removed, the upright must be
supported by use of an overhead
chain hoist of adequate capacity. If
not supported, the upright can
move with one cylinder connected
because oil will be pushed from the
cylinder to the disconnected hoses.
Temperature
80F (26.7C)
Drift
0.256 in. (6.5 mm)
100F (37.8C
120F (48.9C)
NOTE
Put a drain pan under the truck at
the tilt cylinder position when
removing hydraulic lines.
32-01-4
Return
OCTOBER 1995
OCTOBER 1995
Return
32-01-5
IMPORTANT
CLEANLINESS!
Perform
procedures in a clean environment.
Make sure all parts are cleaned
before disassembly and kept clean
during assembly.
32-01-6
Return
OCTOBER 1995
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
OCTOBER 1995
Return
Ring, Back-up
Seal, Barrel
Lock, Gland
Seal, Gland
Spacer, Piston Rod
Seal, Piston
Rod & Piston, Tilt Cylinder
Plug, Port Fitting
Seal, Port Fitting Plug
Barrel, Tilt Cylinder
Gland, Tilt Cylinder
Packing, Gland
Wiper, Piston Rod
Ring, Gland
Retainer, Gland
32-01-7
32-01-8
Return
IMPORTANT
If there were both split and solid
shims removed, be certain to
alternate them upon installation, i.e.
one split shim followed by one solid
shim. (There should be no more
than six shims per cylinder.)
OCTOBER 1995
NOTE
O ring face seal fittings are used on
this truck. If you are unfamiliar with
this type connection, refer to Face
Seal
Fittings,
Assembly
Suggestions on next page before
making connections.
OCTOBER 1995
Return
32-01-9
Assembly Suggestions
IMPORTANT
Check to be sure the O ring face
seal is lubricated, seated and
properly retained in fitting groove.
See below. If the seal is missing or
not fitting properly in its groove, the
connection will leak.
32-01-10
Return
OCTOBER 1995
OCTOBER 1995
Return
WARNING
Do not use your hands to check for
hydraulic leakage. Use a piece of
cardboard or paper to search for
leaks.
Escaping
fluid
under
pressure can penetrate the skin
causing serious injury. Relieve
pressure
before
disconnecting
hydraulic or other lines. Tighten all
connections
before
applying
pressure. Keep hands and body
away from pinholes and nozzles
which eject fluids under high
pressure.
32-01-11
IMPORTANT
If upright racks or twists, this
indicates unequal stroke of the tilt
cylinders rods. The rod length of
one cylinder is longer than the
other. To correct this condition, you
must shorten the cylinder rod that
has the longest length.
32-01-12
Return
OCTOBER 1995
OCTOBER 1995
Return
32-01-13
Return
Group 33
SELECTOR SOLENOID VALVE
OCTOBER 1995
Return
33-00-1
33-00-2
Return
OCTOBER 1995
Section 1.
OCTOBER 1995
Return
33-01-1
NOTE
A device selector solenoid valve
may be joined to this valve to add
another auxiliary function.
33-01-2
Return
Selector Solenoid
Valve Troubleshooting
A problem with the selector solenoid valve will be
either in the electrical or hydraulic circuits. Use the
truck electrical or hydraulic circuits. Use the truck
electrical and hydraulic schematics to determine
which selector solenoid valve cartridge is faulty.
Because the solenoid and valve cartridges can not
be serviced internally, it will be necessary to replace
the defective cartridge to repair the valve.
OCTOBER 1995
IMPORTANT
IMPORTANT
Remove valve components only in a
clean, dust-free location, using clean
tools and equipment. Dirt or grit will
result in leakage or premature failure of
components. Cleanliness of hydraulic
circuit is extremely important to proper
operation and maintenance of system.
When
removing
or
installing
hydraulic lines and components, it
is necessary to prevent any dirt
particles
from
entering
the
hydraulic system. The smallest
particles are capable of severely
damaging the system.
NOTE
WARNING
Secure upright to an overhead
hoist. Upright can tilt or carriage
can fall when hydraulic lines are
disconnected.
covers
and
top
WARNING
Wear eye protection and protective
clothing when drying with air
pressure. Reduce air pressure to 30
psi (207 kPa). Debris removed with
air pressure can cause injury.
at valve cartridges.
WARNING
Trapped hydraulic oil may create
pressure in lines. Carefully loosen
connections to relieve pressure.
Watch for any movement of the
upright.
WARNING
Do not use your hands to check for
hydraulic leakage. Use a piece of
cardboard or paper to search for leaks.
