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Electrical System Troubleshooting

PS

S5.4

5460

F-code

Section

C-code

Version no

T-code

001

OE35

199

Service Manual

1996-10-15

© BT Products

Electrical Syste
Troubleshooting

Troubleshooting can be broken down into Control Circuits
and  Power  Circuits.  By knowing the  exact  symptoms  of the
truck  operation,  many hours  of  troubleshooting time can be
saved. If the proper contactor operates for the chosen
direction and  speed  then  the  problem  can  be  found in the
Power Circuits troubleshooting procedures. If a particular
contactor  does  not  operate  when  a  function is chosen  then
the problem can be found in the Control Circuits
troubleshooting procedures.

To use this troubleshooting guide go to the appropriate
section, and locate the symptom that best describes the truck
operation. Follow the instructions for the tests that are
outlined. All tests, unless otherwise specified, instruct the
technician to test for battery voltage at a particular point. If the
proper voltage is present, continue with the next point in the
testing procedure. If the voltage is not present, or if the
voltage is too low, perform the repairs listed directly below the
test procedure.

Voltage tests are made with the negative lead of the volt
meter connected  to  battery  negative.  If  the negative lead is
connected to a negative terminal on the  electrical panel you
must verify the negative connection to the battery by touching
the positive meter lead to the positive battery post. The
battery voltage must be at least 25.2 volts for a 24 volt
system,  37.8  for  a 36  volt system.  If  the battery voltage is
below 22 volts (24 volt system) and 33 volts (36 volt system)
(with no load) then the controller may not operate properly.
You will then have to charge the battery before starting the
troubleshooting procedure.

When testing voltage the “positive side” of any component
refers to the terminal on that component that is closest
electrically to the to the battery

positive terminal.

The

“negative side” of any component refers to the terminal on
that component that is farthest electrically from the battery. It
is possible, and in many cases desirable, to measure battery
voltage on the negative side of a component.

“Forward” direction refers to travel with forks trailing.
“Reverse” direction refers to travel in the fork direction.

Return

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Summary of Contents for OE35

Page 1: ...operating it DO NOT operate this equipment unless all factory installed guards and shields are properly secured in place WARNING WARNING Part no 301460 003 Date January 29 1998 OE35 Electric Counterbalanced Order Selector Effective Serial Number OE35027319000 Return ...

Page 2: ...Return ...

Page 3: ...orksheet standard W Code Working code R Code Reason code SO Code Assortment C Code List No Function Group C Code 0 Chassis 0000 1 Drive Motor 1000 2 Drive Gear Transmission 2000 3 Brake Wheel System 3000 4 Steering System 4000 5 Electrical System 5000 6 Hydraulic Pneumatic System 6000 7 Operating Function lifting Mast Cylinders 7000 8 Peripheral Installation Equipment 8000 9 Optionals Attachments ...

Page 4: ...000 Version no T code F code Section C code BT Standard Codes 2 Service Manual 1997 07 15 Return ...

Page 5: ...ication 25 Conversion of Metric and English Units 31 Technical Service Data 33 Ordering Spare Parts 37 Service Schedule 39 Planned Maintenance Schedule 39 Planned Maintenance Procedures 43 Services to be performed daily or at each 8 hour operating shift 43 Services to be performed monthly or every 250 operating hours 45 Services to be performed annually or every 1200 operating hours 48 Lubrication...

Page 6: ...and Troubleshooting 77 When Changing Brushes 82 Transmission 83 System description 83 Troubleshooting 83 Removal 84 Transmission Disassembly Assembly 87 Disassembly 88 Installation 95 Drive Wheel 97 Load Wheels 99 Stabilizing Caster Spring Loaded 101 Removal 102 Inspection 104 Disassembly 105 Torque Generator 107 Disassembly 109 Assembly 114 Steering System Pump 121 General Information 122 Removal...

Page 7: ...isplay 155 General Information 155 Location 156 Operational Checks 156 Status Codes 157 EV100 LX Control Status Codes 159 SCR Component Checks 177 Main Logic Card 177 Capacitor 1C 178 Contactors Forward Rearward 1A Power Steering and Pump 178 Potentiometer in Accelerator 178 SCR s 1REC 2REC 5REC 178 Rectifiers 3REC 4REC Diode Blocks 180 Thermal Protector TP 180 Filter Block 23FIL etc 181 Filter Bl...

Page 8: ... Disassembly 220 Assembly 222 EV100 Handset Operation 225 General Information 225 Purpose 226 Operation 227 Function Set Up Procedures 228 Description and Location 230 Function Numbers for Controllers 231 Hydraulic System 239 Hydraulic Schematic 239 General Information 240 Maintenance 242 Adjustments 242 Hydraulic Troubleshooting 243 Troubleshooting Chart 243 Lift Pump Assembly 247 Removal 248 Dis...

Page 9: ...ge 287 Micro 70 Wire Guidance Important Information 291 Powering Up 291 Powering Down 291 Micro 70 Wire Guidance 293 Electrical Schematic Part 1 293 Electrical Schematic Part 2 294 Electrical Schematic Part 3 296 Electrical Schematic Part 4 298 Cautions and Warnings 300 Operation Information 302 Component Function and Relationship 306 Truck Set Up On Site 308 Troubleshooting Information 311 Troubl...

Page 10: ... BT Products 8 Table of Contents Return ...

Page 11: ...n on the risks describe the consequences and instruct how to avoid accidents DANGER Warns that an accident will occur if you do not follow the instructions The consequences are serious personal injury or possibly death and or extremely large material damage WARNING Warns that an accident can occur if the instructions are not followed The consequences are serious personal injury or possibly death a...

Page 12: ...If open flames are used in situations where open flames are prohibited a serious accident can occur GENERAL PROHIBITION If the prohibition is ignored a serious accident can occur 1 Ordinance Symbols SAFETY SHOES When the directive for safety shoes is given safety shoes shall always be worn to avoid personal injury PROTECTIVE GLASSES When the directive for protective glasses is given protec tive gl...

Page 13: ...al is missing from the truck a new manual may be obtained by contacting BT Prime Mover Inc 3305 N Highway 38 Muscatine Iowa 52761 8800 319 262 7700 This service manual is not a training manual The information contained in this service manual is intended as a guide to help authorized technicians safely service this truck The Service Manual is divided into four separate sections which cover differen...

Page 14: ...M 000 Version no T code F code Section C code Introduction Service Manual 12 Service Manual 1997 07 15 Return ...

Page 15: ...M F code Section C code Version no T code 001 BT Products 13 Service Manual 1997 07 15 Contents Section M 1 Machine Information M1 0 GENERAL PRODUCT INFORMATION M2 0 TECHNICAL SERVICE DATA M3 0 ORDERING SPARE PARTS Return ...

Page 16: ...M 001 Version no T code F code Section C code Contents Section M 14 Service Manual 1997 07 15 Return ...

Page 17: ...ties of 3000 lbs review data plate on the truck to note the maximum lifting capacity These trucks are equipped with a 24V or optional 36V electrical system and the speed is regulated by means of a SCR controller to provide gentle control of acceleration and speed while operating The forks are raised by means of an electric powered hydraulic pump unit Both raising and lowering are done electrically...

Page 18: ... technical data which is of value with daily use of the trucks The truck s lifting capacity and weight can be found on the truck s data plate Truck data 24Volt 35 Volt Lifting capacity rated load lb Up to 3000 lb Lift height inches Up to 300 in Operating speed without load mph Below 24 in 24 in to 150 in 151 in and 225 in Above 225 in 5 4 mph 2 5 mph 1 0 mph 0 mph 5 8 mph 2 5 mph 1 0 mph 0 mph Ope...

Page 19: ...vice Manual 1997 09 24 1 4 OE35 Dimensions The following diagram shows external dimensions for the OE35 truck in its standard design 2 0 33 0 41 0 OALH 58 2 76 0 2 Stage 77 0 3 Stage 2 5 7 5 27 0 36 0 60 0 Picking Height 76 0 or 80 0 42 0 24 0 Minimum 30 0 Maximum 4 0 70 Turning Radius Fork Length Return ...

Page 20: ...ram shows the data plate used on the truck Legend 1 Truck model number 2 Truck serial number 3 Truck capacity 4 Mast serial number 5 Attachments 6 Truck type 7 Truck weight less battery 8 Back tilt degree NOT USED ON THIS TRUCK 9 Minimum battery weight 10 Maximum battery weight 11 Battery maximum AMP hours 12 Battery voltage 13 Battery type Return ...

Page 21: ...E35 BT Products 19 Service Manual 1997 09 24 1 6 U L Construction Type Know the U L construction type of this truck and make certain that trucks of this type may be operated in restricted areas before you enter Never take an unauthorized truck in restricted or hazardous areas Return ...

Page 22: ...ter key switch is turned on to start trucks operation 7 Steering direction indicator Displays the direction the transmission is headed 8 Fork lower switch The forks will lower when switch is pressed or until lower stops are reached 9 Fork raise switch The forks will raise when switch is pressed or until lift stops are reached 10 Horn switch The horn sounds to warn others of your position 11 Hydrau...

Page 23: ...nly 19 Electronics All the electronics are collected in a protected compartment 20 Circuit circuit fuses 15A BT Control fuse part number 201324 400A 24 volt BT Pump fuse part number 25094 03 300A 36 volt BT Pump fuse part number 25094 04 300A BT Drive fuse part number 25094 04 21 Travel speed direction selection To select direction rotate in the direction you wish to move The further in that direc...

Page 24: ...M1 0 000 OE35 Version no T code F code Section C code General Product Information 22 Service Manual 1997 09 24 Main Components Chart 13 17 1 2 3 7 10 11 12 15 16 16 18 18 19 20 21 22 6 4 8 9 14 5 23 Return ...

Page 25: ... are several standards used by these countries in the manufacture of threaded fasteners Many of these fasteners are similar but cannot be used as direct replacements Service persons must use replacement fasteners that have the same specifications Fasteners made to each specification have identification marks for that specification This specification is commonly called grade for SAE standards and p...

Page 26: ...lature and only the UNC Unified National Coarse or UNF Unified National Fine is shown This number of threads per inch is not shown because a UNC or UNF fastener has a standard number of threads per inch for a specific diameter The length of a shank is often indicated as part of the description of a fastener This length is shown in inches for inch fasteners and in millimeters for metric fasteners A...

Page 27: ...often not marked Grades for inch bolts go from 2 to 8 Grade 2 fasteners normally do not have marks The following tables show the marks that identify the grades and property classes for different fasteners When fasteners must be replaced the new fasteners must be of the same strength or greater than the original fasteners The new fasteners must also be the correct size WARNING NOTE Identification m...

Page 28: ...h Levels SAE Grades Metric Fasteners Strength Levels Property Classes Markings Not Required Markings Hex Head Bolts Cap Screws Hex Hea Flange Screws Same As Above 12 Point Flange Screws Markings Not Required Hex Socket Head Cap Screws SEMS for size M5 and Larger 2 5 5 2 7 8 5 8 5 8 5 1 4 8 9 8 8 8 12 9 4 6 4 8 5 8 8 8 9 8 10 9 12 9 4 6 4 8 5 8 8 8 9 8 10 9 12 9 8 8 12 9 4 8 9 8 Return ...

Page 29: ...ired Metric Fasteners Strength Levels Property Classes Markings Not Required 5 Studs 5 2 8 8 1 Markings Not Required Markings Not Required Hex Nuts Hex Slotted Nuts Hex Flange Nuts 2 5 8 or or 5 8 9 10 12 5 8 9 10 12 5 8 9 10 12 5 8 9 10 12 5 8 9 10 12 5 5 8 8 9 9 12 12 10 10 or 4 6 4 8 5 8 8 8 9 8 10 9 12 9 Optional Geometric Symbols for Size M5 through M11 ONLY Markings for size M5 and Larger 4 ...

Page 30: ... Manual 1997 09 24 Table 3 Torque Nut Designations Types of Fasteners Inch Fasteners Strength Levels SAE Grades Metric Fasteners Strength Levels Property Classes All Metal Pre vailing Torque Nuts or or or All Metal Pre vailing Torque Flange Nuts B A C B C 5 9 10 9 10 F G 5 9 10 9 10 Return ...

Page 31: ...le 4 Torque Nut with Nylon Insert Designations Types of Fasteners Inch Fasteners Strength Levels SAE Grades Metric Fasteners Strength Levels Property Classes Markings Not Require Markings Not Required Nylon Insert Pre vailing Torque Nuts Nylon Insert Pre vailing Torque Flange Nuts or 9 10 9 10 5 9 10 5 9 10 or or or Return ...

Page 32: ...rs of property class 12 material Size and Pitch Property Class 8 8 Property Class 10 9 Property Class 12 9 N m in lb N m in lb N m in lb M5 x 0 8 M6 x 1 M8 x 1 25 5 6 8 10 20 25 44 53 71 88 177 221 7 8 12 14 30 35 62 71 106 124 8 10 14 16 71 88 124 142 N m ft lb N m ft lb N m ft lb M8 x 1 25 M10 x 1 5 40 45 30 33 60 65 22 26 44 48 34 40 70 75 26 30 52 55 M12 x 1 75 M14 x 2 70 80 110 125 30 33 52 5...

Page 33: ...ards 0 914 meters m meter 1 094 yards yd miles 1 609 kilometers km kilometer 0 621 miles mi MASS Multiply By To Get Multiply By To Get ounces oz 28 49 grams g grams 0 035 ounces oz pounds lb 0 454 kilograms kg kilograms 2 205 pounds lb tons 2000 lb 907 18 kilograms kg kilograms 0 001 tons 2000 lb tons 2000 lb 0 907 metric ton t metric ton 1 102 tons 2000 lb POWER Multiply By To Get Multiply By To ...

Page 34: ...738 foot pounds ft lb VELOCITY Multiply By To Get Multiply By To Get miles hour 1 609 kilometer hour km h kilometer hour 0 621 miles hour mph VOLUME Multiply By To Get Multiply By To Get inches 16 387 centimeters cm centimeters 0 061 inches in inches 0 016 liters liters 61 024 inches in quarts U S 0 946 liters liters 1 057 quarts U S qt quarts U S 0 83 quarts Imp qt quarts Imp 1 205 quarts U S qt ...

Page 35: ...MISSION GEAR Type Double reduction Double reduction Gear ratio 14 1 14 1 Oil volume About 1 quart About 1 quart Normal temperature SAE 80W90 SAE 80W90 5oF 15 C ATF ATF WHEELS Drive wheel 102 in x 5 in x 62 in 102 in x 5 in x 62 in Drive wheel weight without load with battery lb Drive wheel weight with rated load and battery lb Torque axle Screw 125 ft lb 125 ft lb Load wheel 4 in x 6 in 4 in x 6 i...

