Forklift Prime Mover Smx45 4e1f4q

Front Cover

Master Service Manual SMX45

Electric Walkie Low-Lift Pallet Truck Effective Serial Number SMX__4533227001 - UP

Warning

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

Warning

DO NOT operate this equipment unless all factory installed guards and covers are properly secured in place.

Part no: 313084-000

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Date: December 12, 2006

BT Prime-Mover is a trademark of BT Prime-Mover Inc., ©

2006 BT Prime-Mover Inc., Muscatine, Iowa. All Rights Reserved.

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Ordering Spare Parts

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Ordering Spare Parts Supply the following information will assure prompt, efficient handling of the order: 1. Identify truck model and serial number. 2. Refer to Parts Book and locate page with the exploded diagram. 3. Find item number for the part required. Select the column for the actual truck model and serial number. 4. The following is an explanation of a serial number:

SMX 00 3 6 045 001 Number of unit for that day Day of year (365) Year (2006) Decade (2000) Capacity (3000lb) Model (SMX)

CAUTION Although some trucks appear to be similar, component parts may not be interchangeable. If an incorrect part is used, the truck may malfunction. 5. Note part number. 6. Call your local Prime-Mover Dealer and state part number. 7. If the truck model, serial number, or article number cannot be found on the truck, call your local PrimeMover Dealer for assistance.

© BT Prime-Mover, Inc.

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SMX

Standard Codes B-Code

= Business area

F-Code

= Product family

T-Code

= Product type

C-Code

= Component function

Worksheet standard W-Code = Working code R-Code

= Reason code

SO-Code = Assortment F-Code List PT

Low-Lift Pallet Truck

T-Code List No.

Model SMX45

C-Code List No Function Group


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C-Code

0

Frame

0000

1

Motors

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

9000

10

Tools

10000


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Table of Contents Table of Contents Ordering Spare Parts .................................................................................... 1 Standard Codes ............................................................................................. 3 Warning Symbols ......................................................................................... 13 Warning Levels .................................................................................................... 13

Prohibitory Symbols .................................................................................... 14 Ordinance Symbols .............................................................................................. 14

Safety ............................................................................................................ 15 General Safety ..................................................................................................... 15

Battery Safety ............................................................................................... 20 Static Discharge Precautions ..................................................................... 25 Welding Safety ............................................................................................. 27 Introduction, Service Manual ...................................................................... 29 Contents, Section M ..................................................................................... 31 Machine Information ............................................................................................ 31

General Product Information ...................................................................... 33 Truck Presentation ............................................................................................... 33 Truck Side Views .......................................................................................................... Intended Truck Application ........................................................................................... Prohibited Truck Application ......................................................................................... Truck Data .................................................................................................................... Dimensions ................................................................................................................... Data Plate .....................................................................................................................

33 33 34 34 35 36

Main Components ................................................................................................ 37

Inch (SAE) and Metric Fasteners ................................................................ 39 Introduction .......................................................................................................... Nomenclature, Threads ........................................................................................ Strength Identification .......................................................................................... Truck Torque Specifications ................................................................................. Conversion of Metric and English Units ...............................................................

39 40 41 47 48

Technical Service Data ................................................................................ 51 Contents, Section P ..................................................................................... 55 Planned Maintenance .......................................................................................... 55

Introduction, Maintenance .......................................................................... 57


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Table of Contents Jacking Truck Off The Floor ................................................................................. 58 Fork Section ................................................................................................................. 59 Tractor Section ............................................................................................................. 59

Lubricants ............................................................................................................ 59 Standard ....................................................................................................................... 59 Cold Storage ................................................................................................................ 59

Service Schedule ......................................................................................... 61 Planned Maintenance Schedule .......................................................................... 61 Planned Maintenance Procedures ....................................................................... 64 General ......................................................................................................................... Hardware ................................................................................................................. Noise ....................................................................................................................... Leaks ....................................................................................................................... Cables and Connections ......................................................................................... Grease Location Points ........................................................................................... Services Performed Daily or Every 8 Operating Hours ................................................ Frame ...................................................................................................................... Brakes ..................................................................................................................... Wheels/Tires ........................................................................................................... Steering Control Handle .......................................................................................... Functions/Operations .............................................................................................. Battery ..................................................................................................................... Battery Connector ................................................................................................... Services Performed Every Two Months or Every 250 Operating Hours ...................... Frame ...................................................................................................................... Motors ..................................................................................................................... Drive Unit ................................................................................................................ Brake ....................................................................................................................... Electrical Control System ........................................................................................ Battery ..................................................................................................................... Electrical ....................................................................................................... Hydraulic System .................................................................................................... Lifting Devices ......................................................................................................... Services Performed Annually or Every 1500 Operating Hours .................................... Drive Unit ................................................................................................................ Hydraulic System ....................................................................................................