Escaping fluid under pressure can
penetrate the skin causing serious
injury.
Relieve
pressure
before
disconnecting hydraulic or other lines.
Tighten all connections before applying
pressure. Keep hands and body away
from pinholes and nozzles which eject
fluids under high pressure.
9. Remove
OCTOBER 1995
Return
33-01-3
33-01-4
Return
NOTE
Selector solenoid valve should with
device selector solenoid valve
attached. If device selector solenoid
valve is not used, an end plate is
attached to selector solenoid valve
instead.
OCTOBER 1995
Group 34
UPRIGHTS
IMPORTANT
Related service information is covered in Group 29, Hydraulic Pump, Sump
and Filter, Group 30, Hydraulic Control Valves and Group 32, Cylinders.
OCTOBER 1995
Return
34-00-1
34-00-2
Return
OCTOBER 1995
Section 1.
Upright
OCTOBER 1995
Return
34-01-1
Upright Maintenance
WARNING
Review all described procedure before
starting any maintenance or service
function. The procedures for checking,
maintaining, and adjusting uprights,
carriages, and forks involve movement
of the components. Always use
extreme caution. Failure to follow this
warning can result is serious injury.
NOTE
Use a shim block under the "C"
clamp on the inside of channel rail.
Torque on the "C" clamp should not
exceed 20 lb./ft. (27 Nm).
34-01-2
Return
Feeler
Gauge
Gauge will
Pass/Not Pass
Shimmed
Correctly
Shim
Qty.
0.020 in.
0.51 mm
Not Pass
Pass
Yes
Try Next Seq.
0
-
0.040 in
(1.02 mm)
Not Pass
Pass
Yes
Try Next Seq.
0
-
0.060 in.
(1.52 mm)
Not Pass
Pass
Yes
Try Next Seq.
2
-
0.080 in.
(2.03 mm)
Not Pass
Pass
No
Try 0.100 in.
(2.54 mm)
3
-
OCTOBER 1995
OCTOBER 1995
Return
34-01-3
IMPORTANT
Before application of the "C" clamp
to the carriage, remove the fork bar
thrust roller opposite the intended
"C" clamp position, if applicable.
Refer to balloon area of previous
illustration.
NOTE
Use a shim block under the "C"
clamp on the inside of channel rail.
Torque on the "C" clamp should not
exceed 20 lb./ft. (27 Nm).
chain
or
Wood Blocks
1
1
1
1
1
4
NOTE
Reference to "Left" or "Right" is
utilized relative to position of truck
operator in the seat.
34-01-4
Return
OCTOBER 1995
After
shimming
requirements
have
been
established, the first step is removal of the carriage.
Set tilt to 0 degrees (vertical) and raise the forks a
minimum of 6 in. (152 mm). Place a good
substantial pallet under the forks.
Lower carriage and forks onto the pallet and
continue to lower until the carriage lift (center
mounted) Cylinder piston rod is completely
collapsed into the cylinder.
CAUTION
Use care when pulling on carriage
chains to collapsed carriage lift
(center) cylinder. Avoid areas where
finger can be pinched. It may be
necessary to have anther person
move the control handle to the
lowering position while chains are
pulled to collapse cylinder.
OCTOBER 1995
Return
34-01-5
34-01-6
Return
OCTOBER 1995
8. Check opposite
squareness.
side
of
carriage
for
OCTOBER 1995
Return
34-01-7
NOTE
Make sure that upright tilt is still 0
degrees (vertical).
34-01-8
Return
NOTE
Top of the rails should be flash.
OCTOBER 1995
From the left rear of the upright pull, the left chain
anchor out and tie it to the top left outer tie bar area.
Remove the final lift cylinder rod fastener, located
on the intermediate rail top tie bar. Some models
may have two fasteners in the top of final lift cylinder
rod. In either case, the lift chain particularly covers
the cylinder rod fastener(s) and must be moved
over to remove fastener(s).
Remove the chain or strap from the inner rail tie bar
and attach it to the intermediate rail top tie bar.
Raise the hoist until the intermediate rail is high
enough to place a 12 inch (305 mm) long 4 x 4 block
vertically into the outer rail channel under the
intermediate rail. Then lower the intermediate rail
block. The primary lift cylinder must remain on the
block installed earlier.
OCTOBER 1995
Return
34-01-9
IMPORTANT
Truck is now ready to expose the rail rollers for
shimming.