Page 36: ...2 30 oz Part number 200075 301492 000 HYDRAULIC SETTING Lifting pressure at rated load 2400 psi 2400 psi Steering relief valve setting 850 psi 850 psi Brake relief valve setting 180 psi 180 psi Pump flow Tank volume 7 3 gal 7 3 gal Normal temperature Sunoco TH Sunoco TH 10 F 23 C Texaco 15 Texaco 15 FUSES Pump circuit fuse 400 Amp 400 Amp Drive circuit fuse 300 Amp 300 Amp Control fuse 15 Amp 15 A...

Page 37: ...hout load 2 Stage slow speed fast speed 35 44 fpm 54 67 fpm 35 44 fpm 54 67 fpm Lift without load 3 Stage slow speed fast speed 34 42 fpm 50 62 fpm 34 42 fpm 50 62 fpm Lift with rated load 2 Stage slow speed fast speed 25 31 fpm 33 41 fpm 25 31 fpm 33 41 fpm Lift with rated load 3 Stage slow speed fast speed 24 30 fpm 32 40 fpm 24 30 fpm 32 40 fpm Lower without load 2 Stage slow speed fast speed N...

Page 38: ... 180 Amp 260 Amp 180 Amp 260 Amp Lifting with load 2 Stage slow speed fast speed 285 Amp 480 Amp 285 Amp 480 Amp Lifting with load 3 Stage slow speed fast speed 290 Amp 520 Amp 290 Amp 520 Amp Steering motor Not steering Pump at relief 20 Amp 60 Amp 20 Amp 60 Amp MODEL 24 Volt 36 Volt NOTE Performance may vary up to 10 due to motor and system efficiency tolerance The performance shown represents n...

Page 39: ...mber 3 Locate the page with the exploded diagram and find the position number for the part you require 4 Locate the position number in the table Select the column for the actual machine model and serial number 5 Note the part number 6 Call the local BT dealer and state the part number If you cannot find the machine model serial number or the article number call the local BT dealer and he will help...

Page 40: ...PS M3 0 000 Version no T code F code Section C code Ordering Spare Parts 38 Service Manual 1997 07 15 Return ...

Page 41: ...Double shift 6 am 2 pm 2 pm 10 pm 50 hours per week usage Triple shift 6 am 2 pm 2 pm 10 pm 10 pm 6 am 75 hours per week usage The schedules are intended only as a guide not as a rigid structure Operators of trucks may wish to adapt them to local requirements but it is emphasized that the schedules represent minimum manufacturer requirements and all items should be included in a service program to...

Page 42: ...PS P1 0 000 Version no T code F code Section C code Introduction Maintenance 40 Service Manual 1997 07 15 Return ...

Page 43: ...tors operational X 0640 2 Check that the horn button is operational X 0640 3 Check that the hydraulic buttons are operational X 0840 Driver s Protection 0840 1 Check that the emergency stop button is operational X 0840 2 Check that the start button is operational X 0840 3 Check that all shields and guards are secure and install correctly X 1700 Drive Motor 1700 1 Check for arcing due to poor conne...

Page 44: ...10 3 All cell and link covers intact X 5110 4 Check battery specific gravity X 5200 Instrument Panel 5200 1 Check battery indicator and hourmeter for correct operation X 5300 Electrical Control System 5300 1 Check key switch X 5300 2 Check brake switch X 5300 3 Check power cables and control wiring harness for proper routing X 5400 Electrical Panel 5400 1 Cleaning and mounting to chassis X 5400 2 ...

Page 45: ...000 4 Check correct oil level X 6000 5 Change the hydraulic oil X 7310 Lift Cylinder 7310 1 Check for leakage X 7310 2 Check mounting X 7310 3 Lube all grease fittings X 7400 Lifting device 7400 1 Check the clearance of the forks X 7400 2 Check the forks for damage and cracks X 7400 3 Check the forks for wear and cracks X 7400 5 Lube all grease fittings X ITEM WORK REQUIRED Interval in Hours 5 25 ...

Page 46: ...PS P2 0 000 OE35 Version no T code F code Section C code Service Schedule 44 Service Manual 1997 10 21 5110 1700 2550 0000 0640 3100 3500 4100 5200 5300 5400 5710 6000 7310 7400 Return ...

Page 47: ...mately responsible for the safe operation of the truck 1 1 Battery Discharge Indicator with slow down The battery guard indicates the current charge status of the truck s battery 1 Full charge battery 1 2 Half charged battery 0 Discharged battery The battery guard has an integrated cut out function that cuts out the truck s lift function when a predetermined charge level has been reached This prev...

Page 48: ... All shields must be in place and functional Report any problems to the proper authorities DO NOT operate the truck until it has been inspected and repaired by a qualified technician 1 5 Wheels Tires Inspect wheels and tires for wear and damage Trash that is wrapped around wheels and axles will cause premature tire wear and bearing damage The floors should be kept clear of trash to prevent damage ...

Page 49: ...ocedure should be more thorough and minor deficiencies should be corrected 2 2 Transmission Inspect for oil leakage 2 3 Brakes The brakes should stop a fully loaded truck at full speed in approximately one truck length 2 4 Battery Contact your battery dealer for specific instructions on care and maintenance of the battery An average battery will have a specific gravity of 1 170 at the 80 discharge...

Page 50: ...ting or burning Minor pitting of the tips is not a problem However if the tips are pitted through the tip to the copper bar the tips should be replaced DO NOT file tips Replace tips only in complete sets Some contactors have concealed tips or are fully sealed so that tips cannot be replaced 2 7 Motor Brushe Minimum brush lengths are given in the specifications section of this manual As a rule of t...

Page 51: ...wn and Chassis lubricating grease The total number of grease fittings depends on the truck options when built A truck with a cold storage freezer use or corrosive environment application package will have more grease fittings than a standard truck Look for flush type grease fittings on the load wheel axles Regular fittings may be found on the transmission mounting bearing and the mast chain sheave...

Page 52: ...ransmission fluid should be drained once a year The drain port is located on the lower portion of the side cover opposite the drive tire Remove the plug to drain the transmission fluid Flush the transmission case with safety solvent Pour clean safety solvent into the fill port on top of transmission case With drive tire off the floor allow solution to run out of drain port while transmission is ru...

Page 53: ...ge air from system Check oil level fill to line Put rated truck capacity load on forks and adjust pressure relief valve if necessary so that truck will lift rated load 3 5 Brakes The brake release cylinder should have 3 8 in to 1 2 in of travel The cylinder travel itself in non adjustable and the only brake adjustment is the aggressiveness Three allen head screws on transmission cover case adjust ...

Page 54: ...PS P2 0 000 OE35 Version no T code F code Section C code Planned Maintenance Procedures 52 Service Manual 1997 10 21 Return ...

Page 55: ...cation Chart L Lubrication C Check O Oil change Pos No Service Point Interval Running Hours Lubricant See Chart in Section 6 for Code 250 h 600 h 1200 h 1 Wheel bearings L A 2 Mast bearings L A 3 Lifting linkage L D 4 Hydraulic syste C O B 5 Steering bearings L A 6 Drive gear C O C 7 Drive gear drain 1 3 4 2 5 6 7 Return ...

Page 56: ...PS P3 0 000 OE35 Version no T code F code Section C code Lubrication Chart 54 Service Manual 1997 10 21 Return ...

Page 57: ...ion Application area 14 F 10 C 14 F 10 C 13 F 25 C A Grease Tex Ref C and C 880 Mobiltemp SHC 32 Mobiltemp SHC 32 Bearings and bushings B Hydraulic oil Sunoco TH ATF Texaco 15 Hydraulic system C Transmission oil SAE 80w 90 SAE 75w ATF Gears D Motor oil SAE 40 SAE5w 20 SAE5w 20 Chains E Grease Molykote 200025 Molykote 200025 Molykote 200025 Mast rails F Grease 49670 00 49670 00 49670 00 Mast rails ...

Page 58: ...PS P4 0 000 OE35 Version no T code F code Section C code Oil and Grease Specifications 56 Service Manual 1997 10 21 Return ...

Page 59: ...S 1 Service Instructions NO FUNCTION GROUP C CODE 0 CHASSIS 0000 1 DRIVE MOTOR 1000 2 DRIVE GEAR TRANSMISSION 2000 3 BRAKE WHEEL SYSTEM 3000 4 STEERING SYSTEM 4000 5 ELECTRICAL PNEUMATIC SYSTEM 5000 6 HYDRAULIC SYSTEM 6000 7 LIFTING MAST CYLINDERS 7000 8 PERIPHERAL INSTALLATION 8000 EQUIPMENT 9 OPTIONS ATTACHMENTS 9000 Return ...

Page 60: ...PS S 000 Version no T code F code Section C code Contents Section S 58 Service Manual 1997 04 15 Return ...

Page 61: ...S NO DESCRIPTION POS NO DESCRIPTION POS NO DESCRIPTION 7 Lockwasher 17 Panel dash 24 Rivet pop 9 Nut 18 Panel 25 Guard right spring 10 Channel Harness 19 Cable manual 26 Guard left spring 11 Shield back cover 20 Rivet pop 27 Shield front top 12 Screw socket head 21 Shield 28 Nut clip 13 Washer flat 22 Mat floor 14 Nut 23 Pocket manual Return ...

Page 62: ...platform 5 Remove windshield bracket and windshield 6 Remove steering wheel Use puller split bearing type 7 Remove retainer ring from steering shaft 8 Loosen steering chain stop 9 Remove chain from idler sprocket and steer indicator sprocket 10 Tap steering shaft 2 in toward front of truck 11 Loosen steer indicator idler sprocket bracket Remove beaded chain 12 Remove key switch by rotating lock on...

Page 63: ... 001 OE35 BT Products 61 Service Manual 1997 10 23 16 Open wire harness plug Push wires out of plug Use AMP tool 305183 17 Remove other handle bracket 18 Slide handle to right and remove 19 Remove three screws in bottom of dash panel Tip dash from bottom and remove Return ...

Page 64: ...PS S0 1 0340 001 OE35 Version no T code F code Section C code Inspection Covers 62 Service Manual 1997 10 23 Return ...

Page 65: ...n can be taken before a major component is damaged beyond serviceability The brushes and commutator should be inspected for even wear and good commutation 2 Operating Conditions Operating environment of lift truck motors varies widely The following recommendations should be applied as actual conditions dictate Normal Service Basically an eight hour day of indoor material handling Severe Service Ex...

Page 66: ...23 34 51 52 See Chattering or noisy brushes 55 57 59 50 Etched or burned bands on brush face Overcommutation Undercommutation Too rapid reversal of current 7 12 31 33 7 12 30 32 7 12 30 32 Pitting of brush face Glowing Embedded copper See Glowing at brush face See Copper in brush face Rapid brush wear Commutator surface condition Severe sparking Imperfect contact with commutator Wrong brush grade ...

Page 67: ...e 5 44 60 Eccentric surface 1 19 22 52 High commutator bar Sparking 17 Low commutator bar streaking or threading of surface Sparking Copper or foreign material in brush face Glowing 2 25 43 44 45 46 49 59 2 3 46 47 48 61 See Glowing at brush face Bar etching or burning Sparking Flashover 2 3 7 12 30 31 32 33 5 11 14 35 38 39 41 53 Bar marking at pole pitch spacing Sparking 25 37 Bar marking at slo...

Page 68: ...rly equalized parallel operation lack of ventilation 38 41 42 53 18 19 20 21 27 28 29 8 19 22 25 27 28 29 37 7 13 23 24 Heating at commutator Severe load condition Severe sparking High friction Poor commutator surface Depreciation High contact resistance 38 41 42 7 8 9 12 20 33 45 57 10 11 36 43 45 49 58 59 See specific surface fault in evidence 6 24 56 Heating at brushes Severe load condition Fau...

Page 69: ...t brush angle 11 Incorrect spring tension 12 Interpoles improperly adjusted 13 Series field improperly adjusted Mechanical Fault in Machine 14 Brushes tight in holders 15 Brushes too loose in holders 16 Brush holders loose at mounting 17 Commutator loose 18 Loose pole pieces or pole face shoes 19 Loose or worn bearings 20 Unequal air gaps 21 Unequal pole spacing 22 Dynamic unbalance 23 Variable an...

Page 70: ... Plugging 42 Dynamic braking 43 Low average current density in brushes 44 Contaminated atmosphere 45 Contact poisons 46 Oil on commutator or oil mist in air 47 Abrasive dust in air 48 Humidity too high 49 Humidity too low 50 Silicone contamination Disturbing External Condition 51 Loose or unstable foundation 52 External source of vibration 53 External short circuit or very heavy load surge 54 Comm...

Page 71: ...POS NO DESCRIPTION 1 Screw com clamp 11 Lockwasher 21 Pole main 2 Cover 12 Nut 22 Coil field 3 Screw retainer 13 Holder brush 23 Bearing 4 Shield com end 14 Brush 24 Retainer 5 Terminal 15 Spring 25 Armature 6 Washer 16 Screw brush 26 Shield drive 7 Bushing 17 Screw holder 27 Seal shaft 8 Gasket 18 Bushing 28 Screw clamp 9 Washer 19 Washer 29 Kit EE 10 Washer 20 Screw pole Return ...

Page 72: ...screws and remove plate to replace brushes Remove each brush from brush holder and inspect brushes and commutator for worn condition and uneven wear 4 The brush springs may be checked at this time for proper tension 5 Separate the armature and drive end head as an assembly from the frame and field coil stator 6 Separate the armature from the drive end head This operation is usually done by pressin...

Page 73: ...Check brush holders and springs for wear 2 3 Bearings 1 Check bearings by turning them with your fingers Feel for binding or gritty effects and excessive looseness or wobble A good bearing should also have a small amount of drag or stiffness caused by the lubrication but should turn smoothly If the bearing turns very freely it should be replaced Bearings should also be changed if worn out damaged ...

Page 74: ...rush springs Refer to the Brush Chart at the end of this section 2 5 Armature 1 Check security of fan 2 Check for loose commutator bars Loose commutator bars will usually be indicated by excessive wear or burning on one bar The commutator can be checked for loose bars by lightly tapping all of the bars with the handle of a plastic or wooden handled screwdriver A contrasting dull thud or vibration ...

Page 75: ...rred the serviceability of the coils is questionable Burned or charred insulation is a result of coil overheating due to overloading conditions grounded or shorted coil windings Check condition of all other insulation such as brush rigging under coil connections and around terminal studs 2 6 1 Testing Frame and Field Assembly After thorough inspection the Frame and Field Assembly should be checked...