64 64 64 64 65 65 65 65 65 65 65 66 66 66 67 67 67 67 67 67 68 68 68 68 68 68 69

Lubrication Chart ......................................................................................... 71 Oil and Grease Specifications .................................................................... 72 Lubricants ............................................................................................................ 72 Grease Location Points ........................................................................................ 72

Contents, Section S ..................................................................................... 73 Service Instructions .............................................................................................. 73

Frame ............................................................................................................ 75 Theory of Operation ............................................................................................. 75 Maintenance ........................................................................................................ 75 Inspection ..................................................................................................................... 75

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Table of Contents Troubleshooting ................................................................................................... 76 Repair and Rebuild .............................................................................................. 76

Inspection Covers ........................................................................................ 83 Theory of Operation ............................................................................................. Maintenance ........................................................................................................ Troubleshooting ................................................................................................... Repair and Rebuild ..............................................................................................

83 83 83 83

Decals ............................................................................................................ 85 Decal with Protective Sheet ................................................................................. 85 Decal without Protective Sheet ............................................................................ 85

Electric Motors ............................................................................................. 87 Theory of Operation ............................................................................................. Maintenance ........................................................................................................ Troubleshooting ................................................................................................... Repair and Rebuild ..............................................................................................

87 87 88 89

Motor Brushes .............................................................................................................. Drive Motor .............................................................................................................. Pump Motor ............................................................................................................. Brush Inspection ..................................................................................................... Brush Replacement ................................................................................................. Pump Motor .................................................................................................................. Removal .................................................................................................................. Installation ............................................................................................................... Drive Motor ................................................................................................................... Drive Motor ................................................................................................................... Removal .................................................................................................................. Installation ...............................................................................................................

89 89 90 90 91 92 92 93 94 96 97 97

Transmission ................................................................................................ 99 Theory of Operation ............................................................................................. 99 Maintenance ........................................................................................................ 99 Fluid Changing ............................................................................................................. 99

Troubleshooting .................................................................................................. 100 Repair and Rebuild ............................................................................................. 100

Parking Brake System ................................................................................ 109 Theory of Operation ............................................................................................ 109 Maintenance ....................................................................................................... 111 Mechanical Brake Release .......................................................................................... 111 Brake Adjustment ........................................................................................................ 111


Drive Wheel .................................................................................................. 115 Theory of Operation ............................................................................................ 115 Maintenance ...................................................................................................... 115


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Table of Contents Drive Wheel Nut Inspection ......................................................................................... 115


Load Wheels ................................................................................................ 121 Theory of Operation ............................................................................................ Maintenance ....................................................................................................... Troubleshooting .................................................................................................. Repair and Rebuild .............................................................................................

121 121 121 122

Caster Wheel (Optional) ............................................................................. 125 Theory of Operation ............................................................................................ 125 Maintenance ....................................................................................................... 125 Inspection .................................................................................................................... 125


Steering Control Handle ............................................................................. 129 Theory of Operation ............................................................................................ 129 Maintenance ....................................................................................................... 129 Inspection .................................................................................................................... 129


Steering Control Head ................................................................................ 135 Theory of Operation ............................................................................................ Maintenance ....................................................................................................... Troubleshooting .................................................................................................. Repair and Rebuild .............................................................................................

135 135 135 136

Steering Bearing ......................................................................................... 141 Theory of Operation ............................................................................................ Maintenance ....................................................................................................... Troubleshooting .................................................................................................. Repair and Rebuild .............................................................................................

141 141 141 142

Electrical Functions .................................................................................... 145 Theory of Operation ............................................................................................ 145 Battery Plugged In With Keypad ................................................................................. Battery Plugged In With Key Switch ............................................................................ Main ON/OFF Switch/Keypad ON ............................................................................... Travel, Low Speed ...................................................................................................... Travel, High Speed ...................................................................................................... Reverser ...................................................................................................................... Lift ................................................................................................................................ Lower ...........................................................................................................................

146 147 148 150 152 153 154 155

Maintenance ....................................................................................................... 156 Wiring .......................................................................................................................... 156 Definitions .............................................................................................................. 156

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Table of Contents Shorts to Frame Test ............................................................................................. 157

Troubleshooting .................................................................................................. 161 Troubleshooting Flowchart .......................................................................................... Main Harness Replacement ........................................................................................ Operator Display and Programming ............................................................................ Special Modes ........................................................................................................ Service Display ...................................................................................................... Digital Inputs/Outputs from Transistor Controller ................................................... Transistor Controller System Mode ........................................................................ Changing Driver Accessible Parameters (P) ............................................................... Changing Service Parameters .................................................................................... Parameter Description ........................................................................................... Operating Parameter Programming ....................................................................... Display Part Numbers (Pn) .................................................................................... Error Codes (E) ........................................................................................................... Error Code History ................................................................................................. Truck Fault Codes .................................................................................................. Troubleshooting Chart Index ....................................................................................... Travel (Forward / Rearward) System ..................................................................... Wiring System ........................................................................................................ Other Possible Troubleshooting Issues ................................................................. Troubleshooting Charts ............................................................................................... Electrical Schematic 1(2) ............................................................................................. Electrical Schematic 2(2) .............................................................................................