A. To expose the outer rail
intermediate rail lower rollers:
upper
and
IMPORTANT
Check to assure that lift chains and
anchors will not catch, jam, or
interfere when raising and lowering
the rails.
NOTE
Both rails must be on the floor at
this time.
34-01-10
Return
NOTE
Inner rail must remain on the floor
during this procedure.
OCTOBER 1995
WARNING
Do not use your hands to check for
hydraulic leakage. Use a piece of
cardboard or paper to search for leaks.
Escaping fluid under pressure can
penetrate the skin causing serious
injury.
Relieve
pressure
before
disconnecting hydraulic or other lines.
Tighten all connections before applying
pressure. Keep hands and body away
from pinholes and nozzles which eject
fluids under high pressure.
IMPORTANT
DO NOT remove 14 in. (356 mm)
block under carriage lift cylinder.
CAUTION
DO NOT reach through upright to
attach fasteners.
OCTOBER 1995
Return
34-01-11
IMPORTANT
Use extreme care that tools do not
make nicks and burrs on the
interior surface of the cap or the
exterior surface area of the piston.
IMPORTANT
CLEANLINESS!
Perform
procedures in a clean environment.
Make sure all parts are cleaned
before disassembly and kept clean
during assembly.
34-01-12
Return
Wiper
Seal, U-cup
Cap, Gland
O ring
Rod cylinder
Ring, back-up
Packing
8.
9.
10.
11.
12.
13.
Ring, wear
Valve, flow control
Ring, back-up
Seal
Retainer
Barrel cylinder
OCTOBER 1995
IMPORTANT
Removal of material that produces a
notch, groove or out-of-roundness
may cause excessive leakage upon
beginning operation or at best a
shortened life.
IMPORTANT
Installation of some parts require
special attention or tools. O rings
should be carefully installed to
prevent cuts or twisting. U-cup
seals should be installed with tools
shown at the end of this section.
1. Wiper
2. Seal, U-cup
3. Cap, Gland
4. O ring
5. Bearing
6. Spacer
7. Rod cylinder
8. Ring, back-up
9. Seal, U-cup
10. Ring, wear
11. Barrel cylinder
IMPORTANT
Check to be sure the seal is
inserted with the U-side toward the
cylinder barrel for proper seal
operation.
OCTOBER 1995
Return
34-01-13
NOTE
It may be necessary to let the seals set for 30
minutes so they will return to their original size.
After all seals and packings are replaced, Carefully
install piston into cylinder barrel so not to damage
seals. Install gland and torque to 50-60 lb./ft. (68-81
Nm).
WARNING
Review all described procedure before
starting any maintenance or service
function. The procedures for checking,
maintaining, and adjusting uprights,
carriages, and forks involve movement
of the components. Always use
extreme caution. Failure to follow this
warning can result is serious injury.
34-01-14
Return
OCTOBER 1995
Checking
Seq.
Feeler
Gauge
Gauge will
Pass/Not Pass
Shimmed
Correctly
Shim
Qty.
0.020 in.
0.51 mm
Not Pass
Pass
Yes
Try Next Seq.
0
-
0.040 in
(1.02 mm)
Not Pass
Pass
Yes
Try Next Seq.
0
-
0.060 in.
(1.52 mm)
Not Pass
Pass
Yes
Try Next Seq.
2
-
0.080 in.
(2.03 mm)
Not Pass
Pass
No
Try 0.100 in.
(2.54 mm)
3
-
OCTOBER 1995
Return
34-01-15
NOTE
IMPORTANT
Before application of the "C" clamp
to the carriage, remove the fork bar
thrust roller opposite the intended
"C" clamp position, if applicable.
Refer to balloon area of previous
illustration.
NOTE
Use a shim block under the "C"
clamp on the inside of channel rail.
Torque on the "C" clamp should not
exceed 20 lb./ft. (27 Nm).
After
shimming
requirements
have
been
established, the first step is removal of the carriage.
Set tilt to 0 degrees (vertical) and raise the forks a
minimum of 6 in. (152 mm). Place a good
substantial pallet under the forks and lower onto
pallet. Continue to lower until tension on chain is
removed.
Remove cotter pins and chain anchor pins from the
chain anchors located on lower rear side of fork
bars.
Use a C clamp to clamp one fork to the pallet. This
will prevent the carriage from falling over after it is
removed from the inner rails.
Wood Blocks
1
34-01-16
Return
chain
or
OCTOBER 1995
OCTOBER 1995
Return
34-01-17
8. Check opposite
squareness.
side
of
carriage
for
34-01-18
Return
OCTOBER 1995
NOTE
Make sure that upright tilt is still 0
degrees (vertical).