Page 76: ...e presumed good 2 6 2 Frame and Field Service Notes If the inside of the motor is exceptionally dirty and there is evidence of a grounding condition caused by the dirt the inside of the motor can be given an additional coat of insulating varnish Red glyptol can be used if a better material is not available however we recommend using a class H Polyurethane air drying insulating varnish This is read...

Page 77: ...d with a soldering iron After field coil installation connect the solder joint making sure the solder is flowing properly to avoid a cold soldered joint Pole Shoe Screw Removal Installation Field Coil Removal Installation Continue assembly in the reverse of disassembly paying particular attention to the following points 2 7 2 Bearing Installation 1 Whenever ball bearings are pressed into an end he...

Page 78: ...uld be connected as specified in Troubleshooting and tested to the specifications When testing motors the voltmeter connections must be made at the motor terminals 3 When changing brushes When changing brushes the commutator must be serviced as follows Resurface the commutator by taking only light cuts each time 0 005 in 0 12mm If reslotting undercutting is necessary the final operation is to ligh...

Page 79: ...35 BT Products 77 Service Manual 1997 10 21 Drive Motor 36 Volt POS NO DESCRIPTION POS NO DESCRIPTION 1 coil field 8 Head commutstor end 2 Lead 9 Band head 3 Brush 10 Armature assembly 4 Spring brush 11 Fan 5 Plate brush 12 Head drive end 6 Ring retainer 13 Seal 7 Bearing Return ...

Page 80: ...ews and remove plate to replace brushes Remove each brush from brush holder and inspect brushes and commutator for worn condition and uneven wear 4 The brush springs may be checked at this time for proper tension 5 Separate the armature and drive end head as an assembly from the frame and field coil stator 6 Separate the armature from the drive end head This operation is usually done by pressing t...

Page 81: ...Check brush holders and springs for wear 2 3 Bearings 1 Check bearings by turning them with your fingers Feel for binding or gritty effects and excessive looseness or wobble A good bearing should also have a small amount of drag or stiffness caused by the lubrication but should turn smoothly 2 If the bearing turns very freely it should be replaced Bearings should also be changed if worn out damage...

Page 82: ...ed brush shunts Discolored brush springs 2 5 Armature 1 Check security of fan 2 Check for loose commutator bars Loose commutator bars will usually be indicated by excessive wear or burning on one bar The commutator can be checked for loose bars by lightly tapping all of the bars with the handle of a plastic or wooden handled screwdriver A contrasting dull thud or vibration will indicate a loose ba...

Page 83: ...bility of the coils is questionable Burned or charred insulation is a result of coil overheating due to overloading conditions or grounded or shorted coil windings Check the condition of all other insulation such as brush rigging under coil connections and around terminal studs 2 6 1 Testing After thorough inspection the Frame and Field Assembly should be checked for grounded open or shorted circu...

Page 84: ... can be presumed good 2 6 2 Frame and Field Service Notes 1 If the inside of the motor is exceptionally dirty and there is evidence of a grounding condition caused by the dirt the inside of the motor can be given an additional coat of insulating varnish Red glyptol can be used if a better material is not available however we recommend using a class H Polyurethane air drying insulating varnish This...

Page 85: ...tions should then be tinned with a soldering iron 2 After field coil installation connect the solder joint making sure the solder is flowing properly to avoid a cold soldered joint Pole Shoe Screw Removal Installation Field Coil Removal Installation Continue assembly in the reverse of disassembly paying particular attention to the following points 2 7 2 Bearing Installation 1 Whenever ball bearing...

Page 86: ... Assembly 1 The motor should be connected as specified in Troubleshooting and tested to the specifications 2 When testing motors the voltmeter connections must be made at the motor terminals 3 When Changing Brushes When changing brushes the commutator must be serviced as follows 1 Resurface the commutator by taking only light cuts each time 0 005 in 0 12 mm 2 If reslotting undercutting is necessar...

Page 87: ... shaft The brakes are on the drive motor 2 Troubleshooting Because of the uncomplicated nature of this transmission troubleshooting is limited to identifying whether problems are mechanical or electrical in nature Fluid leaks are obviously mechanical in nature and can be found by visual inspection Unusual noise and or slow running could be mechanical or electrical in nature Generally speaking if t...

Page 88: ... NO DESCRIPTION 1 Screw cap 8 Lockwasher 15 Washer 2 Lockwasher 9 Screw cap 16 Bearing 3 Clamp 10 Bearing roller 17 Nut twin 4 Spacer 11 Eccentric adjuster 18 Switch 5 Ring retainer 12 Screw cap 19 Screw machine 6 Bracket 13 Washer flat 20 Nut jam 7 Frame main 14 Transmission 21 Fitting grease 1 2 3 4 5 6 7 10 11 12 13 14 15 16 17 18 19 20 21 9 8 Return ...

Page 89: ...lve to the filter Unbolt the control valve bracket from the truck frame Lay the control valve off to the side 8 Remove the brake cylinder from the transmission It is not necessary to disconnect the hydraulic hose 9 Raise and block the front of the truck for access under truck 10 Drain fluid from transmission 11 Put transmission in straight ahead position and mark the location of steering chain to ...

Page 90: ...5 Version noT code F code Section C code Transmission 88 Service Manual 1997 10 21 17 Remove retaining ring from pivot tube and remove pivot mounting bracket The pivot bearing outer race is pressed into the bracket Return ...

Page 91: ...eat spring 25 Pinion motor 2 Cover 14 Cover case 26 O ring 3 Shim 0 10 in 15 Screw set 27 Shaft 4 Nut 16 Nut 28 O ring 5 Case gear 17 Cover 29 Bearing 6 Pin dowel 18 Shim 0 010 in 30 Gear 7 Plate brake 19 Screw cap 31K Seal oil 8 Disc brake 20 Screw cap 32K Hub axle 9 Rod brake 21 Lockwasher 33K Locknut 10 Lever brake 22K Gear drive K Kit drive axle 11 Pin roll 23K Bearing 12 Spring 24 Bearing Tor...

Page 92: ...ve four motor mounting hollow hex key cap screws from the cover side of the transmission and remove the drive motor 4 Lay transmission on work surface with cover side up 5 Remove cover bolts and 1 2 in locknut from side cover 6 Use four threaded holes in cover with cover bolts to push cover off of dowels Apply pressure equally with all four pusher bolts Be extremely careful when working with solve...

Page 93: ...ting rod from over top of brake discs 9 Remove brake discs plates and retaining shafts 10 Remove axle locknut and nub from axle Remove axle from case Screw Locknut O ring Retaining Shaft Adjusting Rod O ring Roll Pin Spring Spring Seat Cover Shim Intermediate Gear Bearing Bearing Brake Lever Drive Motor O ring Bushing Brake Adjusting Rod Motor Adapter Motor Pinion Brake Separator Pads Brake Disc R...

Page 94: ...afety solvent and dry with compressed air 16 Inspect all gears for damage and wear 17 Discard all o rings and bearings New parts should be used during reassembly 18 Install the drive axle bearing races into the gear case Races should be installed with the smallest inside diameters back to back and tight against the snap rings 19 Press one bearing cone on the drive axle with the large diameter agai...

Page 95: ...nut on axle Torque locknut to 250 ft lb while rotating the axle 27 Press the intermediate gear bearing into the gear case Install the bearing cone and one 0 010 in shim Use Loctite 515 as sealant and use Loctite threadlock on the cover screws Do not install the intermediate gear at this time 28 Install the motor adapter and motor pinion gears on the drive motor armature shaft If new adapter and pi...

Page 96: ...f the separator plate The hub of the disc must be towards the motor down 36 Install a second separator plate over the brake disc 37 Place the second brake disc over the second separator plate Position this brake disc with the hub away from the drive motor Orient the disc so that the rivets are spaced between the rivets of the first disc at a 45 degree angle 38 Place the third separator plate over ...

Page 97: ...ever and separator plate to determine contact area d Tightening the nut will move the adjusting rod towards the drive motor and will move the contact area towards the brake lever pivot Incorrect adjustment will cause the brakes to drag or loss of braking force 43 Place three springs with spring seats into the three countersunk spring seat holes in the brake lever 44 Install the baffle in the botto...

Page 98: ...51 Install three spring adjusting hollow hex key screws Tighten the screw until they just touch the spring seats then 1 4 additional turn Install locknuts on screws 52 Install the bearing for the intermediate gear into the gear case cover The outer race must NOT be below the cover It may be flush with or above the cover 53 Place shims around bearings so that shims are flush with outer race 54 Inst...

Page 99: ...with shims and Loctite 515 The bearing cover must be shimmed so that it is 0 010 in above the outer bearing race Put shims around bearing so they are 0 010 in higher than the bearing 57 Fill transmission with about one quart of ATF Dextron II 58 Install the steering guide ring with six bolts and lockwashers Torque bolts to 50 ft lb 59 Install the drive wheel assembly to the hub with five bolts Tor...

Page 100: ...transmission in a straight ahead position during chain installation Adjust the chain tension for a maximum of 1 8 in side to side motion at the mid point of the chain between the transmission and the sprocket 10 Verify that the transmission will turn an equal amount in each direction 11 Lower truck to ground 12 Reinstall the brake cylinder onto transmission case Be sure that brake rod is lined up ...

Page 101: ...eel can be removed without removing the transmission by following these steps 1 Park truck on level surface and block truck from moving 2 Disconnect the battery 3 Hoist machine and securely block truck with drive tire about 1 in off floor 4 Remove lug bolts and remove tire and wheel assembly 5 Press drive tire 2 from wheel hub 3 Lug Bolts 1 2 3 Return ...

Page 102: ...00 Service Manual 1997 10 21 5 2 Installation 1 Press drive tire 2 onto wheel hub 2 This is usually done while pressing off old tire Press hub to center of tire 2 Install drive tire and hub on axle The drive tire lug bolts should be torqued to 125 ft lb 1 2 3 Lug Bolts Return ...

Page 103: ... so load wheels are approximately two inches off of the floor and securely block 3 Drive roll pin 5 further in support arm to allow nut 6 to be removed 4 Remove nut 6 axle 7 and load wheel assembly from support arm 5 Drive roll pin 5 from support arm 6 Inspect bearings 10 POS NO DESCRIPTION POS NO DESCRIPTION 5 Pin roll 9 Seal oil 6 Nut 10 Bearing 7 Axle 11 Wheel load 8 Fitting grease Return ...

Page 104: ...l 11 and bearing 10 as needed 7 Install load wheel assembly in support arm Slide axle 7 in support arm from outside and install nut 6 8 Tighten nut 6 only until all end play is removed from load wheel assembly Then turn nut 6 to closest slot that lines up with roll pin 5 hole and install roll pin 5 to lock nut 6 in place Return ...

Page 105: ... DESCRIPTION POS NO DESCRIPTION POS NO DESCRIPTION 1 Base plate 10 Lockwasher 19 Washer spacer 2 Bearing thrust 11 Screw 20 Bearing ball 3 Seal 12 Spring inner 21 Wheel 4 Frame 13 Spring outer 22 Frame wheel 5 Pin 14 Plate spring 23 Washer spacer 6 Washer 15 Bushing 24 Screw 7 Nut slotted 16 Washer shim 25 Bearing roller 8 Pin 17 Fitting grease 9 Cap hub 18 Axle caster Return ...

Page 106: ...rom operating 6 Remove four cap screws and nuts securing caster assembly to frame 7 Remove caster assembly from truck 8 Before disassembly thoroughly clean exterior of the caster assembly in a cleaning solvent to remove all contamination NOTE CLEANLINESS Perform procedures in a clean environment Make sure all parts are cleaned before disassembly and kept clean during assembly Be extremely careful ...

Page 107: ...ode Section C code Version no T code 001 OE35 BT Products 105 Service Manual 1997 07 15 Compressed air used for cleaning MUST be reduced to less than 30 p s i and then only with effective chip guarding and personal protective equipment WARNING Return ...

Page 108: ...and replace if needed NOTE CLEANLINESS Perform procedures in a clean environment Make sure all parts are cleaned before disassembly and kept clean during assembly Be extremely careful when working with solvent Even a small explosion or fire could cause injury or death WARNING Compressed air used for cleaning MUST be reduced to less than 30 p s i and then only with effective chip guarding and perso...

Page 109: ...5 Assemble caster in reverse order 3 1 Installation 1 Install caster assembly under truck and secure with cap screws and nuts 2 Lift truck and remove all blocking 3 Reconnect the negative wire to pump solenoid 4 Connect battery to truck 5 Close access door NOTE CLEANLINESS Perform procedures in a clean environment Make sure all parts are cleaned before disassembly and kept clean during assembly Be...

Page 110: ...PS S3 2 3560 001 OE35 Version no T code F code Section C code Stabilizing Caster Spring Loaded 108 Service Manual 1997 07 15 Return ...

Page 111: ...Torque Generator PS S4 0 4130 F code Section C code Version no T code 001 OE35 BT Products 109 Service Manual 1997 10 27 Torque Generator Return ...

Page 112: ...ESCRIPTION POS NO DESCRIPTION 1 Hosing valve 9 Pin 17 Seal quad 2 Seal shaft 10 Plate spacer 18 Key woodruff 3 Washer 11 Spacer 19 Shaft power end 4 Ring retainer 12 Geroler 20 Washer 5 O ring 13 Plate spacer 21 Washer 6 Spool 14 Drive control end 22 Retainer 7 Spring 15 Screw cap 23 Shaft power end 8 Sleeve 16 Housing power end Return ...

Page 113: ...point drive E10 socket wrench and remove seven cap screws early production units used 12 point drive screws Be extremely careful when working with solvent Even a small explosion or fire could cause injury or death WARNING NOTE Although not all drawings show the torque generator in a vise or on a bench we recommend that you follow instructions in the steps as to the placement of parts whether it be...

Page 114: ...al end up Use small screwdriver or similar tool to remove quad seal from the housing Housing with two bearing sets needle type use the same output shaft quad seal washers and retaining ring as the standard housing however if bearings are to be replaced they are not sold separately as replacement parts Housing and Shaft Assembly Key Cap Screw NOTE In most cases it is not necessary to remove the ret...

Page 115: ...om the gerotor or Geroler 9 Remove O ring from the gerotor or Geroler 10 Remove the gerotor or Geroler 11 Remove the spacer 12 Using a small screwdriver or similar tool remove the O ring from the spacer plate 13 Remove spacer plate from the valve housing Drive power end O ring Gerotor or Geroler Spacer Plate O ring Drive Spacer Plate Spacer Geroler NOTE Remove the gerotor or Geroler try to keep al...