161 164 168 168 169 170 171 172 174 176 179 179 180 180 181 188 188 188 188 189 194 195

Battery .......................................................................................................... 199 Theory of Operation ............................................................................................ 199 Maintenance ....................................................................................................... 199 Inspection and Care .................................................................................................... Exterior Cleaning ......................................................................................................... Charging ...................................................................................................................... Storage ........................................................................................................................ History Record .............................................................................................................

199 200 200 201 202


Swing Out Battery Pack .............................................................................. 205 Theory of Operation ............................................................................................ 205 Maintenance ....................................................................................................... 205 Electrical Testing ......................................................................................................... 205 Required Equipment .............................................................................................. 205 Instructions ............................................................................................................. 205


Battery Connector ....................................................................................... 215 Theory of Operation ............................................................................................ 215 Maintenance ....................................................................................................... 215 Inspection .................................................................................................................... 215



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Table of Contents Switches ....................................................................................................... 219 Theory of Operation ............................................................................................ Maintenance ....................................................................................................... Troubleshooting .................................................................................................. Repair and Rebuild .............................................................................................

219 220 222 223

Main ON/OFF Switch .................................................................................................. Arm Angle Switches .................................................................................................... Lift Limit Switch ........................................................................................................... Key Switch (Optional) .................................................................................................. Horn Switch ................................................................................................................. Converting Keypad to Key Switch ...............................................................................

224 224 225 226 226 227

Fuses/Circuit Breakers ............................................................................... 229 Theory of Operation ............................................................................................ 229 Maintenance ....................................................................................................... 229 Wiring Harness ............................................................................................................ Power Cables .............................................................................................................. Circuit Breaker ............................................................................................................. Master Control Relay ...................................................................................................

230 231 232 233


or ........................................................................................... 235 Theory of Operation ............................................................................................ 235 Maintenance ....................................................................................................... 235 Troubleshooting .................................................................................................. 235 Resistance Testing ...................................................................................................... 235

Repair and Rebuild ............................................................................................. 236

Transistor Controller .................................................................................. 239 Theory of Operation ............................................................................................ 239 Basics Of Circuit Operation ......................................................................................... Interface ...................................................................................................................... Control Features .......................................................................................................... Motor Circuit ................................................................................................................ Control Circuit .............................................................................................................. Definitions ....................................................................................................................

239 240 241 241 242 243

Maintenance ....................................................................................................... 244 Safety .......................................................................................................................... 244 Cleaning ...................................................................................................................... 244

Troubleshooting .................................................................................................. 245 Diagnostics and Troubleshooting ................................................................................ 245 Fault Codes ................................................................................................................. 245

Repair and Rebuild ............................................................................................. 247

Electronic Tiller Arm Card (ETAC) ............................................................. 249 Theory of Operation ............................................................................................ Maintenance ....................................................................................................... Troubleshooting .................................................................................................. Repair and Rebuild .............................................................................................

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249 250 250 251

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Table of Contents Hydraulic System ........................................................................................ 253 Theory of Operation ............................................................................................ 253 Lift ................................................................................................................................ 254 Lower ........................................................................................................................... 255 Relief Pressure ............................................................................................................ 256

Maintenance ....................................................................................................... 257 Changing Hydraulic System Fluid ............................................................................... 257 Hydraulic Pump Pressure Relief Valve ....................................................................... 259

Troubleshooting .................................................................................................. 259 Troubleshooting Chart Index ....................................................................................... 260 Troubleshooting Charts ............................................................................................... 261

Repair and Rebuild ............................................................................................. 264 Hydraulic Unit .............................................................................................................. Hydraulic Solenoid ...................................................................................................... Reservoir ..................................................................................................................... Filter Screen and Inlet Tube ........................................................................................ Lift Pump .....................................................................................................................

266 267 268 269 270

Lift Cylinder ................................................................................................. 271 Theory of Operation ............................................................................................ 271 Maintenance ....................................................................................................... 271 Inspection .................................................................................................................... 271



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Warning Symbols T-code

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

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

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

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

NOTE! Marks the risk of a accident or breakdown if the instructions are not followed.


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

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

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

1. Ordinance Symbols

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

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

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

Know the truck controls and what they do.

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


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Operate truck only from the position of the operator.

Before working on this truck always press the red OFF (O) key on the keypad and disconnect the truck battery connector (unless this manual states otherwise.)

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

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Follow the scheduled inspection steps.

lubrication,

maintenance,

and

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

Do NOT Use an open flame near the truck.