CAUTION
DO NOT reach through upright.
OCTOBER 1995
Return
34-01-19
CAUTION
NOTE
Repeat preceding paragraphs for the opposite lift
cylinder.
Wrap chain or strap around top tie bar of inner rails
and raise a few inches to remove block from under
the inner rail.
Lower inner rail to floor so that top and bottom
rollers are exposed.
34-01-20
Return
Check
the
hydraulic
hose
connection in bottom of cylinder so
connection as aligned with proper
hose as removed.
OCTOBER 1995
WARNING
Do not use your hands to check for
hydraulic leakage. Use a piece of
cardboard or paper to search for leaks.
Escaping fluid under pressure can
penetrate the skin causing serious
injury.
Relieve
pressure
before
disconnecting hydraulic or other lines.
Tighten all connections before applying
pressure. Keep hands and body away
from pinholes and nozzles which eject
fluids under high pressure.
OCTOBER 1995
Return
34-01-21
IMPORTANT
IMPORTANT
CLEANLINESS!
Perform
procedures in a clean environment.
Make sure all parts are cleaned
before disassembly and kept clean
during assembly.
IMPORTANT
Use extreme care that tools do not
make nicks and burrs on the
interior surface of the cap or the
exterior surface area of the piston.
IMPORTANT
Removal of material that produces a
notch, groove or out-of-roundness
may cause excessive leakage upon
beginning operation or at best a
shortened life.
34-01-22
Return
LIFT CYLINDER
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Set, packing
Gland, cylinder
Bushing, gland
O ring
Rod cylinder
OCTOBER 1995
IMPORTANT
Check to be sure the seal is
inserted with the U-side toward the
cylinder barrel for proper seal
operation.
OCTOBER 1995
Return
34-01-23
34-01-24
Return
OCTOBER 1995
OCTOBER 1995
Return
34-01-25
34-01-26
Return
OCTOBER 1995
Section 1.
Periodic Inspection............................................................................ 2
Elongation ................................................................................. 4
Edge Wear ................................................................................ 4
Turning or Protruding ................................................................ 4
Cracked Plate ........................................................................... 4
Ultimate Strength Failure .......................................................... 5
Tight Joints................................................................................ 5
Chain Length Adjustments ............................................................... 5
Standard Upright Chain Length Adjustments............................ 6
Triple-Stage Upright (TSU) Chain Length Adjustment.............. 6
Chain Lubrication .............................................................................. 8
Chain Removal and Replacement .................................................... 8
General Guidelines ................................................................... 8
Lift Chains (Standard and TSUs) .............................................. 9
Carriage Chains (TSUs)............................................................ 9
Other Chain Service Notes .............................................................. 10
OCTOBER 1995
Return
34-02-1
34-02-2
Return
OCTOBER 1995
OCTOBER 1995
Return
34-02-3
Periodic Inspection
Each 50-250 hours of operation (more Frequently in
severe or extreme environments), chains should be
inspected and lubricated. Inspection should focus
on the following:
Elongation
When a length of 12 in. (305 mm) of new chain has
elongated to a length of 12-3/8 in. (315 mm), it
should be discarded and replaced. It is important to
measure the chain in the section that moves over
the sheaves because it receives the most wear.
Measuring the chain near its ends could give an
erroneous reading as it would not have flexed as
frequently, if indeed at all, as nearer the middle of
the assembly.
Cracked Plates
Chains should be replaced when wear
exceeds 3% or when 12 in. (305 mm) of
chains is starched 3/8 in. (10 mm).
Edge Wear
Check the chain for wear on the links plate edges
caused by running back and forth over the sheave.
The maximum reduction of material should not
exceed 5&. This can be compared to a normal link
plate height by measuring a portion of chain that
dose not run over the sheave. Distorted or battered
plates on leaf chain can cause tight joints and
prevent flexing.
34-02-4
Return
OCTOBER 1995
Tight Joints
Arc-like cracks in plates are a sign of
stress corrosion.
More than one crack can often appear on a
link plate. In addition to rusting, this
condition can be caused by exposure to an
acidic or caustic medium or atmosphere.
Stress corrosion is an environmentally
assisted failure. Two conditions must be
present: a corrosive agent and static stress.
In the chain, static stress is present at the
pin hole due to the press fit pin. No cyclic
motion is required, and the plates can crack
during idle periods. The reactions of many
chemical agents (such as battery acid
fumes) with hardened steel can release
hydrogen which attacks and weakens the
steel grain structure.