Page 116: ...n valve housing shaft end up Use a small screwdriver or similar tool to remove shaft seal 18 Remove the washer from spool sleeve assembly 19 To separate spool from the sleeve the cross pin must be removed To remove the cross pin use a small screwdriver or similar tool and push pin from the spool sleeve Valve Housing Washer Shaft Seal can be Quad Seal or Lip Seal Sleeve Spool Centering Springs Reta...

Page 117: ...ining ring on spool need not be removed if no damage is apparent NOTE To prevent possible loss of the six centering springs cover the control spool and springs with a clean shop towel when pushing springs from the spool This will help contain springs in one location step 21 Plug O ring Relief Valve Valve Housing for Relief Valve Option NOTE Valve housing with inlet relief valve has one O ring on t...

Page 118: ...ing opening of the spool with the spring notches in the sleeve 2 In preparation of installing the control spool and sleeve centering spring set stand all springs on a clean flat surface with the notched side of the centering spring pointed down Next place centering springs with arched side of each set of three pointing toward each other as shown above 3 To install centering springs first insert sp...

Page 119: ... the spool until top of the centering springs are flush with upper surface of the sleeve 5 Install the cross pin into the spool sleeve 6 Lubricate and install the washer into the valve housing 7 Quad Seal In preparation of installing the quad seal first install the spool sleeve assembly into the valve housing backwards shaft end up Carefully retain the NOTE When spring installation tool is not ava...

Page 120: ...Quad Seal After seal installation make sure the seal is not twisted Turn the valve housing over and remove the spool sleeve assembly 10 Lip seal Insert this seal into valve housing without shaft installed from the inside and guide it with your finger all the way into the seal groove the seal lip must be positioned so it is towards the inside of the valve housing 11 With the washer still resting fi...

Page 121: ...od helps assures proper alignment of the drive and gerotor or Geroler star meter section 16 Install the drive make sure you fully engage the slot on the end of the drive with the cross pin in the spool and sleeve assembly 17 This illustration above shows the correct relationship of the spool sleeve assembly cross pin and the gerotor or Geroler star for proper torque generator timing 18 With the O ...

Page 122: ...e with the seal groove side facing upward Install by aligning the cap screw holes with the matching holes in the gerotor or Geroler 23 Lubricate and install the O ring in the groove located in the spacer plate Drive power end O ring Gerotor or Geroler Spacer Plate NOTE The spline on one end of the drive is not as thick as the other and this thinner spline end must be installed into the gerotor or ...

Page 123: ...on the washer with the matching recess in the power end housing 27 Lubricate and install the second washer in the power end housing 28 Lubricate and install the power end shaft in the housing 29 Before engaging the power end housing assembly align the input and output shaft keyways and cross holes Spline on the drive and the spline in the power end shaft should line up With the power end assembly ...

Page 124: ...PS S4 0 4130 001 OE35 Version no T code F code Section C code Torque Generator 122 Service Manual 1997 10 27 Return ...

Page 125: ...Steering System Pump PS S4 0 4150 F code Section C code Version no T code 001 OE35 BT Products 123 Service Manual 1997 10 29 Steering System Pump 24 VOLT 36 VOLT Return ...

Page 126: ...brakes will apply 2 Removal 1 Drain hydraulic fluid from reservoir The truck hydraulics may be used to pump the fluid out of the reservoir 2 Disconnect battery 3 Remove electrical wires from solenoid mounted on pump body 4 Remove hoses from pump 5 Remove four bolts that mount the pump onto the motor and lower the pump to separate it from motor Be careful to not lose the spider coupling POS NO DESC...

Page 127: ... and set pressure relief valves The brake pressure relief setting is made by disconnecting the hose from the brake cylinder and deadheading it directly into a gauge The steering pressure relief may be measured at the quick disconnect tap between the pump and the torque generator it is necessary to block transmission from turning before the steering stops hit at the steering wheel shaft 9 Install t...

Page 128: ...POS NO DESCRIPTION 1 Shaft drive 11 Gear 21 O ring 2 Key 12 Gasket 22 O ring 3 Pin 13 Housing gear 23 Ring backup 4 Ring retainer 14 Plug 24 Plug 5 Gear 15 Housing end gear 25 Pin 6 Cap hex 16 Screw cap 26 Shaft idler 7 Gasket copper 17 Valve solenoid 27 Stator 8 Screw adjustment 18 Coil 28 Seal oil 9 Spring 19 Valve 10 Spring ball 20 Kit seal Return ...

Page 129: ...rom intermediate body 8 Remove lower pump gears and pins keys from shafts 9 Remove intermediate body from front housing The driven shaft and gear may come out with intermediate body 10 Remove retaining ring drive gear woodruff key and second retaining ring from drive shaft 11 Remove drive shaft from front housing by pulling it out the front side of the housing 12 Remove seal from front housing 13 ...

Page 130: ...sing 2 On drive shaft install one retaining ring woodruff key drive gear and second retaining ring 3 Install driven shaft with gear into front housing so that gears mesh 4 Place gasket on mating surface of front housing install intermediate body onto front housing Insure that dowel pins are in place and match marks line up 5 Install keys and gears for lower pump onto shafts Compressed air used for...

Page 131: ...dy 7 Tighten eight bolts holding pump together to 10 ft lb 0 5 ft lb 8 Install relief valve balls springs and screws Do not tighten down caps until relief pressures have been checked and adjusted 9 Install shaft seal in front housing Outer face of seal should be recessed 0 5 in from front edge of bore 10 Install coupling half on front of input shaft 11 Install solenoid valve and coil in end body R...

Page 132: ...PS S4 0 4150 001 OE35 Version no T code F code Section C code Steering System Pump 130 Service Manual 1997 10 29 Return ...

Page 133: ...ts and bolts 2 Adjust steering chain around transmission and bottom sprocket of torque generator Loosen two 3 8 in NC bolts that lock chain ends to transmission case Turn adjusting turnbuckle to tighten chain so that it has 1 8 in to 1 4 in of slack on one side Tighten locking bolts 3 Adjust upper chain around torque generator and jackshaft Jackshaft mounting bracket is on a pivot Loosen locknuts ...

Page 134: ...PS S4 0 4170 001 OE35 Version no T code F code Section C code Steering System 132 Service Manual 1997 10 29 Return ...

Page 135: ...no T code 001 OE35 BT Products 133 Service Manual 1997 10 23 Electrical System with TX and TT Card 1 Electrical Schematic Part 1 NOTE Items represented with dashed lines are options that may not be present on all models See Electrical Schematic Part 2 for further information Return ...

Page 136: ...00 001 OE35 Version noT code F code Section C code Electrical System with TX and TT Card 134 Service Manual 1997 10 23 2 Electrical Schematic Part 2 See Electrical Schematic Part 1 for further information Return ...

Page 137: ... card checks that 1C is charged and unlocks the gate to 1REC and 5REC The control card then supplies a gate pulse to 1REC turning it on to a conducting state allowing current to flow from the battery through 1REC motor field motor armature sensor and back to the battery 5 REC turns on and allows current to flow T4 T3 1C 1REC 5 REC to T4 T3 This current charges the bottom of 1C positive with respec...

Page 138: ...age motor current measured will be greater than the average battery current The SCR control in effect converts battery current at battery volts into a higher motor current and a lower motor volts The time for the next ON and OFF cycle to start is determined by the time that the control card takes to oscillate This frequency of oscillation is controlled by the potentiometer in the accelerator and a...

Page 139: ...N time with a nominal 1 8 milliseconds ON time and 1 8 millisecond OFF time This corresponds to a maximum operating frequency of about 300 hertz At creep the ON time will decrease to approximately 0 8 milliseconds while OFF time will become in the order of 20 milliseconds At full SCR operation this condition will be reversed short OFF time long ON time This variation of ON and OFF time of the osci...

Page 140: ...g and the directional lever is moved from one direction to the other the motor field is reversed The plug signal is initiated by the fact that the directional switch has moved from one direction to the other The motor armature driven by the inertia of the vehicle acts as generator This generated current passes through 4REC and the sensor The oscillator circuit regulates at a plug current limit lev...

Page 141: ... adjustment of the rate of time it takes for the control to accelerate to 96 applied battery voltage to the motor on hard acceleration The 1A contactor will automatically close Two seconds after the controlled acceleration stops and the accelerator input is less than 5 volts or less than 50 ohms C A is adjusted by function 3 from 1 to 22 seconds 4 8 1A Current Drop Out This adjustable feature can ...

Page 142: ...is activated If the voltage is less than 2 5 volts the control will not start This is to assure that the control is calling for low speed operation at start up 4 11 Coil Driver Module These drivers are internal to the logic card They are the power devices that operate forward rearward 1A and power steering contactor coils These drivers open or close these coils on command from the logic card All m...

Page 143: ...ward internal coil drivers are shorted or if 3 REC diode is shorted The PMT circuit will shut down operation of the control opening of the forward or rearward contactor under the following conditions If 1REC fails to commutate shut off or if 1A power tips remain closed when they should be open After opening the forward or rearward contactor the PMT circuit will check for a fault and if none is fou...

Page 144: ...100 control is designed for use down to 50 percent of a nominal battery volts of 36 84 V and 75 percent of a nominal battery volts of 24 V Lower battery volts may cause the control to not operate correctly however the PMT should open the forward or rearward contactor in the event of a commutation failure 4 17 Top Speed Motor volts Limit This feature provides a means to limit motor volts to three a...

Page 145: ...off 4 21 Internal Resistance Compensation This feature is used when the Battery Discharge Indicator is present Adjustment of this function will improve the accuracy of the BDI This is adjustable by function 14 4 22 Stored Status Code This feature furnishes a function register function 1 that contains the last fault that shut down vehicle operation PMT type fault that is reset by cycling the key sw...

Page 146: ...ercent charge Display blinks at 20 charge Disables pump circuit with 10T charge Auto ranging for 36 48 volt operation Adjustable for use on 24 to 80 volts 4 25 Handset This is a multi functional tool to be used with the EV100 LX and LXT SCR controls The Handset consist of a Light Emitting Diode LED display and a keyboard for data entry Features and functions Monitor existing system status code for...

Page 147: ...ltered Refer to vehicle manufacturer for specifications The control should not be steam cleaned In dusty areas use low pressure air to blow off the control In oily or greasy areas a mild solution of detergent or denatured alcohol can be used to wash off the control and then blow completely dry with low pressure air The control can also be cleaned with Freon TF degreaser For the SCR panel to be mos...

Page 148: ...lugging a Handset into the logic card s plug Y location and then reading the status code With the status code number follow the procedures outlined in the status code instruction sheets to determine the problem Checking and replacement of components are also outlined in sections of this instruction book Please refer to these sections as needed The same device designations have been maintained on d...

Page 149: ...an 20 000 ohms can cause misleading symptoms Resistance less than 1000 ohms should be corrected first Before proceeding visually check for loose wiring misaligned linkage to the accelerator switch signs of overheating of components etc Tools and test equipment required are a 6 volt lamp 6 volt battery two A14 diodes 1 Amp 400 volts clip leads volt ohm meter 20 000 ohms per volt and general hand to...

Page 150: ...PS S5 0 5000 001 OE35 Version noT code F code Section C code Electrical System with TX and TT Card 148 Service Manual 1997 10 23 Return ...

Page 151: ...that if there is a current passing through the relay contacts when the instrument registers empty battery the contacts stay closed until the current ceases There will be no lockout of the lift during the lift operation The hourmeter features a liquid crystal display LCD which has six segment digits with a decimal point before the last digit This provides resolution of 0 1 hours or 6 minutes 2 Elec...

Page 152: ...hen the battery is fully charged the LED to the right will be illuminated As the battery discharges LEDs to the right will stop glowing and show the current discharge level When the battery is 70 percent discharged the two LEDs from the left will flash alternately to warn the driver that he should recharge the battery When the battery is 80 percent discharged the last LED is lit and the relay is o...

Page 153: ... they start to flash at higher specific gravity the discharge U potentiometer should be turned counterclockwise towards K If the two LEDs start to flash at a specific gravity below 1 14 turn the potentiometer clockwise towards P The letter designations for the voltage per cell VPC multipliers at empty battery are specified as tabulated below Battery Ah 180 L M 210 M N 240 N O SETTING VPC SETTING V...

Page 154: ...he connection number 6 at the rear of the BC With the key switch OFF the hourmeter will not respond to the connection number 6 and the LCD of the hourmeter will be off 400 AMP Controllers The drive transistor controller enables the timing function of the hourmeter whenever there is current going to the drive motor Also the timing function is enabled whenever S52 raise switch is closed NOTE The dis...

Page 155: ...ent Replace this connection and measure the voltage across the gauge at its pin 7 or 8 and pin 5 It must be above 2 09 volts per cell If it is and the gauge does not reset to indicate full charge the instrument is defective The second method of resetting the instrument is by using the high voltage reset This reset function also has two requirements to reset the instrument The voltage across pin 7 ...

Page 156: ...flashing the two left most red LEDs for lockout to occur The J output functions like an SCR At lockout pins 3 and 4 will open as long as lift is inactive To test this output 1 Remove the wire leading to pin 3 when at lockout 2 Replace the wire and then try to lift If the lift ceases to operate the instrument is good but there is a leakage current somewhere in the lift circuit 3 Check across the li...

Page 157: ...asurement 2 Repeat this procedure with the voltmeter s positive lead on pin 5 and its negative lead on the battery s negative terminal and record the voltage measured 3 Add the two voltage readings This total should be less than 1 percent of the nominal battery voltage Voltage higher than this will cause the instrument to calculate battery state of charge from incorrect readings 4 1 7 LEDs Do Not ...

Page 158: ...nes must be active If the key switch is on one or both inputs are correct and the hourmeter icon does not flash the instrument is defective 4 2 3 Hourmeter Glass Icon Always Flashes When the icon is flashing the hourmeter is accumulating time Turn the truck s key switch off This should remove voltage from pin 2 of the instrument Should voltage be present at pin 2 and the hourmeter s icon continues...

Page 159: ...g diode LED display that displays the status codes hourmeter readings and battery discharge indication from the controller Connections are made to the dash display by means of five 22 gauge wires to plug Y of each SCR control In some cases shielded cable must be required to eliminate signal interference DASH DISPLAY Back View of display 1 2 3 4 5 1 2 3 4 5 PY3 PY1 PY2 PY4 PY1 PY2 PY3 PY4 PY5 Retur...

Page 160: ...urn on the key switch 2 Push start switch button and hold in 3 The display is hourmeter LED reading 3 2 Checking Battery Condition BDI 4 Turn on the key switch 5 Push start switch button and do not hold in 6 Depress foot brake pedal and hold down 7 The display is percent of battery discharge 8 The battery condition is displayed anytime unit is in the operating mode 3 3 Checking Status Code wrench ...