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


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

Always operate and park truck indoors.

Do not park truck in a cold storage area overnight.

Do NOT wash truck with a hose.

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


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

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

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

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


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

Press the red OFF (O) key on the keypad before disconnecting the battery from the truck at the battery connector. Do NOT break live circuits at the battery terminals. A spark often occurs at the point where a live circuit is broken.

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

Keep batteries clean. Corrosion causes shorts and possibly sparks to the frame.

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

Cable

Filler Plugs

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

Filler Plug

Vent Hole

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


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

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

Follow the charging procedures available by the supplier on the “Battery” and “Battery Charger”.

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PT Static Discharge Precautions Version no

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Static Discharge Precautions Electronic circuit board and devices used on the truck can be damaged by the discharge of static electricity, called electrostatic discharge. Static charges can accumulate from normal operation of the truck as well as movement or between nonconductive materials such as plastic bags, synthetic clothing, synthetic soles on shoes, styrofoam coffee cups, etc. Accumulated static can be discharged through human skin to a circuit board or component by touching the parts. Static discharge is also possible through the air when a charged object is placed close to another surface at a different electrical potential. Static discharge can occur without seeing or feeling it. Whenever working on or near static-sensitive electronics, always use static discharge precautions. 1. Static-sensitive items are to remain in their protective containers except when actually in use at the static-free station. 2. Before removing the item(s) from their protective container, the operator should place the container on the conductive grounded bench top. Make sure the wrist strap fits snugly around the wrist and is properly plugged in/attached to ground receptacle or the truck. The operator should then touch hands to the conductive bench top, workstation, or truck. 3. All operations should be performed with the items in with the truck or grounded bench top. 4. Do not allow conductive magazine (static-sensitive items) to touch hard-grounded test gear or bench top. 5. Ordinary plastic solder-suckers and other plastic assembly aids should not be used. 6. In cases where it is impossible or impractical to ground the operator with a wrist strap, a conductive shoe strap can be used along with conductive tile/ mats.


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7. When the operator moves from any other place to the static-free station, the start-up procedure should be the same as the preparation for working at a static-free workstation. 8. “Plastic snow” polystyrene foam, peanuts, or other high-dielectric materials should never come in with or be used around electrostatic sensitive items, unless they have been treated with an antistatic compound. Such treatment is often indicated by a pink color on the foam material. 9. Static-sensitive items should not be transported or stored in trays, tote boxes, vials, or similar containers made of untreated plastic material unless items are protectively packaged in conductive material.

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


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CAUTION Disconnect battery before attempting to inspect, service or repair truck. Discharge residual charge in the transistor controller by connecting a load across the transistor controllers B+ and B- terminals (such as a or coil or by pressing the horn button.)

• Check for shorts to frame. If any shorts are detected, remove before proceeding with the welding operation. • Clean the area to be welded. • Protect all truck components from heat, weld spatter and debris. • Attach the ground cable as close to the weld area as possible. • Disconnect all electrical cards before any type of electric resistance welding is done. • Only trained, qualified, and authorized personnel should weld on the truck. • Do not perform any welding operations near the electrical components. • If welding must be done, remove the battery from the truck. • When welding is completed, perform all ground tests and electrical inspections before the truck is operated.

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Introduction, Service Manual The information in this service manual covers model SMX45. Federal and State laws require that operators be completely trained in the safe operation of lift trucks in accordance with OHSA regulation 1910.178. An operator’s manual is sent with every Prime-Mover truck when it is manufactured. If the operator’s manual is missing from the truck, a new manual may be obtained by ing: BT Prime-Mover, Inc. 3305 N Highway 38 Muscatine, Iowa

52761-8800

(563) 262-7700 The information contained in this service manual is intended as a guide to help trained, qualified, and authorized technicians safely service the truck. The service manual is divided into four separate sections which cover needed information for servicing the truck types. The main subject for each of these sections is described below.


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SECTION

SUBJECT

M

MACHINE INFORMATION

P

PLANNED MAINTENANCE

S

SERVICE INSTRUCTIONS

O

OPTIONS


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M1.0

GENERAL PRODUCT INFORMATION

M2.0

TECHNICAL SERVICE DATA


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General Product Information 1. Truck Presentation The SMX45 is a battery powered walkie low-lift pallet truck. The truck is intended solely to be operated indoors carrying pallets or similar load carriers. The truck is equipped with a steering control handle with all the controls for operating within easy access. The trucks lifting capacities can be found on the truck’s data plate. The SMX45 truck is equipped with a 24 volt electrical system. Speed is regulated by means of a transistor controller to provide infinite control of acceleration and speed while driving. The forks are raised by means of a hydraulic unit. The control of the lift/lower is done electrically with push buttons on the steering control handle.