For this same reason, never attempt to
electroplate a leaf chain or its components.
The plating process releases hydrogen, and
hydrogen embrittlement cracks will appear.
These are similar in appearance to stress
corrosion cracks.
WARNING
An upright or
unexpectedly:
carriage
can
move
If a plated chain is required, consult PrimeMover. Plated chains are assembled from
modified, individually plated components
which may reduce the chain rating.
OCTOBER 1995
Return
when making
adjustment.
any
check
or
34-02-5
IMPORTANT
The carriage stop must not be
allowed to contact the upright stop
under any circumstance during
normal operations.
3. Carriage stop-to-upright:
A. Lift upright to its full height and check for
clearance on the carriage safety stop.
B. If the carriage stop hits the upright stop,
adjust the chain anchor adjustment nuts
out until there is at least 0.12 in. (3 mm)
clearance between the stops.
1. Fork-to-ground clearance:
A. Put the upright in the vertical position.
B. Break the jam nuts loose on the chain
anchors.
34-02-6
Return
OCTOBER 1995
IMPORTANT
For all chain anchor adjustments:
1. Fork-to-ground clearance:
A. Put the upright in the vertical position.
B. Break the jam nuts loose on the chain
anchors.
C. Turn the chain adjustment nuts until
clearance between forks and ground is
0.40-0.80 in. (10-20 mm).
2. Carriage roller position:
A. Raise carriage about 3.2 ft. (1m) and
apply a bead of grease from the bottom
approximately 3 in. (75 mm) long on
inner rail in the area of the roller pattern.
B. Tilt upright fully back and completely
lower.
C. Raise carriage about 3.2 ft. (1 m) and
measure the distance from when the
center of the bottom carriage roller
stopped to the bottom edge of the inner
rail. Distance should be not less than
0.80 in. (20 mm) or chain length
adjustment is required.
IMPORTANT
The carriage stop must not be
allowed to contact the upright stop
under any circumstance during
normal operations.
3. Carriage stop-to-upright:
OCTOBER 1995
Return
34-02-7
Chain Lubrication
General Guidelines
34-02-8
Return
OCTOBER 1995
Chain
OCTOBER 1995
Return
34-02-9
34-02-10
Return
OCTOBER 1995
Group 40
SPECIFICATIONS
Specifications........................................................................................ Section 1
Data Plate............................................................................................... Section 2
Lubricants and Shop Supplies ............................................................ Section 3
OCTOBER 1995
Return
40-00-1
40-00-2
Return
OCTOBER 1995
Section 1.
Specifications
OCTOBER 1995
Return
40-01-1
Group 12 - BATTERY
Maximum Size and Rating
RCX 25/30C
RCX 30
RCX 35
RCX 40,45,50
36V
36V
36V
36V
18 cell, 11 plate
18 cell, 13 plate
18 cell, 15 plate
18 cell, 17 plate
27.0 kWh
32.2 kWh
37. 6 kWh
43.0 kWh
Fully Charged:
1.275 specific gravity (1.3010 Exide Load Hog)
Discharge:
1.120 specific gravity
Recommended Battery Fluid: Distilled water only
Battery Compartment Size
RCX
Length
Width
Height
RCX 25/30C
13.88 in
38.80 in
31.50 in
RCX 30
16.13 in
38.80 in
31.50 in
RCX 35
18.38 in
38.80 in
31.50 in
RCX 40,45,50
20.75 in
38.80 in
31.50 in
WIRE CODE
Color Code
Black
Brown
Red
Orange
Yellow
Green
Blue
Violet
Gray
White
40-01-2
Return
0
1
2
3
4
5
6
7
8
9
Example
Wire no. 13 is a brown stripe on an orange wire.
Wire no. 33 is a solid orange wire.
OCTOBER 1995
Drive Motor
Weight:
54 lb (24.5 kg)
Brushes:
Dimension
Grade
CM880
Worn Length
Weight:
43 lb (19.3 kg)
Brushes:
Dimension
Grade
CM880
Worn Length
0.420 in.(10.65mm)
on longest side.
11.5-12.6oz(326-357g)
When below
Weight:
93 lb (42.2 kg)
Brushes:
Dimension
Grade
CM880
Worn Length
OCTOBER 1995
Return
40-01-3
FUSES:
Fuse
Rating
Function
1FU
2FU
500 amp
15 amp
CONTACTORS:
Function
Rating
Coil Resistance
1A
150 amps
19.55 ohms
For.&Rev.