Page 161: ...start switch is pressed return directional switch to neutral then select direction Status Code 03 Indicates rearward switch was closed before the key switch or start switch or brake switch was closed With key switch on and start switch is pressed return directional switch to neutral then select direction Status Code 04 Indicates forward or rearward switch was closed before the key switch or start ...

Page 162: ...PS S5 3 5230 001 OE35 Version no T code F code Section C code Dash Display 160 Service Manual 1997 12 15 Return ...

Page 163: ...EV100 LX Control Status Codes PS S5 7 5410 F code Section C code Version no T code 000 OE35 BT Products 161 Service Manual 1997 10 22 EV100 LX Control Status Codes Return ...

Page 164: ...Dash Display Handset Figure 1 STATUS INDICATION CRITERIA This indicates a lack of input voltage to the logic card and or display unit STATUS CODE 01 DESCRIPTION MEMOR RECALL No No foot switch input CIRCUIT Traction SYMPTOM Forward or reverse contactor will not pick up POSSIBLE CAUSE Mis adjusted or defective foot switch Check foot switch to insure proper switch closure Open circuit between battery...

Page 165: ...yed when TB5 is greater than 60 battery volts at initial power up STATUS CODE 03 DESCRIPTION MEMOR RECALL No Reverse directional switch is closed on initial power up CIRCUIT Traction SYMPTOM Reverse contactor will not pick up static return to off SRO lock out POSSIBLE CAUSE Reverse directional switch closed on initial power up Battery plugged in key switch and foot switch closed Return directional...

Page 166: ...ss than 60 battery voltage disconnect battery and remove wire and measure resistance from wire to SCR negative Value should be less than 22K ohms Figure 1 STATUS INDICATION CRITERIA This status code is displayed when TB2 voltage is less than 60 of battery volts at initial start up foot switch closure STATUS CODE 05 DESCRIPTION MEMOR RECALL No Brake switch fails to close CIRCUIT Traction SYMPTOM Fo...

Page 167: ...ntrol will not operate when control is rotated on status code 07 is displayed then disappears when the vehicle starts to accelerate POSSIBLE CAUSE Accelerator input mis adjusted or defective Input voltage at TB1 should be less than 3 7 volts Adjust or replace accelerator unit to insure that the voltage at TB1 will vary from 3 5 volts to less than 5 volts when the pedal is depressed Open circuit be...

Page 168: ...RIA This status code will be displayed when the accelerator input voltage at TB1 is less than 3 0 volts and any of the following connections are opened and closed battery plug foot switch or key switch STATUS CODE 09 DESCRIPTION MEMOR RECALL No Both forward and reverse directional switches are closed at the same time CIRCUIT Traction SYMPTOM Forward or reverse contactor will not pick up POSSIBLE C...

Page 169: ...ON MEMOR RECALL No Battery volts too high CIRCUIT Traction SYMPTOM Forward or reverse contactor will not pick up POSSIBLE CAUSE Incorrect control card adjustment Check function 15 for proper adjustment for battery being used See handset instructions for details Adjust to proper setting Open circuit in regen sensor circuit Check yellow wire from sensor 2 to PA4 for broken wire loose connections or ...

Page 170: ...valid number STATUS CODE 23 DESCRIPTION MEMOR RECALL No Forward or reverse contactor coil current low CIRCUIT Traction SYMPTOM Forward or reverse contactor will not pick up Status code may alternate between code 23 and code 24 Complete check for code 23 if the problem is not found perform check for code 24 POSSIBLE CAUSE Defective F and R contactor coil circuit Check for open circuit or loose conn...

Page 171: ... to the A2 connection on the SCR control panel Defective 1A or SP contactor Perform checks as outlined in status 23 Figure 1 STATUS INDICATION CRITERIA This status code is displayed when T2 volts is greater than 12 of battery volts and the F and R driver is energized STATUS CODE 25 DESCRIPTION MEMOR RECALL Yes 1A contactor does not drop out or drops out slowly CIRCUIT Traction SYMPTOM Short tip li...

Page 172: ...otector or control over temperature CIRCUIT Traction SYMPTOM Reduced or no power to traction motor in SCR range POSSIBLE CAUSE Open thermal protector circuit Check for loose connection or broken wire between Black wire Thermal protector and PZ1 Gray wire Thermal protector and PZ5 Defective thermal protector Disconnect wires from PZ1 and PZ5 At room temperature 25 C or 75 F measure resistance betwe...

Page 173: ...when voltage between PY7 and negative is greater than 1 6 volts with no current flowing in the motor circuit STATUS CODE 43 DESCRIPTION MEMOR RECALL No SCR motor current sensor input missing CIRCUIT Traction SYMPTOM Stall currents in SCR range higher than normal and uncontrollable with C L adjustment POSSIBLE CAUSE Open sensor wire circuit to PZ3 Check for loose connections or broken wire yellow w...

Page 174: ...STATUS INDICATION CRITERIA This status code is displayed when during SCR operation 1REC fails to turn off STATUS CODE 45 DESCRIPTION MEMOR RECALL Yes 1REC did not turn on properly CIRCUIT Traction SYMPTOM Forward or reverse contactor will open and close then open and then can only be closed by opening and closing the key switch POSSIBLE CAUSE Defective 2REC circuit Check for shorted 2REC Check for...

Page 175: ... volts STATUS CODE 47 DESCRIPTION MEMOR RECALL Yes 2REC does not turn on properly CIRCUIT Traction SYMPTOM Forward or reverse contactor will open and close then open and then can only be closed by opening and closing the key switch POSSIBLE CAUSE Defective 2REC circuit Check that 2REC will gate on Check for open circuit or loose connection between 2REC gate and PZ10 white red wire Check for open c...

Page 176: ...IPTION MEMOR RECALL Yes 5REC does not turn on properly CIRCUIT Traction SYMPTOM Forward or reverse contactor will open and close then open and then can only be closed by opening the key switch POSSIBLE CAUSE Defective 5REC circuit Check for shorted 5REC Check for shorted 5REC snubber 25REC Check that 5REC will gate on Check for open circuit or loose connection between 5REC gate and PZ12 white viol...

Page 177: ...ATION CRITERIA This status code is displayed when 2REC circuit fails to turn on at initial start up STATUS CODE 51 DESCRIPTION MEMOR RECALL Yes Excessive capacitor voltage when motor current is high CIRCUIT Traction SYMPTOM Forward or reverse contactors open and close then can only be closed by opening and closing the key switch POSSIBLE CAUSE Excessive source inductance Tag lines without filters ...

Page 178: ...orward or reverse contactor opens and closes then opens and can only close by opening and closing the key switch POSSIBLE CAUSE 1 REC turn off failure not related to plugging Stall vehicle in both directions and note any status codes displayed that may more closely define the failure mode Troubleshoot per new status code 1 REC turn off related to plugging Check 4 REC circuit for open 4 REC loose o...

Page 179: ...EMOR RECALL Yes Current sensor output voltage polarity check CIRCUIT Traction SYMPTOM Forward or reverse contactors open and close then can only be closed by opening and closing the key switch POSSIBLE CAUSE Reversed yellow and green current sensor wires Insure that the green wire connects to PZ4 with no open circuits and the yellow wire connects to PZ3 with no open circuits or loose connections R...

Page 180: ...PS S5 7 5410 000 OE35 Version no T code F code Section C code EV100 LX Control Status Codes 178 Service Manual 1997 10 22 Return ...

Page 181: ...conclusion being then that the card is faulty 1 1 Instructions for Removal of Control Card Remove control wires on the screw terminals 1 through 6 as required Unplug A B and Z plugs by pressing down on tab with wide blade screwdriver and rotating 90 degrees Remove the two mounting screws and lift card box Reverse procedure to install new control card NOTE Do not attempt to remove circuit broad fro...

Page 182: ...M to the wire that was removed from TB1 and to negative Place the VOM on the Rx100 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 5 SCR s 1REC 2RE...

Page 183: ...shorted and must be replaced 2 If check 1 was satisfactory test the SCR for its ability to be turned on by the gate Connect positive through two diodes to the gate terminal If the gate is operative the lamp will come on and remain on when the gate is removed Some SCR s will operate correctly even if the lamp dose not remain on particularly with a weak battery 3 If the lamp cannot be lit under step...

Page 184: ... Z plug that connects to the control card Read the resistance between these two wires with the VOM set on the Rx100 scale VOM should read 100 to 200 ohms if the 1REC heatsink is at room temperature 75 F or 25 C Set the VOM to the highest ohm scale and read from each wire end to the 1REC heatsink Reading should be infinity NOTE If you do not have a test light to check the SCR s as described above t...

Page 185: ...bserved replace the filter block 9 Filter Block 23FIL etc Filter block test 4K is only to detect an open or shorted filter If the control has symptoms as in 1E interchange 22REC and 25REC and try again If the problem is corrected the old 25REC is marginal and should be replaced If the problem is not corrected replace both filters 10 1X Choke and Reactor T3 T4 Refer to panel wiring diagram to locat...

Page 186: ...position 5 Coat insulator with a light coat of heat transfer grease similar to GE 350 6 Set new module on insulator and start screws back into base Be sure to use the original screws and washers Run screws into base finger tight 7 Check that the bottom of the module is flat against the insulator or base 8 Alternately tighten the two screws by 1 4 turn until firm 9 Replace all connections removed i...

Page 187: ...l board insert a medium size flat blade screwdriver in this gap and gently pry out the plug alternating sides To remove a terminal from the plug body Referring to Figure 1 insert the terminal removal tool into the plug body which depresses the terminal locking lance With a gentle push pull motion on the wire remove the wire USE AMP REMOVAL TOOL 91065 1 NOTE When replacing these devices use the ori...

Page 188: ...djust the lance Insert the terminal into the plug body until it latches A CLICK sound will be heard when the terminal latches Check for correct latching by moving the wire gently with a push pull motion 12 3 Reference A Plug 27694 00 B Plug 27702 02 Receptacle AMP 102103 3 Loose AMP 102099 5 Reel side feed Crimp Tool AMP 90274 2 wire size 18 22 Removal Tool AMP 91065 1 Terminal Lube AMP 561232 1 F...

Page 189: ...ase magnet 10 Spring 19 Bar bus 2 Coil 11 Insulation 20 Lockwashe 3 Frame magnet 12 Locknut 21 Tip contact 4 Spring 13 Clamp 22 Clamp 5 Armature 14 Tip contact 23 Washer flat 6 Base bus 15 Cover 24 Seat 7 Tip contact 16 Lockwasher 25 Carrier 8 Tip contact 17 Screw 26 Bushing 9 Tip movable 18 Screw 27 Tip contact 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 7 27 26 25 24 23 24 9 Return ...

Page 190: ... 2 Remove replace contact tips 1 Disconnect power cables from contactors Remove bolts with washers lockwashers and spacers from contacts Move power cables out of the way 2 Disconnect connecting bus bars from contacts 3 Disconnect wiring from contactor coil terminals 4 Remove mounting bolts securing Forward and Reverse Contactor Assembly to the control panel base plate that is attached to the truck...

Page 191: ...e return spring should come off with the armature as it fits into a recess in the bottom of the armature 13 Secure support in a vice equipped with soft jaws using minimum pressure to hold support 14 Loosen and remove nut freeing core parts washer insulators movable contacts spring seats and spring Note the position and location of each part for proper reassembly Remove these parts 15 Pull insulato...

Page 192: ... holes to be certain they are perfectly round and not egg shaped damaged Inspect coil terminals for damage Replace damaged parts with new ones 25 Reassembly The Contactors Install both coils onto contactor base Terminal connections must point outward away from center of base Be certain the coils are properly located over the base alignment pins 26 Locate Brackets 3 on each coil and onto the base B...

Page 193: ... contactor base 32 Install the long lower bus bar and stationary contacts having threaded holes in one end into the grooves located on the top side of each contactor support The cable end of the bus bar should extend outward on the right hand side of the forward contactor support and extend outward on the left hand side of the reverse contactor support Be certain the notches in the bus bar and sta...

Page 194: ...ntacts are in alignment and press both covers downward with one hand hold in this position and install all cover screws until snug Check to be sure all parts are in proper alignment and position the power cable bolts with lockwashers and washers through the upper bus bar contacts and spacers Tighten bolts finger tight into the lower bus bar contacts 37 Tighten cover screws to 14 18 in lb 1 6 2 0 N...

Page 195: ...actor POS NO DESCRIPTIO POS NO DESCRIPTION POS NO DESCRIPTION 1 Base magnet 8 Bushing 15 Clamp 2 Coil 9 Carrier 16 Lockwashe 3 Frame magnet 10 Tip movable 17 Screw machine 4 Spring 11 Cap 18 Suppression 5 Armature 12 Spring 19 Seat 6 Base bus 13 Washer flat 7 Tip contact 14 Nut lock 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Return ...

Page 196: ...eplaced before they wear through and damage copper base 2 Disassembly 1 Disconnect power cables from contactors Remove bolts with washers and lockwashers from contacts Move power cables out of the way 2 Disconnect wiring from contactor coil terminals 3 Remove mounting bolts securing contactor assembly to the control panel base plate that is attached to the truck Remove assembly from truck 4 Remove...

Page 197: ...damaged they should be replaced with new ones Material on the armature stem has been up set in four places to retain the washer Inspect all four places to be certain this thin washer is properly retained and free to rotate about the armature stem Inspect the cone surface of the armature and the corresponding surface in the base plate for scoring etc Inspect the small white bushing for wear The bus...

Page 198: ...ure stem Install spring and upper spring seat upper contact upper insulator lockwasher and nut onto armature stem Torque nut to 18 20 lb in 2 0 2 4 N m 4 Remove support and movable contact assembly from the vice 5 Now locate the contactor support and movable contact assembly over Bracket 3 6 Install the stationary contacts into the grooves located on the top side of contactor support Be certain th...

Page 199: ...he bus bar contacts Tighten bolts finger tight into bus bar contacts 8 Tighten cover screws to 14 18 lb in 1 6 2 0 N m 9 Use a bar or rod to move contacts Be sure movement is free of binding and that tips are in correct orientation and tips contact correct mating parts 10 Install contactor assembly to panel base plate Return ...

Page 200: ...PS S5 7 5450 000 OE35 Version no T code F code Section C code 1A Speed Contactor 198 Service Manual 1997 10 29 Return ...

Page 201: ...ge is not present or if the voltage is too low perform the repairs listed directly below the test procedure Voltage tests are made with the negative lead of the volt meter connected to battery negative If the negative lead is connected to a negative terminal on the electrical panel you must verify the negative connection to the battery by touching the positive meter lead to the positive battery po...