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

Forward (Tractor-first)

Rearward (Forks-first)

Right Side

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


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1.3. Prohibited Truck Application The trucks are designed for handling goods indoors. It is not permitted to use the trucks for other purposes including the following: •

As a towing tractor for trailers.

•

To tow other trucks.

•

To transport/lift engers.

•

To drive on gravel or grass.

1.4. Truck Data The following table provides information regarding technical data which is of value with daily use of the trucks. Lifting capacity and weight can be found on the truck’s data plate (see page 36.) Metric dimensions and capacities are shown in parenthesis and have been rounded for convenience. Truck Data Lifting capacity rated load, lb (kg)

4500 (2241)

Lift height, inch (mm)

5.0 (127.0)

Operating speed without load, mph (kph)

3.6 (5.8)

Operating speed with load, mph (kph)

3.4 (5.5)

Service weight without battery, lb (kg)

640 (290)

Service weight including battery Minimum battery weight is 200 lbs (91 kg) 24 volt

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1.5. Dimensions The following diagram shows external dimensions for the SMX45 truck in its standard design.

A

68.6 inch (1742 mm) 23.0 inch (585 mm)

Battery Compartment 27.0 inch (685 mm)

26.6 inch

E (675 mm)

28.0 inch (711 mm)

6 (15 0 inch 25 mm )

6.8 inch (172 mm)

B

6° Battery Compartment 7.8 inch (198 mm) 47.9 inch (1216 mm)

40°

33°

C

8°

48.0 inch Nominal (1220 mm)

5.4 inch (137 mm)

3.25 inch (83 mm)

31.2 inch (792 mm)

D

3.1 inch (79 mm)

53.0 inch (1346 mm) Full Load Gradeability: 6% 2500 lbs (1133 kg) Load Gradeability: 10% Dimensions shown in parentheses are metric, others are standard U.S. measure.


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SMX

Use only batteries that meet the following specifications: Battery Pack Dimension Specifications 24 Volt Battery Pack

Amp Hour

Length

Width

Height

Max Weight

Swing-out Upper Trays with 15 amp charger

152

26.5 inch (675 mm)

7.5 inch (192 mm)

26.45 inch (672 mm)

300 lbs (136 kg)

GNB PalletPro™ with 25 amp charger

195

26.5 inch (675 mm)

7.5 inch (192 mm)

26.25 inch (665 mm)

300 lbs (136 kg)

1.6. Data Plate The illustration shows the data plate used on this truck.

2

1

5

4 7

6

3

8 10

9

Legend

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1

Truck model number

6

Truck voltage DC

2

Truck serial number

7

Battery type UL class

3

Truck type

8

Battery maximum AMP hours

4

Truck lifting capacity

9

Minimum battery weight

5

Truck weight (less battery)

10

Maximum battery weight


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SMX

2. Main Components 1. Steering Control Handle: The truck is to be controlled by the operator with 180 degree steering angle. The truck has the ability to right-angle stack. The brake is applied in the upper and lower position of the steering control head.

2. Hydraulic unit: Pump motor, pump, electric valve and oil tank integrated in a compact unit.

3. Hydraulic lowering valve: For controlling lifting and lowering functions with hydraulic lowering valve.

4. Battery: 24 volt with different capacities and weights.

5. Drive unit with brake: Drive unit with a electromagnetic brake assembly, drive motor, drive wheel, and transmission assembly. The steering bearing is located at the top of the drive unit.

6. Steering pivot point. 7. Data plate: See data plate on page 36.

8. Operator Display: Display includes hourmeter, error codes, parameters, hardware and software part numbers.

9. Electrical : 24 volt electrical system. Truck speed is regulated by means of a transistor controller.

10. Fuse/Circuit breaker: 10A, Fuse Keypad and ETAC (supplied with main harness) 10A, Fuse Main ON/OFF (supplied with main harness) 110A, Power Circuit Breaker

11. Load wheel: Lubricate load wheels to prevent wheels from locking up. Load wheels with sealed bearings.

12. Keypad: Enter PIN-key code in the keypad and press green key (I) on the keypad starts truck. Press red OFF (O) on the keypad to shut off electrical power to the control system. Up to 10 operators can be assigned their own individual PIN-key code for access to the truck.


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13. Main ON/OFF switch The main ON/OFF switch will cut off all electrical power to the control functions on the truck when pressed.

14. Travel speed / direction selection To select direction, rotate thumb controls in the direction of travel. The further you rotate in that direction the faster the travel.

15. Fork lower switch Forks will lower when switch is pressed or until lower stops are reached.

16. Fork raise switch Forks will raise when switch is pressed until lift limit switch is opened.

17. Horn switch Activates horn to warn others of your position. Horn button is also used to cycle through special truck mode displays (see page 168.)