150 amps
19.55 ohms
Steering
100 amps
49 ohms
Cold Storage DC
100 amps
29 ohms
Pump
150 amps
20 ohms
Pneumatic -
2000psi(13,790kPa)
RCX 40,45,50
2300psi(15,858kPa)
Group 23 - BRAKES
Brake System: Spring Applied, Hydraulic Released
Recommended Brake Fluid:
Heavy-duty hydraulic brake fluid.
Refer to Lubrication Chart in Group 01.
Master Cylinder:
40-01-4
Return
0.75 in diameter
OCTOBER 1995
Temperature
Drift
80F (26.7C)
100F (37.8C)
120F (48.9C)
OCTOBER 1995
Return
40-01-5
Group 34 - Uprights
Upright Speeds:
Nominal performance for Upright at cut-off MFH
Check with hydraulic fluid at operating temperature 110 to 130F (43.3 to 54.4C).
Lifting
ft./min
Lowering
ft./min
RCX
25,30C,30
Loaded:
63
95
Empty:
101
RCX 35
Loaded:
Empty:
Loaded:
55
95
Empty:
101
80
Loaded:
N/A
N/A
Empty:
N/A
N/A
Loaded:
N/A
N/A
Empty:
N/A
N/A
RCX 40
RCX 45
RCX 50
Lifting
ft./min
Lowering
ft./min
Loaded:
60
85
80
RCX
25,30C,30
Empty:
93
85
59
95
RCX 35
Loaded:
56
85
101
80
Empty:
93
85
Loaded:
52
85
Empty:
93
85
Loaded:
44
60
Empty:
70
65
Loaded:
42
63
Empty:
70
65
RCX 40
RCX 45
RCX 50
Test Load: a capacity load evenly distributed on lift forks. (If a pallet is used, load should not
extend beyond pallet. Load Should be stacked to provide maximum stability.) Forks must
completely engage load and be adjusted as wide as possible to provide even distribution of
weight.
40-01-6
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OCTOBER 1995
Group 40 - Specifications
RATED LOAD CAPACITY AT LOAD CENTER:
RCX 25
2500 lbs @ 24 in (1134 kg @ 600 mm)
RCX 30C
3000 lbs @ 24 in (1360 kg @ 600 mm)
RCX 30
3000 lbs @ 24 in (1360 kg @ 600 mm)
RCX 35
3500 lbs @ 24 in (1590 kg @ 600 mm)
RCX 40
4000 lbs @ 24 in (1815 kg @ 600 mm)
RCX 45
4500 lbs @ 24 in (2041 kg @ 600 mm)
RCX 50
5000 lbs @ 24 in (2268 kg @ 600 mm)
NOTE:
Rated capacity applies when using uprights with maximum MFH up to and including:
Clear-View STD 151 in. (3835 mm) Clear-View TSU 152 in (3875 mm)
TRUCK WEIGHTS
Approximate, with typical upright:
25
8425
50
10686
Axle Loading
Front
With load (lb)
25
8911
30C
9975
30
35
40
45
50
25
30C 30
9987 10878 11731 12507 13673 2014 1757 2068
Front
Without load (lb)
25
4266
30C
4404
Rear
With load (lb)
30
4527
OCTOBER 1995
Return
35
4659
35
2040
40
2021
45
2064
50
2013
45
5257
50
5580
Rear
Without load (lb)
40
45
50
25
30C 30
4779 4814 5106 4159 4331 4528
35
4758
40
4973
40-01-7
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Section 2.
Data Plate
OCTOBER 1995
Return
40-02-1
40-02-2
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OCTOBER 1995
1. Model Number
2. Type Construction: E, or EE.
3. Truck Serial Number
4. Truck Attachment if
Number)
any.
(Name
or
WARNING
OCTOBER 1995
Return
40-02-3
40-02-4
Return
Minimum
1280 lb.
(581 kg)
1590 lb.
(721 kg)
1885 lb.
(855 kg)
2175 lb.
(987 kg)
2454 lb.
(1116 kg)
1845 lb.
(837 kg)
2454 lb.
(1116 kg)
Maximum
2005 lb.
(909 kg)
2005 lb.
(909 kg)
2290 lb.
(1039 kg)
2645 lb.
(1200 kg)
3025 lb.
(1372 kg)
3025 lb.
(1372 kg)
3025 lb.
(1372 kg)
OCTOBER 1995
Section 3.