Page 202: ...ltage open circuit and at hydraulic operation under full load the precise operating symptoms and the exact results of the testing you have done The first steps of any troubleshooting procedure are to 1 Inspect the truck for physical damage or mechanical malfunction Contactors must be free to move and the tips must not be welded or burnt 2 Check for ground faults from the electrical system to the f...

Page 203: ...tery positive or battery negative The functions should be adjusted to the following values These functions control the speed of the truck when raised The function should be adjusted to the prescribed setting and then the speed of the truck should be checked and the function readjusted if necessary Function 11 controls the speed at lift heights 24 inches The top speed of the truck must be 2 5 MPH F...

Page 204: ...enter and when above 226 inches The truck must not travel although contactors will close The travel speed is most easily determined by timing the truck through a 50 foot run At 2 5 MPH the vehicle will take 13 seconds to travel 50 feet At 1 0 MPH the vehicle will take 34 seconds to travel 50 feet The speed limiting function is vital to the safety of the vehicle and must never be bypassed or set ab...

Page 205: ...en 1 1 Emergency Disconnect Contactor 1 1 1 Emergency disconnect contactor will not close Conditions for test Battery plugged battery fully charged key switch in start position Check for battery voltage at 1 Positive side of fuse 3 0 volts repair open wiring from battery to fuse 3 2 Negative side of fuse 3 0 volts replace fuse 3 3 Positive side of key switch 0 volts repair open wiring from fuse 3 ...

Page 206: ... coil check for mechanical binding of contactor Battery volts repair open wiring from contactor coil to battery negative wire 22 1 1 2 Emergency disconnect contactor closes but drops out when start switch is released Condition for test Battery plugged in key switch ON position Test for battery volts at 1 Negative side of key switch wire 14 0 volts replace key switch 2 Positive side of emergency di...

Page 207: ...connect contactor closes with push start button and remains closed when start button is released but truck will not operate no lift no travel Condition for testing Battery connected to truck Key switch in ON position start button pressed and released with emergency disconnect contactor closed Negative lead of volt meter connected to negative stand off terminal on SCR panel for this test only Test ...

Page 208: ...ide of steer pump contactor coil 0 volts repair open wiring from emergency disconnect button to contactor coil 2 Negative side of steer pump contactor Refer to status code 23 and 24 in section 1 4 of this manual 1 2 2 Brakes will not release steering okay lift okay Condition for test Battery plugged in key switch ON start button pushed and released emergency disconnect contactor closed foot pedal ...

Page 209: ...r side bus bar on SP contactor 0 volts repair SP contactor replace tips 3 A1 terminal on SP motor 0 volts repair open cable 4 from SP contactor 4 S2 terminal on SP motor 0 volts repair SP motor 5 Repair open cable 13 to battery negative 1 3 Travel 1 3 1 No travel lift lower okay steering pump motor runs Conditions for test Battery plugged in key switch ON start button pushed and released emergency...

Page 210: ...iring from brake switch to contactor coil 6 Negative side of directional contactor coil with wire disconnect 0 volts replace contactor coil 7 Test all limit switches for proper operation 8 Refer to EV 100 handset instructions 1 4 Lift 1 4 1 No lift lift pump LP contactor does not close Condition for test Battery plugged in key switch in on position start button pushed and released emergency discon...

Page 211: ...Negative side of second gate switch 0 volts adjust or replace second gate switch 7 Positive side of lift switch 0 volts repair open wiring from second gate switch to lift switch 8 Negative side of lift switch 0 volts replace lift switch 9 Positive of lift pump contactor coil 0 volts repair open wiring from lift switch to contactor coil 10 Negative side of contactor coil 0 volts check contactor for...

Page 212: ...ive side of staging chain tension switch on mast column crossbar 0 volts repair open wiring between platform chain tension switch and mast column chain tension switch 4 Negative side of staging chain tension switch 0 volts replace staging chain tension switch 5 Positive side of high speed lift switch 0 volts repair open wiring from staging chain tension switch to high speed lift switch 6 Negative ...

Page 213: ...r 0 volts repair open cable 5 from fuse 1 400 AMP 2 Pump motor side of contactor bus bar 0 volts repair contactor replace tips 3 A1 terminal on lift pump motor 0 volts repair open cable 20 from LP contactor 4 S2 terminal on motor 0 volts repair motor Battery volts repair open cable 13 to battery negative 1 5 Lowering 1 5 1 No low speed lowering low and high speed raise okay Conditions for test Bat...

Page 214: ... side of 1 lowering solenoid valve coil 0 volts replace coil Battery volts repair open wire from solenoid valve coil to battery negative wire 22 1 5 2 No high speed lowering low speed lowering okay Conditions for test Battery plugged in key switch in on position start button pushed and released emergency disconnect contactor closed gate switches closed foot pedal switch closed platform raised abov...

Page 215: ...d lowering switch to 24 inch limit switch 4 Negative side of 24 inch limit switch 0 volts adjust or replace 24 inch limit switch 5 Positive side of 2 lowering valve coil wire 53 0 volts repair open wiring from 24 inch limit switch to 2 lowering valve coil 6 Negative side of 2 lowering valve coil Battery volts repair open wire from lowering valve coil to battery negative wire 22 Return ...

Page 216: ...PS S5 4 5460 001 OE35 Version no T code F code Section C code Electrical System Troubleshooting Charts 214 Service Manual 1996 10 15 Return ...

Page 217: ...r POS NO DESCRIPTIO POS NO DESCRIPTION POS NO DESCRIPTION 1 Base magnet 8 Bushing 15 Clamp 2 Coil 9 Carrier 16 Lockwashe 3 Frame magnet 10 Tip movable 17 Screw machine 4 Spring 11 Cap 18 Suppression 5 Armature 12 Spring 19 Seat 6 Base bus 13 Washer flat 7 Tip contact 14 Nut lock 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Return ...

Page 218: ...laced before they wear through and damage copper base 2 Disassembly 1 Disconnect power cables from contactors Remove bolts with washers and lockwashers from contacts Move power cables out of the way 2 Disconnect wiring from contactor coil terminals 3 Remove mounting bolts securing contactor assembly to the control panel base plate that is attached to the truck Remove assembly from truck 4 Remove c...

Page 219: ...maged they should be replaced with new ones Material on the armature stem has been up set in four places to retain the washer Inspect all four places to be certain this thin washer is properly retained and free to rotate about the armature stem Inspect the cone surface of the armature and the corresponding surface in the base plate for scoring etc Inspect the small white bushing for wear The bushi...

Page 220: ...e stem Install spring and upper spring seat upper contact upper insulator lockwasher and nut onto armature stem Torque nut to 18 20 lb in 2 0 2 4 N m 4 Remove support and movable contact assembly from the vice 5 Now locate the contactor support and movable contact assembly over Bracket 3 6 Install the stationary contacts into the grooves located on the top side of contactor support Be certain the ...

Page 221: ... bus bar contacts Tighten bolts finger tight into bus bar contacts 8 Tighten cover screws to 14 18 lb in 1 6 2 0 N m 9 Use a bar or rod to move contacts Be sure movement is free of binding and that tips are in correct orientation and tips contact correct mating parts 10 Install contactor assembly to panel base plate Return ...

Page 222: ...PS S5 7 5610 000 OE35 Version no T code F code Section C code Pump Contactor 220 Service Manual 1997 10 29 Return ...

Page 223: ... Contactor POS NO DESCRIPTIO POS NO DESCRIPTION POS NO DESCRIPTION 1 Base magnet 8 Bushing 15 Clamp 2 Coil 9 Carrier 16 Lockwashe 3 Frame magnet 10 Tip movable 17 Screw machine 4 Spring 11 Cap 18 Suppression 5 Armature 12 Spring 19 Seat 6 Base bus 13 Washer flat 7 Tip contact 14 Nut lock 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Return ...

Page 224: ...e replaced before they wear through and damage copper base 2 Disassembly 1 Disconnect power cables from contactors Remove bolts with washers and lockwashers from contacts Move power cables out of the way 2 Disconnect wiring from contactor coil terminals 3 Remove mounting bolts securing contactor assembly to the control panel base plate that is attached to the truck Remove assembly from truck 4 Rem...

Page 225: ...be damaged they should be replaced with new ones Material on the armature stem has been up set in four places to retain the washer Inspect all four places to be certain this thin washer is properly retained and free to rotate about the armature stem Inspect the cone surface of the armature and the corresponding surface in the base plate for scoring etc Inspect the small white bushing for wear The ...

Page 226: ...ature stem Install spring and upper spring seat upper contact upper insulator lockwasher and nut onto armature stem Torque nut to 18 20 lb in 2 0 2 4 N m 4 Remove support and movable contact assembly from the vice 5 Now locate the contactor support and movable contact assembly over Bracket 3 6 Install the stationary contacts into the grooves located on the top side of contactor support Be certain ...

Page 227: ... the bus bar contacts Tighten bolts finger tight into bus bar contacts 8 Tighten cover screws to 14 18 lb in 1 6 2 0 N m 9 Use a bar or rod to move contacts Be sure movement is free of binding and that tips are in correct orientation and tips contact correct mating parts 10 Install contactor assembly to panel base plate Return ...

Page 228: ...PS S5 7 5610 000 OE35 Version no T code F code Section C code Steering Pump Contactor 226 Service Manual 1997 10 29 Return ...

Page 229: ...000 BT Products AB 227 Service Manual 1997 09 15 EV100 Handset Operation 1 General Information The Handset is a multi functional tool to be used with the EV100 LX and LXT SCR controls The Handset consist of a Light Emitting Diode LED display and a keyboard for data entry Return ...

Page 230: ... Monitor or adjust the following control functions Creep speed Controlled Acceleration and 1A time Current Limit Steer pump time delay Plugging distance Current Pedal position plug range or disable A drop out current or disable Speed limit points SL1 SL2 and SL3 Internal resistance compensation for battery state of charge indication Battery voltage 36 48 volts is auto ranging Selection of card ope...

Page 231: ...fore 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 WARNING Start up Display Sequence Key Switch ON Verify Display Seqments for one second 8888 BDI Display or Blank Display No BDI used BDI Display or Blank Display No BDI used Diagnostics override with fault Diagnostics override with fault Ru...

Page 232: ...truck can now be operated with the handset connected or the handset can be Set Up Mode Action Display shows Remarks Hold down CONT turn on key 8888 Segment check displayed Push function number U 005 Selected function number is displayed After one second time delay 085 Stored value for the function is displayed Push CONT 088 Displayed valve will blink Charge value with adjustment knob 0125 Value ch...

Page 233: ...ode Section C code Version no T code 000 BT Products AB 231 Service Manual 1997 09 15 disconnected before operation NOTE You can return to the segment check mode at any time by holding down the ESC key until 8888 appears in the display Return ...

Page 234: ...PS S5 5 5710 000 Version no T code F code Section C code EV100 Handset Operation 232 Service Manual 1997 09 15 5 Description and Location Return ...

Page 235: ...nstant creep speed frequency will be maintained when an accelerator input voltage between 3 7 and 3 5 volts or an accelerator ohmic input between 6K and 4 7K ohms is provided Range 5 to 15 on time Set 0 to 255 Resolution 03 per set unit Example Setting of 20 5 6 on time 6 3 Function 3 Controlled Acceleration and 1A Time Push 3 This function allows for the adjustment of the rate of time it takes fo...

Page 236: ...he truck The larger the current setting the shorter the stopping distance Range 200 to 1000 amps Set 0 to 255 Resolution 3 14 amps per set unit Example Setting of 20 1263 amps 6 6 Function 6 1A Drop Out Current Push 6 This function allows for the adjustment of the 1A contactor drop out current The 1A contactor will be dropped out and the vehicle motor torque will be limited to SCR current limit wh...

Page 237: ...L1 limit switch is normally closed switch connected to battery negative the switch opening enables speed limit Range 96 to 0 battery volts Set 0 to 180 Setting of 0 set units will disable speed limit function and allow top speed with no limit switch connected 6 8 Function 12 Speed Limit 2 SL2 Push 12 Same as function 11 except using SL2 limit switch for input 6 9 Function 13 Speed Limit 3 SL3 Push...

Page 238: ...amps in 1A and record the voltage VO at the SCR positive and negative power terminal 2 Load the drive motor to 200 amps in 1A and record the voltage VL at the SCR positive and negative power terminal 3 Calculate voltage drop VD as follows VD VO VL 4 Use the table below to determine the setting using the calculated VD as a reference Setting EV100 VD Setting EV100 VD Setting EV100 VD Setting EV100 V...

Page 239: ...osition Plug Push CONT and 1 This function will allow the adjustment of the pedal position plug range Pedal position will reduce the plugging current to the current value set by this function as the accelerator is returned to the creep speed position Maximum plug current is obtained with the accelerator in the top speed position Range 100 to 930 amps Set 0 to 255 Resolution 3 2 amps per set unit E...

Page 240: ...gen FW STD C L 0 to 4 20 to 24 40 to 44 High C L 5 to 9 25 to 29 45 to 49 STD C L Auto plug 10 to 14 30 to 34 50 to 54 High C L Auto plug 15 to 19 35 to 39 55 to 59 EV200 Standar Speed Function with F Limit Regen FW STD C L 64 to 68 84 to 88 104 to 108 STD C L Auto plug 74 to 78 94 to 98 114 to118 These settings must be changed by authorized personnel only following instructions supplied by the ma...

Page 241: ...tion allows for the selection of steer pump contactor pick up input either seat switch or directional switch closing and adjustment of the time delay for the contactor drop out Pick up on foot pedal switch closure and time delay drop out on foot pedal switch opening Range 1 5 to 65 seconds Setting Between 0 and 128 Resolution 5 seconds per set unit Example Setting of 20 10 5 seconds Return ...

Page 242: ...PS S5 5 5710 000 Version no T code F code Section C code EV100 Handset Operation 240 Service Manual 1997 09 15 Return ...

Page 243: ... OE35 BT Products 241 Service Manual 1997 10 23 Hydraulic System 1 Hydraulic Schematic Motor Electric Hydraulic Pump Filter Reservoir Vented Cylinder Single Acting Cylinder Double Acting Check Valve Hydraulic Lines Crossing Component Enclosure Hydraulic Lines Joining Return ...

Page 244: ...through hoses to the lift cylinders Oil flowing into the lift cylinder acts upon all the internal surfaces of the cylinder The pressure of the oil forces the cylinder rod to extend out the top of the cylinder All lift cylinders are the positive displacement type The only seals are in the cylinder head gland nut There are no seals on the cylinder rod piston Equal oil pressure is applied to both the...