18. Battery disconnect Disconnecting the battery connector will shut off all electrical power to the truck. 17

16 1

12 1 4 7 O

2 5 8 0

3 6 9 I

14

15

13, 18 9, 10 8

2, 3

7

4 6 5 11

38

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

T-code

001

SMX

Inch (SAE) and Metric Fasteners

5

9

10

5

9

10

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


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

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

Metric

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

M12 x 1.75 x 50 A B C

A =Shank diameter B =Number of threads per unit of length C =Type of thread D =Shank length

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A =Thread size B =Pitch C =Length

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


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

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Table 1. Bolt and Screw Designations

Types of Fasteners

Metric Fasteners

Inch Fasteners

Strength Levels: Property Classes

Strength Levels: SAE Grades

2

5

5.2

7

* Markings Not Required 8

Hex Head Bolts & Cap Screws 5

4.6*

4.8*

5.8*

8.8

4.6

4.8

5.8

8.8

9.8

10.9

12.9

9.8

10.9

12.9

Markings for size M5 and Larger

8

Same As Above

Hex Head Flange Screws 5

8

12 Point Flange Screws Markings Not Required

8.8

12.9

8.8

12.9

Hex Socket Head Cap Screws 5.1

4.8*

9.8

4.8

9.8

Sems

42

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Table 2. Stud and Nut Designations

Types of Fasteners

Inch Fasteners

Metric Fasteners

*

* Markings Not Required



Markings Not Required

5*

5.2*

8*

4.6*

4.8*

5.8*

8.8

4.6

4.8

5.8

8.8

9.8

10.9

12.9

9.8

10.9

12.9

Markings for size M5 and Larger

8.1 or

Studs

Optional Geometric Symbols for Size M5 through M11.

2

5

8

or

or

8

5

8

9

5

8

9

10

Hex Nuts


Hex Slotted Nuts

9

5

12

10

12

10

12

5

8

9

5

8

9

10

10

5

8

9

10

5

8

9

10

12

12 12


Hex Flange Nuts


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Table 3. Torque Nut Designations

Types of Fasteners

Inch Fasteners


A

B B

C C

Metric Fasteners


5

9

5

9

10 10

or All Metal Prevailing Torque Nuts

F

G 9

10

9

10

or All Metal Prevailing Torque Flange Nuts

or

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Table 4. Torque Nut with Nylon Insert Designations

Types of Fasteners

Inch Fasteners


Metric Fasteners


5

9

10

5

9

10

or

Nylon Insert Prevailing Torque Nuts


or or


9

10

9

10

or

Nylon Insert Prevailing Torque Flange Nuts


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Table 5. Fastener Torque Values

Size and Pitch

Property, Class 8.8*

Property, Class 10.9**

Property, Class 12.9***

N•m

in-lbs

N•m

in-lbs

N•m

in-lbs

5-6 8-10 20-25

44-53 71-88 177-221

7-8 12-14 30-35

62-71 106-124 265-309

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

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

N•m

ft-lbs

N•m

ft-lbs

N•m

ft-lbs

M8 x 1.25 M10 x 1.5

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

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

29-35 60-65

22-26 44-48

34-40 70-75

26-30 52-55

M12 x 1.75 M14 x 2

70-80 110-125

30-33 52-59

100-110 155-180

74-81 114-133

115-130 180-210

85-96 133-155

M16 x 2 M20 x 2.5

170-190 340-380

125-140 251-280

240-270 450-500

177-199 332-369

280-320 550-600

207-236 406-443

M24 x 3

580-650

428-479

800-900

590-664

900-1050

664-774

M30 x 3.5

1150-1300

848-959

1600-1800

1180-1328

1850-2100

1364-1549

M36 x 4

2000-2250

1479-1660

2800-3150

2065-2323

3250-3700

2397-2729

M5 x 0.8 M6 x 1 M8 x 1.25

Size and Pitch

*

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

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

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4. Truck Torque Specifications Description


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Torque Specification

Drive motor end cover bolts

70.5 - 77.3 ft-lbs (95.6 - 104.8 N•m)

Gear case cover mounting bolts

30 ft-lbs (42 N•m) (sealant, see page 72)

Drive wheel axle nut

55 ft-lbs (74.6 N•m)

Drive wheel studs

23 - 28 ft-lbs (32 - 38 N•m)

Friction disk mounting bolts

50 in-lbs (5.6 N•m)

Hydraulic motor or coil nut Hydraulic reservoir clamp

48 - 60 in-lbs (5.5 - 7 N•m)

Hydraulic filter screen fitting

245 - 275 in-lbs (27 - 31 N•m)

Lift motor mounting bolts

40 - 45 in-lbs (4.5 - 5 N•m)

Cylinder retention screw

71 - 88 in-lbs (8 - 10 N•m)

Hydraulic adapter body

204 - 240 in-lbs (23-27 N•m)


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5. Conversion of Metric and English Units Area Multiply