OCTOBER 1995
Return
40-03-1
Lubricants
Transmission Fluid Specifically Recommended:
H200, H210 and H211
HR500 and HR600
TA-12 and TA-18
This product provides proper frictional characteristics, superior wear protection for gears, excellent
water tolerance to avoid excessive foaming and rusting within the system, good filterability, and low
temperature fluidity. These fluids meet CMHC MS-276A and the requirements for the following:
John Deere Quatrol Q-4
Allison C-3
Caterpillar TO-2
International Harvester Hy-Tran B-6
40-03-2
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OCTOBER 1995
Hydraulic Fluid
BT Prime-Mover premium anti-wear hydraulic fluid is tailored to meet the special requirements of BT
Prime-Mover hydraulic systems. BT Prime-Mover hydraulic fluid will not oxidize to form sludge and
guards against rust by plating all metal parts with a film that is impervious to moisture. It stands up to
high-heat ranges and pressure and protects precision-tuned parts against abnormal wear. Above all,
it is compatible with the chemistry of the seals, packings, and hoses so it cannot cause deterioration
of these vital components. Every hydraulic fluid formulated for BT Prime-Mover hydraulic systems
must pass strict tests complying the BT Prime-Mover specification MS-68 which calls for an antiwear additive plus many other properties. This fluid also meets the stringent requirements of
Denison HF-2 and Lee Norse 100-1 specifications.
Transmission/Converter Fluid
BT Prime-Mover transmission-converter fluid is compounded with the special properties required for
BT Prime-Mover torque converters and automatic transmissions. This superior fluid has been
developed to meet General Motors' DEXTRON II specifications and equals or exceeds all
requirements for Type A Suffix A automatic-transmission oil. Genuine BT Prime-Mover transmissionconverter fluid flows freely in low temperatures, yet resists high temperatures, pressure, and
oxidation while preventing corrosion and seal deterioration.
Super Heavy-Duty Brake Fluid
BT Prime-Mover Super Heavy-Duty Brake Fluid protects the vital metal and rubber components
found in your equipment's brake system. It is non-corroding and lubricates all metal parts while
keeping the rubber parts from shrinking or becoming brittle. To insure quality performance, Federal
regulations VV-H-91Oa Amendment I and SAE specifications 70R1, 70R3, and J70B are surpassed
by BT Prime-Mover Super Heavy-Duty Brake Fluid.
Anti-Seize
Lubricates to protect against galling, pitting, and corrosion on equipment subject to temperature
extremes (up to 2000F [1093C]) or in corrosive applications. Assures easy disassembly of
components. Use for wheel lug nuts and fasteners, upright and frame mounting bolts and in
corrosive environments.
Superlube Synthetic Lubricant With Teflon
Multipurpose lubricant for machinery and equipment. Compatible with other lubricants and is safe on
metal, rubber, plastics, wood, leather and painted surfaces. For cables, hinges, locks, linkages,
gears, and pulleys.
Lubriplate
A white grease for bearings, Lubriplate withstands high temperatures and increase the life of
bearings.
Spray Lube
Spray Lube is easy to apply to open gears and reaches hard-to-get places. It acts as a rust
preventive and does not drip off.
Innerslide Lubricant
This lubricant is a "dripless" grease, ideal for sliding tandems and fork trucks. Cuts greasing time,
prevents rust and provides constant lubrication to minus 60F (minus 51C).
OCTOBER 1995
Return
40-03-3
Sealants
Battery Saver
Battery Saver preserves battery power by retarding acid action, preventing corrosion, and sealing
vibration cracks.
Spray-Kote
Spray-Kote renews, insulates, and protects. It seals electrical wires and keep them pliable while
preventing rust and corrosion. Resists extreme heat or cold and requires no pre-cleaning before use.
Conquer-3
Conquer-3 is a water dispersive and corrosion preventive that protects against oxidation. It displace
water and moisture, even from wet insulation, and leaves a protective film. Excellent for protecting
SCR control panels.
GE Silicone
Protects SCR's by weatherproofing and sealing while resisting chemicals, oils, and solvents.
Mechanical Paste Lubricant
Protects motor, solid state control cable and wire (screw-on type) connections against corrosion.
Dielectric Tune-Up Grease
Protects electric connections and wiring from salt, dirt, and corrosion. Extends the life of the bulb
sockets. Prevents voltage leaks around any electrical connection. Also prevents spark plugs from
fusing to boots. Use in extremely dusty, dirty, or corrosive applications.