Page 245: ...eering torque generator The torque generator is a sophisticated valve and pump assembly that multiplies input torque and transfers it to the output shaft It operates on demand only and when not steering the oil is allowed to return freely to the reservoir The input shaft of the torque generator is operated by a series of cables chains and pulleys from the operator s steering wheel Mechanical stops...

Page 246: ...ed the reservoir should be removed and drained for cleaning and replaced with new oil After refilling check the lift lower and other hydraulic functions for proper operation If the truck will not lift a full load then the pressure relief setting should be checked and adjusted During normal operation the pressure relief setting will not change As the pump wears with age some loss performance will b...

Page 247: ...rm IF HYDRAULIC PUMP ASSEMBLY DOES NOT OPERATE PROPERLY A FEW PRELIMINARY CHECKS SHOULD BE MADE 1 Proper oil level 2 All electrical connections tight 3 Battery fully charged After the preliminary check is accomplished install a 0 3000 PSI pressure gauge on the quick coupler in the pressure line from the pump NPTF outlet port in the adapter The installation of the pressure gauge is required to insu...

Page 248: ...perated release See solenoid operated release valve 3 Pump worn replace pump B If pump develops pressure but will not hold 1 Dirt in solenoid operated release See solenoid operated release valve 2 Relief valve seat scored foreign particles under ball or relief valve out of adjustment See relief valve C If pump develops pressure but will not release load 1 No electrical contact to solenoid operated...

Page 249: ...t 7 No oil flow or pressure from pump Check flow from pump Check supply oil to pump hoses and strainer Check pump to motor coupling Check internal pump parts B No high speed lift Low speed lift okay but lift speed does not increase as lift button is pressed to high speed position 1 Solenoid valve not closing opening Verify correct electrical operation replace solenoid valve 2 Internal damage in pu...

Page 250: ...PS M6 0 6000 001 OE35 Version no T code F code Section C code Hydraulic Troubleshooting 248 Service Manual 1997 10 23 Return ...

Page 251: ...POS NO DESCRIPTION POS NO DESCRIPTION 1K Seal shaft 6K Plate wear 11 Washer flat 2 Body 7 Gear drive 12 Screw cap 3 Pin dowel 8K Plate thrust 13 Plug pipe 4K Nylatron 9K Seal gasket 14 Gear driven 5K Spacer rubber 10 Cover side port K Kit seal Bronze Face Toward Gears Bronze Face Toward Gears Torque Screws to 34 38 ft lbs 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Return ...

Page 252: ...ulic pump assembly and cap ends to prevent contaminants from entering the hydraulic system 6 Disconnect electrical power cables from motor and mark their position 7 Remove the screws securing the hydraulic pump and motor assembly to the frame 8 Thoroughly clean exterior of hydraulic pump and motor assembly before disassembly can begin HOT OIL under pressure may be present Be certain truck is safel...

Page 253: ... Clean exterior of pump in a cleaning solvent to remove all contamination 7 Scribe a line on both body and base of pump to aid when reassembling 8 Secure pump in vise with soft jews use light clamping pressure with shaft end down remove screws 12 and washers 11 NOTE CLEANLINESS Perform procedures in a clean environment Make sure all parts are cleaned before disassembly and kept clean during assemb...

Page 254: ...cover 10 always corresponds to the inlet side of the pump The inlet side can be further identified by the gear contact patterns in the body gear bore The wear plate 8 wwill have a somewhat heavier wear pattern on the inlet side The thrust plate 6 will also have a pattern that can be established for reassembly Also note that the long journal of the driven gear 14 is toward the front of the pump Use...

Page 255: ... Service Manual 1997 12 15 12 Lift out drive gear 14 drive gear 7 and wear plate 6 13 Invert pump body with shaft seal up Remove shaft seal 1 by prying it out with a large screwdriver Care should be taken not to damage gouge the shaft seal bore this will result in shaft seal leakage WARNING Return ...

Page 256: ...in body and cover Replace cover or body if bushings are heavily scored or burned 5 Inspect gear journals and faces Replace if journals or faces are scared or worn 6 Inspect body for wear and scoring If gear contact wear on low pressure side inlet exceeds 0 005 in 0 127 mm depth replace pump If the body is NOTE CLEANLINESS Perform procedures in a clean environment Make sure all parts are cleaned be...

Page 257: ...Lift Pump Assembly PS M6 1 6140 F code Section C code Version no T code 001 OE35 BT Products 255 Service Manual 1997 12 15 usable remove wipe burr with suitable de burring tool Return ...

Page 258: ... Ensure outside of W seal is exposed to the discharge pressure or legs of W seal pointing toward the suction port 4 Lubricate bushings in body and face of wear plate with SAE 10 oil 5 Apply Lubriplate or equivalent to outer surface of drive shaft installation sleeve Insert sleeve into shaft seal from front of pump until sleeve contacts NOTE CLEANLINESS Perform procedures in a clean environment Mak...

Page 259: ...il and install trust plate 6 in its original position bronze face toward the gears 7 Apply a small amount of grease to rear cover seal 9 and install seal into groove 8 Lubricate rear cover bushings with SAE 10 oil 9 Position pump with shaft end down install the rear cover 3 aline scribe marks on cover and body 10 Insert cap screws 12 and washers in pump body Torque screws to 34 to 38 ft lb 11 Chec...

Page 260: ...PS M6 1 6140 001 OE35 Version no T code F code Section C code Lift Pump Assembly 258 Service Manual 1997 12 15 Return ...

Page 261: ...Section C code Version no T code 001 OE35 259 Service Manual 1996 10 15 BT Products Mast 2 Stage POS NO DESCRIPTION POS NO DESCRIPTION 1 Platfor 5 Pin dowel 2 Column inner 6 Screw cap 3 Screw cap 7 Pin 4 Column outer 8 Pin cotte Return ...

Page 262: ...until no more may be added 5 Divide shims as equally as possible between the two bearings and install under bearings 6 Hydraulically lift up inner column to remove the platform 7 Lower platform down inner column to expose the bearings Remove bearings to install shims behind bearings 8 Raise platform up inner column as far as it will go under normal operation Check bearing shimming as platform is r...

Page 263: ...in 1 32 in 10 Remove truck from stands and test operation of unit Check operation first with no load then with capacity rated load 11 Install and connect battery to truck 1 2 Shimming the Rails In order to shim the mast rails the platform will have to be removed 1 Disconnect battery and remove from unit 2 The truck will have to be hoisted and blocked a foot off floor 3 Attach a hoist to top of pla...

Page 264: ...aring shimming as inner column is raised Remove shims as required if tight spots are encountered where mast cannot move smoothly Check for excessive bearing clearance with columns in closed position by prying column to one side and check with a 0 030 in shim Maximum clearance must not exceed 0 030 in 11 Attach a hoist to top of platform frame and place platform in inner column 12 Hoist platform up...

Page 265: ...1 OE35 263 Service Manual 1996 10 15 BT Products before platform raises slightly Retighten locknuts on chain anchors 17 Test operation of mast and check for tight or loose spots and reshim as needed Check operation first with no load then with capacity rated load Return ...

Page 266: ...y raise inner column enough to remove platform Lower platform down and out inner column Lower to floor and place out of the way 5 Attach a hoist to top of mast through both inner and outer columns 6 Before disassembling hoses and fittings from cylinder make sure cylinder is in lowered position and thoroughly clean off all outside dirt around fittings After disconnecting hose immediately cap ports ...

Page 267: ...t platform in 4 Hoist platform and slide up inner column 5 Connect lift chain anchor pins 6 Connect steering wheel chain and electrical cable to unit 7 Loosen locking nuts on chain anchors Adjust nuts until both chains are free of twists and of equal tension Tension is correct if you can force lift chain sideways approximately 1 2 in to 1 in before platform raises slightly 8 Retighten locknuts on ...

Page 268: ...ew from top of inner column securing cylinder rod end Remove two cap screws and clamp from bottom of cylinder and remove cylinder assembly 4 Remove chain anchor bolts 5 Remove chain sheaves and cable sheaves from inner column 6 Pull inner column straight forward until it stops hits bearings and then 90 degrees straight up from outer column 7 Remove mast bearings and shim washers from both columns ...

Page 269: ...ion Check bearing shimming as column is extended Remove shims as required if tight spots are encountered where assembler cannot roll mast by hand Check for excessive clearance with columns in the fully closed position by prying column to one side and checking with a 0 030 in shim Maximum clearance must not exceed 0 030 in Check for excessive bearing clearance with columns in the fully extended pos...

Page 270: ...nner column and secure with one cap screw and lockwasher 13 Install bearings in steering chain sheaves grease bearings Install spacer between sheaves and on outside of sheaves 14 Install steering sheaves in proper location on inner column and secure with one cap screw and lockwasher 15 Push inner and outer columns together and install cap screw in inner column to secure lift cylinder 16 Install li...

Page 271: ... Section C code Version no T code 001 OE35 269 Service Manual 1996 10 15 BT Products Mast 3 Stage POS NO DESCRIPTION POS NO DESCRIPTION 1 Platfor 5 Screw cap 2 Column inner 6 Pin 3 Column intermediate 7 Pin cotte 4 Column outer Return ...

Page 272: ...two bearings and install under bearings 6 Hydraulically lift up inner column enough to remove platform 7 Lower platform down inner column to expose bearings Remove bearings to install shims behind bearings 8 Raise platform up inner column as far as it will go under normal operation Check bearing shimming as the platform is raised Remove shims as required If tight spots are encountered where assemb...

Page 273: ...ting nuts wheel nuts and locknuts jam nuts torqued to 200 ft lb 271 N m Chains are to be centered on sheave within 1 32 in 10 Remove hoist from platform and test operation of unit Check operation first with no load then with capacity rated load 11 Install and connect battery to truck 1 2 Shimming the Rails In order to shim the mast rails the platform will have to be removed 1 Disconnect battery an...

Page 274: ...s possible between the two bearings on both top and bottom of column and install under bearings 10 Lower inner column down and out the intermediate column to expose two bottom bearings and install shims under bearings 11 Divide shims as equally as possible between the two bearings on top of intermediate column and install under bearings 12 Raise inner column up intermediate column as far as it wil...

Page 275: ...ing as intermediate column is raised Remove shims as required if tight spots are encountered where assembler cannot move mast smoothly Check for excessive bearing clearance with columns in the fully lowered position by prying column to one side and check with a 0 030 in shim Maximum clearance must not exceed 0 030 in Check for excessive bearing clearance with inner column in fully raised position ...

Page 276: ...cking nuts on lift chain anchors Adjust nuts until both chains are free of twists and of equal tension Tension is correct if you can force lift chains sideways approximately 1 2 in to 1 in before lift platform raises slightly Retighten locknuts on chain anchors 25 Test operation of mast by checking for tight or loose spots and reshim if found Check operation first with no load then with rated load...

Page 277: ...ble Hydraulically raise inner column enough to remove platform Lower platform down and out inner column and set out of way 5 Attach a hoist to top of mast through all three mast columns 6 Before disassembling hoses and fittings from cylinders make sure cylinders are down and thoroughly clean off all outside dirt around fittings After disconnecting hose immediately cap ports on both cylinder and ho...

Page 278: ...inner column 5 Connect lift chain anchor pins steering wheel chain and electrical cable to platform 6 Connect electrical cable and attachment hydraulic hoses to unit 7 Loosen locking nuts on chain anchors Adjust nuts until both chains are free of twists and of equal tension Tension is correct if you can force lift chain sideways approximately 1 2 in to 1 in before lift platform raises slightly 8 R...

Page 279: ...ve chain sheaves and cable sheaves from all columns 5 Remove column stops from outer column 6 Pull inner column straight forward until it stops hits bearings and then 90 degrees straight up from intermediate column 7 Remove cap screws from top of intermediate column and remove staging cylinder assemblies by pushing intermediate column forward 8 Pull intermediate column straight forward until it st...

Page 280: ...ration Check bearing shimming as column is extended Remove shims as required if tight spots are encountered where assembler cannot roll mast by hand Check for excessive clearance with columns in the fully closed position by prying column to one side and checking with a 0 030 in shim Maximum clearance must not exceed 0 030 in Check for excessive bearing clearance with columns in the fully extended ...

Page 281: ...d 0 060 in Check for excessive bearing clearance with columns in the fully extended position by prying column to one side and checking with a 0 030 in shim Maximum clearance must not exceed 0 030 in 11 Install column stops in outer column and torque to 260 ft lb 350 N m 12 Install staging lift cylinder assembly in intermediate column lower end 13 Press roller bearings in lift chain sheaves grease ...

Page 282: ...9 Install lift chain on chain anchors and secure with chain pins After chain pins have been installed run lift chain over chain sheaves making sure chain and sheaves are properly aligned 20 Install freelift cylinder assembly on inner column and secure with four cap screws and nuts 21 Connect hydraulic lines to lift cylinder 22 Lubricate the grease fittings with Tex Ref C C No 880 using a standard ...

Page 283: ...od The lift cylinder can be resealed without removing from the truck POS NO DESCRIPTION POS NO DESCRIPTION POS NO DESCRIPTION 1 Tube cylinder 6 Piston 11 Bearing 2 Retainer 7K Ring wear 12K Ring wear 3 Pin 8 Rod cylinder 13K Seal 4 Spring 9K O ring 14K Wiper 5 Ball 10K Ring backup K Kit seal Torque to 250 300 ft lbs NOTE CLEANLINESS Perform procedures in a clean environment Make sure all parts are...

Page 284: ...od to inner column 5 Lower cylinder so the chains hoses and electric cables are loose Disconnect the battery 6 Remove cylinder bar securing cylinder assembly to bottom of inner column 7 Remove cylinder assembly from mast and truck 8 Clean the exterior of the lift cylinder When blocking mast columns to prevent lowering always block both sides of the column Otherwise the truck could tip over on its ...

Page 285: ... rod wiper in the gland The lip of the wiper must face outward It is not necessary to replace wear ring 7 unless the rod 8 was removed for repair 1 4 Installation 1 Install cylinder assembly in bottom of mast and secure cylinder assembly with cylinder bar using two cap screws 2 Lower mast and secure top of cylinder assembly with cap screw though inner column and cylinder rod 3 Check hydraulic oil ...

Page 286: ...PS S7 3 7310 000 OE35 Version no T code F code Section C code Lift Cylinder 2 Stage 284 Service Manual 1997 12 15 Return ...