By

To Get

Multiply

By

To Get

inches²

6.451

centimeters² (cm²)

centimeters²

0.155

inches² (in²)

feet²

0.093

meters² (m²)

meters²

10.764

feet² (ft²)

Linear Multiply

By

To Get

Multiply

By

To Get

inches

25.4

millimeters(mm)

millimeter

0.03937

inches (in)

feet

0.305

meters (m)

meter

3.280

feet (ft)

yards

0.914

meters (m)

meter

1.094

yards (yd)

miles

1.609

kilometers (km)

kilometer

0.621

miles (mi)

Mass Multiply

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 Get

horsepower

0.746

kilowatts (kW)

kilowatts

1.34

horsepower (hp)

Pressure

48

Multiply

By

To Get

Multiply

By

To Get

pounds/in²

6.895

kilopascal (kPa)

kilopascals

0.145

pounds/in² (psi)

pounds/in²

0.007

megapascal (MPa)

megapascals

145.04

pounds/in² (psi)

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Temperature Multiply

By

To Get

Multiply

By

To Get

(Fahrenheit -32)

0.56

Celsius (C)

(Celsius x 1.8)

+32

Fahrenheit (F)

Torque Multiply

By

To Get

Multiply

By

To Get

inch pound

0.113

Newton meter (N•m)

Newton meter

8.851

inch pounds in-lbs

feet pound

1.356

Newton meter (N•m)

Newton meter

0.738

foot pounds ft-lbs

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

inches³

16.387

centimeters³ (cm³)

centimeters³

0.061

inches³ (in³)

inches³

0.016

liters

liters

61.024

inches³ (in³)

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)

gallons, U.S.

3.785

liters

liters

0.264

gallons, U.S. (gal)

gallons, U.S.

0.83

gallons, Imp. (gal)

gallons, Imp.

1.205

gallons, U.S. (gal)

ounces

29.57

milliliters (ml)

milliliters

0.034

ounces (oz)


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M2.0 Technical Service Data

Version no

T-code

002

SMX

Technical Service Data NOTE!

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

Drive Unit Type

Shunt wound

Power - horsepower [hp] (kilowatts [kW])

1.2 (0.90)

Duty factor

1 hour

Min carbon brush length - inch (mm)

0.59 (15)

Min commutator diameter - inch (mm)

1.85 (47)

Min brush spring tension - ounce-force foot (N•m)

44.8 (3.8)

Gear ratio

22:1

Oil volume, oz (liter)

13.5 (0.4) Drive Gear Ambient Temperatures

Standard operation (see page 59) temperature down down to 32° F (0° C)

Mobil-1 Synthetic Gear Lube 75W-90 or Texaco Synstar GL 75W-90

Cold Storage Conditioning (see page 59) temperatures down to 5° F (-15° C) or down to -13° F (-25° C) for intermittent operation

Mobil-1 Synthetic Gear Lube 75W-90 or Texaco Synstar GL 75W-90

Wheels Drive wheel - inch (mm)

10.0 x 5.0 (255 x 125)

Drive wheel weight without load with battery - lb (kg)

710 (322)

Drive wheel weight with rated load and battery - lb (kg)

1650 (748)

Torque drive axle nut, ft-lbs (N•m)

55 (74.6)

Load wheel - inch (mm)

3.25 x 4.50 (82 x 115)

Load wheel weight with rated load - lb (kg) © BT Prime-Mover, Inc.

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Hydraulic Unit Power - horsepower [hp] (kilowatts [kW])

1.9 (1.4)

Duty factor

10% on 5 min. cycles

Minimum brush length - inch (mm)

0.35 (9)

Minimum commutator diameter - inch (mm)

1.13 (28.8)

Minimum brush spring tension - ounce-force (newton) Relief pressure - psi (kPa) at rated load at operating load

17.98 (5) 3000 (20684)

Pump flow

1.0 cc

Tank volume

Approximately 1 quart Hydraulic Ambient Temperatures

Standard operation (see page 59) temperature down down to 32° F (0° C)

Sunoco TH

Cold Storage Conditioning (see page 59) temperatures down to 5° F (-15° C) or down to -13° F (-25° C) for intermittent operation

AFT

Fuses/circuit Breaker Keypad and ETAC Fuse

10 Amp

Control circuit Fuse

10 Amp

Drive/Pump circuit breaker

110 Amp Batteries

Compartment Dimension L x W - inch (mm) Capacity (recommended Max. Amp-hrs.) Weight (Minimum) - lbs (kg)

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27.0 x 7.8 (685 x 195) 330 200 (91)


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Version no

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Operating Speeds Without load - mph (kph)

3.6 (5.8)

With rated load - mph (kph)

3.4 (5.5) Lifting/lowering Time

Lift empty, high speed (seconds)

2.3

Lift rated load, low speed (seconds)

3.0

Lower with rated load, low speed (seconds)

2.8

Current Readings Driving without load (amps taken at steady state)