Silicone Adhesive Sealant
General purpose, clear RTV indoor/outdoor sealant. Seals, bonds, mends, and secures glass, metal,
plastics, fabrics, vinyl, and weather-stripping. Protects electrical wiring. Waterproof and flexible. Seal
windows, electrical connections, vinyl top, and seams.
Mechanical Lubricant Kit
Excellent for cold storage applications. Protects control panel connections (contactor, drive and
steer), PL and DP plug connections, wire terminal screws against corrosion.
40-03-4
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OCTOBER 1995
Gasket Materials
Gasketmaker
Flexible, non-corrosive gasketing material for use on rigid machined flanges with less than .010 in.
(.255mm) gap. Use where "anaerobic" (cures in the absence of air) gaskets are specified. Seals
transmission cases, transsexual castings, water pumps, and other rigid covers and plates.
Gasket Remover
Quickly removes baked-on gaskets and all types of gasket adhesives. Prepares metal parts for new
gaskets and assembly. For all metal parts.
Ultra Blue
High performance, oil resistant RTV silicone. Low odor, low volatility. Eight times more flexible than
cork/composite gaskets and three times more oil resistant than other silicones. Forms in-place
gaskets on valve covers, oil pans, intake manifold and seals, timing covers, water pumps, and
thermostat housings. Use as a gasket dressing to upgrade conventional metal and pre-cut gaskets.
Hi-Temp TRV Silicone
For very high temperature applications. Replaces cut gaskets. Makes reliable formed-in-place
gaskets that resist cracking, shrinking, and migrating caused by thermal cycling. The temperature
range is -75F to 650F (-60C to 343C). Form in-place gaskets on valve covers, oil pans, intake
manifolds and seals, timing covers, water pumps, and thermostat housings. Use to coat pre-cut
gaskets to increase reliability.
Form-A-Gasket No. 2
Slow drying, non-hardening sealant designed for sealing cut gaskets and stamped parts. Allows for
easy disassembly if required. Use where sealing is more important than adhesion. Temperature
range is -85F to 400F (-65C to 204C). For valve-cover gaskets and oil-pan gaskets.
Form-A-Gasket No. 3
Slow drying, non-hardening sealant for close fitting machine surfaces. Temperature range is -65F to
400F (-54C to 204C). Use for sealing hoses and as a cut gasket dressing.
High Tack_ Spray-A-Gasket
Fast drying adhesive for holding gaskets in place during assembly and sealing. Remains effective
under extreme temperature of -65F to 450F (-54C to 232C). Holds and seals all felt, cork, metal,
paper, rubber, and asbestos gaskets.
Cooper Spray-A-Gasket
Fast drying, metallic-copper sealant helps dissipate heat, prevents gasket burnout and improves
heat transfer. Fills minor surface irregularities and seals instantly. Temperature range is -50F to
500F (-46C to 260C). For cylinder head gaskets, carburetor gaskets, exhaust manifold gaskets,
and other high-temperature applications.
OCTOBER 1995
Return
40-03-5
40-03-6
Return
OCTOBER 1995
Cleaners
Penetrating Oil
An easy-to-use penetrating oil that cuts rust, paint, and grease and is effective on hot surfaces.
Saves time, labor, and broken parts; contains Moly.
Degreaser
This easy-to-use degreaser is water soluble, safe for paint, and does not rust.
Brake Cleaner
This brake cleaner provides fast, complete cleaning, removing oil, dirt, and grease, leaving no film. It
is non-flammable and can be used on brake parts, and electrical and ignition accessories. An
effective, thorough, safe, and economical parts cleaner.
Locquic Primer N
Degreases oil parts and speeds the curing of "anaerobic" products such as threadlockers, pipe
sealant, bearing mount, and gasket maker. Recommended for cold weather use and quick repairs.
Use with anaerobic products to speed assembly in all applications.
Brake and Parts Cleaner
Quickly dissolves and removes oil, grease, brake fluid, and oxidized oils. Dries fast without leaving a
residue and is non-corrosive.
Enviro-Safe Brake and Parts Cleaner
Environmentally safe formula. Biodegradable natural citrus solvents dissolve and remove oil and
grease from brake systems and metal parts. No CFC's or chlorinated solvents. Low toxicity.
Prussian Blue
Aids precision fitting of machined surfaces. Locates high spots on bearings, valves, gears, and other
close-to-tolerance components. Non-drying and easy to clean up.
OCTOBER 1995
Return
40-03-7
Return
Return
PROUDLY
Made in AMERICA
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