Page 287: ...12 15 Freelift Cylinder 3 Stage POS NO DESCRIPTION POS NO DESCRIPTION POS NO DESCRIPTION 1 Retainer 7 Rod cylinder 13K Wiper cylinder 2 Pin 8K O ring 14 Tube cylinder 3 Spring 9K Ring backup 15 Screw 4 Ball steel 10 Bearing 16 Washer seal 5 Piston 11K Ring wear K Kit seal 6K Ring wear 12K Seal Torque to 250 300 ft lbs Return ...

Page 288: ...event lowering 4 Lower cylinder so the chains hoses and electric cables are loose Disconnect the battery 5 Remove chains hoses and electric cables from the crosshead 6 Remove the crosshead from the cylinder rod 7 Clean the exterior of the lift cylinder NOTE CLEANLINESS Perform procedures in a clean environment Make sure all parts are cleaned before disassembly and kept clean during assembly When b...

Page 289: ...p ring O ring rod wiper and bearing retainer from the gland nut 10 Use care NOT to damage the inside of the gland nut 10 1 3 Assembly 1 Install new bearing seals and rod wiper in the gland The lip of the wiper must face outward It is not necessary to replace wear ring 6 unless the rod was removed for repair 1 4 Installation 1 Install crosshead chains hoses and electric cables 2 Connect battery 3 T...

Page 290: ...PS S7 3 7310 000 OE35 Version no T code F code Section C code Freelift Cylinder 3 Stage 288 Service Manual 1997 12 15 Return ...

Page 291: ...Service Manual 1997 07 15 Staging Cylinder 3 Stage POS NO DESCRIPTION POS NO DESCRIPTION 1 Screw 9 Ring wear 2 Washer seal 10 Piston 3 Cylinder tube 1 Port 11 Ring retainer 4 Cylinder tube 2 Port 12 Rod cylinder 5 Plugger assembly 13 O ring 6 Spring 14 Bearing 7 Plug 15 Seal rod 8 O ring 16 Wiper Return ...

Page 292: ...der rods hydraulically 5 Clean the exterior of the lift cylinder 1 2 Disassembly 1 Remove gland nut 12 from the cylinder tube 2 Remove and discard all seals rod wiper 15 and bearing 14 from the gland nut 12 Us care NOT to damage the inside of the gland nut 1 3 Assembly 1 Install new bearing 14 seals and rod wiper 16 in the gland The lip of the wiper must face outward It is not necessary to replace...

Page 293: ... 3 Stage PS S7 4 7310 F code Section C code Version no T code 000 OE35 BT Products 291 Service Manual 1997 07 15 1 4 Installation 1 Install crosshead chains hoses and electric cables 2 Test for proper operation Return ...

Page 294: ...PS S7 4 7310 000 OE35 Version no T code F code Section C code Staging Cylinder 3 Stage 292 Service Manual 1997 07 15 Return ...

Page 295: ...94 is on 1A fuse Wire 72 is on 20A fuse 4 Connect battery to truck 2 Powering Down Transporting the truck Not using an industrial battery 1 Disconnect battery from truck 2 Remove 1A 20A fuse from holder 3 On the center relay move wire 84 from relay terminal position 4 to relay terminal position 1 4 Connect temporary battery to truck This unit is shipped with the N D C Wire Guidance Controller dise...

Page 296: ...o T code F code Section C code Micro 70 Wire Guidance Important Information 294 Service Manual 1997 10 24 20A Fuse 20A Fuse 1A Fuse 1A Fuse Move wire 84 from Position 1 to Position 4 Drawing showing location of fuses and wire Return ...

Page 297: ...T code 001 OE35 BT Products 295 Service Manual 1997 10 24 Micro 70 Wire Guidance 1 Electrical Schematic Part 1 NOTE Items represented with dashed lines are options that may not be present on all models See Truck Electrical Schematic Part 2 for further information Return ...

Page 298: ...S8 0 8200 001 OE35 Version no T code F code Section C code Micro 70 Wire Guidance 296 Service Manual 1997 10 24 2 Electrical Schematic Part 2 See Electrical Schematic Part 2 for further information Return ...

Page 299: ...0 Wire Guidance PS S8 0 8200 F code Section C code Version no T code 001 OE35 BT Products 297 Service Manual 1997 10 24 3 Electrical Schematic Part 3 24 Volt N D C Electrical Schematic Part 3 BLACK RED Return ...

Page 300: ...S S8 0 8200 001 OE35 Version no T code F code Section C code Micro 70 Wire Guidance 298 Service Manual 1997 10 24 4 Electrical Schematic Part 4 36 Volt N D C Electrical Schematic Part 3 BLACK RED Return ...

Page 301: ...fety of the technician and other persons nearby WARNING Perform a daily operational check of the vehicle Do not operate a malfunctions vehicle Report all malfunctions to your supervisor or foreman Operation of a malfunctioning vehicle could result in person injury or property damage WARNING When charging the truck battery make sure that the charger is connected to the battery and not the truck Fai...

Page 302: ...so could result in personal injury WARNING Disconnect battery from vehicle before disconnecting or connecting any cable plugs or components CAUTION All steering and guidance system components must be properly mounted and the battery properly charged before making any adjustments to the guidance system and components CAUTION There are conditions outside of the Micro 70 controller that can cause con...

Page 303: ...anual mode Manual mode is intended for use outside of the guided aisle only and should never be used when operating the truck within the guided aisle The truck operator chooses the mode of operation with a push button switch on the operator s console Prior to operating the truck it is essential that the operator become familiar with all switches and indicators on the console Only trained and autho...

Page 304: ...he guide wire is acquired and then lost the parking brake will automatically set and the loss of wire light will turn on and an audible alarm will sound To reset the Micro 70 system after loss of wire has occurred the manual auto button must be pushed one time to return to manual mode Repeat steps c and d to re acquire the guide wire e Drive the truck into the guided aisle allowing the Micro 70 sy...

Page 305: ... The on wire light will turn on and the steering will be automatically controlled by the Micro 70 system If the guide wire is not acquired as the truck moves over the guide wire the steering may return to the acquisition mode and the on wire light will not turn on If the guide wire is acquired and then lost the parking brake will automatically set and the loss of wire light will be turn on and an ...

Page 306: ...re in addition to any checks recommended in the vehicle operator s manual 1 Check for oil leaks missing or damaged parts or other conditions that may prevent the truck from operating satisfactorily 2 Inspect cables hoses tires and mechanical components for physical damage 3 Check antennas for physical damage 4 Insure that all truck functions are working properly This should include brakes lift con...

Page 307: ...xception of the cable connections into the antenna Both antennas should be mounted on the truck with the epoxy side facing away from the center of the truck One antenna is used for guidance in the steer wheel direction of travel and both antennas are used for guidance in the load wheel direction of travel The steering feedback potentiometer sends a signal to the Micro 70 controller to indicate the...

Page 308: ... used to disconnect the steer motor whenever the truck is not moving CR2 is used to engage the parking brake through a solenoid if a steering malfunction occurs i e loss of wire CR3 is used to enable a truck speed limit when the system is in acquisition mode to reduce the possibility of guide wire overshoot The control panel on the operator console consists of a pushbutton auto manual switch an in...

Page 309: ...the following instructions if the truck has had repairs or component replacement in the Micro 70 system 1 Drive truck so that the truck is centered over guide wire and steering wheel is straight ahead as near as possible 2 Verify correct antenna mountings The antennas must be mounted directly over and level and square to the guide wire Both antennas must be 1 5 in above the floor The epoxy side of...

Page 310: ...the inhibit signal from the FSA and allow the Micro 70 system to try to correct the angle of the steer wheel even though the truck is not traveling 19 Reconnect battery and restart truck 20 Push the Auto Manual button on the console and turn the guidance system on to Auto 21 Step on the Foot Pedal to start the Power Steering Motor running 22 Adjust the Zero Potentiometer so that the steering motor...

Page 311: ...ff the guidewire to the left side then the Zero Potentiometer will require adjustment in the counter clockwise direction 27 Operate truck in Auto mode in load wheel direction of travel and observe position of load wheel antenna and truck in relation to the guidewire Adjust load wheel antenna from side to side as necessary to keep truck centered over guide wire If the truck runs off guidewire or to...

Page 312: ...fier will be referred to as the FSA in the troubleshooting charts It is critical that the Micro 70 components be properly installed In particular the antennas must be installed so that the epoxy filled side is facing away from the center of the truck The Micro 70 frequency must match the frequency of the line driver The Micro 70 frequency can be adjusted with connections on the Micro 70 controller...

Page 313: ...ilure It is inevitable that some problems may occur whose fault cannot be found by normal troubleshooting procedures When this happens the technician is reduced to the task of changing parts until the failed part is replaced and the truck begins to operate properly Even when the technician becomes a parts changer there are certain rules to follow Never install an obviously damaged component on any...

Page 314: ...ctions for testing in the chart If the required voltage is present go to the next test in the chart If the required voltage is not present follow the directions for repair listed at that test Unless otherwise specified all voltage measurements are made with respect to battery negative wire 22 and all tests are testing for positive voltage DC unless the test says different The truck key must be tur...

Page 315: ... manual switch If not zero volts repair open wire 13 between auto manual switch and truck wiring harness d Replace auto manual switch 2 Alarm sounds and parking brake is set in all modes of operation auto and manual lights turn on in turn each time the auto manual button is pushed Tests are to be made with Micro 70 system in manual mode a Check for battery volts on wire 2 at fuse holder of fuse 1 ...

Page 316: ...wire 2 at fuse holder of fuse 1 1 amp control fuse If not battery volts repair open wire 13 from Micro 70 connector K1 2 to truck negative wire 13 h Check for 24 volts at wire 70 on Micro 70 connectors K1 1 K6 12 and K8 10 If not 24 volts repair open wire 70 between emergency disconnect contactor interlock switch 24 volt trucks or voltage regulator 36 volt trucks and Micro 70 connectors If still n...

Page 317: ...0 system will not make any steering corrections steering effort is same in manual and auto modes This chart is meant for a truck that will not make any steering corrections even though the on wire light comes on If the truck even tries to make steering corrections go to chart 6 a Drive the truck in manual mode and take note of the effort required to turn the steering wheel Now drive the truck alon...

Page 318: ... 1 control relay and check for the mechanical operation of the relay If no mechanical operation of relay replace 1 control relay h Check for battery volts on wire 72 at positive terminal on FSA If not battery volts repair open wire 72 between fuse 2 20 amp slow blow control fuse and positive terminal on FSA The following tests require that the front antenna steer wheel antenna be removed from the ...

Page 319: ...ler is likely failed j With the truck power on as shown above in h4 hold the steer wheel antenna one and a half inches 1 5 in over the guidewire and move the antenna from one side of the guidewire to the other about two inches 2 in of total movement Measure the voltage between S red wire and S black wire on the FSA It does not matter which wire the positive lead or negative lead of the volt meter ...

Page 320: ...lack wires connected to the electric steering motor to change from positive to negative up to battery volts If the voltage does not change as stated repair the open wire or open 1 control relay tips between the FSA and the electric steering motor m Replace electric power steering motor 5 The truck will not guide in auto mode Truck operates normally in manual mode but when switched to auto mode and...

Page 321: ...made Also the inhibit signal to the FSA must be disconnected so that the Micro 70 system may try to steer the truck even though the truck is not actually moving Unplug the truck battery before disconnecting or reconnecting any component to the Micro 70 controller b1 Unplug truck battery b2 Disconnect and remove front antenna steer wheel antenna from truck Reconnect antenna after it is removed from...

Page 322: ...volts repair open red or black wire between FTI 7 and Micro 70 controller f Check for positive 5 volts between K2 1 red wire and K2 3 black wire on FTI 7 The red wire on K2 1 should be positive on the volt meter leads and the black wire on K2 3 should be negative If not 5 volts 0 5 volts replace FTI 7 g Check for positive 5 volts between the red wire on terminal 1 of the steering feedback potentio...

Page 323: ... be found in this manual under Operation It is possible for the Micro 70 system to start to make steering corrections without fully acquiring the guidewire if the approach angle is too great Also go to the section in this manual Truck Set Up On Site and go completely through all of the adjusting procedures again before beginning any testing a Check for 12 volts between K7 6 and K7 9 on the Micro 7...

Page 324: ... wire at FTI 7 K2 2 as the truck is steered left and right of straight ahead If not a smooth voltage transition replace feedback potentiometer h With the steering in the straight ahead position check for 5 volts between K3 2 and K3 5 on the FTI 7 K3 2 should be positive on the volt meter leads and K3 5 should be negative If not 5 volts repair open white or black wire between the FTI 7 and the Micr...

Page 325: ...ough the wiring harness to be hidden behind the Micro 70 controller It is unlikely that these connections would be changed by unauthorized persons because the wires are taped down to the harness For 2 2 KHz both connections should be open For 5 2 KHz the wire from K6 7 should be connected to battery negative wire 13 the wire from K6 8 should be left open For 6 25 KHz the wire from K6 8 should be c...

Page 326: ... volts then possible Micro 70 controller failure g Check for positive 12 volts between pin 2 and pin 4 of steer wheel front antenna The positive wire of the volt meter should be on pin 2 and the negative lead on pin 4 If not positive 12 volts repair open red or open common wire between Micro 70 controller and steer wheel antenna h Verify integrity of other leads from antenna to Micro 70 controller...

Page 327: ...ve lead on K3 4 If not positive 12 volts then possible Micro 70 controller failure d Check for positive 12 volts between pin 2 and pin 4 of load wheel antenna The positive lead of the volt meter should be on pin 2 and the negative lead on pin 4 If not positive 12 volts repair open red or open common wire between Micro 70 controller and load wheel antenna e Verify integrity of other leads from load...

Page 328: ...t K1 1 to increase above 5 volts The voltage should change smoothly with a larger change at higher travel speeds If voltage does not increase smoothly replace tachometer g With the truck standing still check for 5 volts at K3 4 on the FTI 7 If not 5 volts 0 1 volts replace FTI 7 and readjust system h While driving the truck in the forward steer wheel direction check for the voltage at K3 4 to decr...

Page 329: ... the guide wire and travels in auto for a short distance before loosing the wire are an indication that the guidance system needs fine tuning See the section in this book Truck Set Up On Site a If the truck runs off the wire with both antennas to the same side of the wire the problem is likely in the adjustment of the steering feedback potentiometer or zero potentiometer b If the truck runs off th...

Page 330: ...PS S8 0 8200 001 OE35 Version no T code F code Section C code Micro 70 Wire Guidance 328 Service Manual 1997 10 24 Return ...

Page 331: ...Return ...

Page 332: ...BT Prime Mover Inc 3305 N Highway 38 Muscatine Iowa 52761 8800 U S A Tel 319 262 7700 Fax 319 262 7600 Return ...

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