14 Amp

Driving with rated load (amps taken at steady state)

42 Amp

Lifting without load (amps are peak when read on motor)

38 Amp

Lifting with rated load (amps are peak when read on motor)

95 Amp


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P Contents, Section P T-code

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Contents, Section P 1. Planned Maintenance


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P1.0

INTRODUCTION, MAINTENANCE

P2.0

SERVICE SCHEDULE

P3.0

LUBRICATION CHART

P4.0

OIL AND GREASE SPECIFICATIONS


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P1.0 Introduction, Maintenance

Version no

T-code

000

SMX

Introduction, Maintenance The schedule of maintenance and lubrication given in this section of the service manual cover up to one year’s operation of the truck. These schedules are based on hourly usage and can be adapted to suit most schedules. The following hourly usage figures have been used when calculating the schedule: Single shift, 30 hours per week usage Double shift, 60 hours per week usage Triple shift, 90 hours per week usage The “Planned Maintenance Schedule” on page 61 is based on the single shift schedule. The schedules are intended only as a guide, not as a rigid structure. Owners of the trucks may wish to adapt to local requirements; but it is emphasized that the schedules represent minimum manufacturer requirements, and all items should be included in a service program to ensure minimum downtime and a high status of the equipment. • •


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Use spare parts approved by BT Prime-Mover. For ordering parts see page 1. Always clean the equipment and carry out a full check after service.


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1. Jacking Truck Off The Floor To perform maintenance that requires the truck to be lifted from the floor, observe the proper precautions as follows: 1. Lower the forks completely. Remove any load. 2. Position all controls in neutral 3. Block the wheels to prevent movement of the truck.

Blocking Fork Section

4. Press the red OFF (O) key on the keypad. Disconnect the battery connector from the truck. Jack only in these areas

WARNING Use extreme care whenever the truck is jacked up for any reason. Keep hands and feet clear from beneath the truck while jacking. After the truck is jacked, position solid blocks beneath it to it. DO NOT rely on the jack alone to the truck. 5. Position the jack under the designated jacking points.

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P1.0 Introduction, Maintenance

Version no

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1.1. Fork Section 1. Using the lift button, raise the forks to maximum height. 2. Block the fork section. The tractor section will remain on the floor. 3. Lower the forks on the blocks. 4. Press the red OFF (O) key on the keypad. Disconnect the battery connector from the truck.

1.2. Tractor Section 1. Place jack in the designated jacking position. 2. Jack one side of the truck so that the drive tire is off the floor no more than 1.0 inch (25.4 mm). 3. Block that side of the truck in place. 4. Jack the other side of the truck level with the first side. 5. Block that side of the truck in place.

2. Lubricants 2.1. Standard The standard conditioning truck is designed for operation in temperatures down to 32 degrees F (0 degrees C).

2.2. Cold Storage Trucks supplied with a cold storage conditioning package are designed to operate in temperatures down to 5 degrees F (15 degrees C) in a continuous duty cycle or down to -13 degrees F (-25 degrees C) for intermittent operation. When a truck is installed in a cold storage environment, change the fluid in the hydraulic reservoir. (See “Lubricants” on page 72.)


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Version no

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Service Schedule 1. Planned Maintenance Schedule WORK REQUIRED ITEM

1 2 3 4 5 0300 0300.1 0300.2 1700 1700.1 1700.2 1700.3 1700.4 2550 2550.1 2550.2 3300 3300.1 3300.2 3300.3 3500 3500.1 3500.2 4100 4100.1 5000 5000.1 5000.2 5000.3 5000.4 5000.5 5000.6 5000.7

8

250

1500

Interval in Days/Weeks/Months

1d

2m

12 m

General Check for loose hardware. Tighten if necessary. Note any unusual noise during operation Check for leaks around drive unit and hydraulic system. Visually inspect all cables for damage. Check grease location points (see page 72.) Frame Check truck data plate and decals for legibility. Check for crack formation and damage. Motors Check connections for proper . Clean motor of dirt and dust. Check condition of brushes, springs, and holders. Check brush length. Replace brushes if necessary (see page 91.) Drive Unit Check oil in drive housing. Check for contamination in the oil (see page 100.) Change transmission oil (see page 99.) Brake Check brake operation. Clean dust and debris. Check brake disk for wear. Wheels Remove all string, wrapping, and debris. Check all wheels for wear. Steering Control Handle Check return of control handle to upper rest position. Electrical Control System Check operation of horn button. Check speed and thumb controls. Check tiller arm/angle switches for adjustment. Check steering operation. Check lift/lower functions. Check operation of main ON/OFF switch. Check for electrical shorts in chassis.


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Interval in Hours


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WORK REQUIRED ITEM 5000.8 5110 5110.1 5110.2 5110.3 5110.4 5110.5 5111 5111.1 5400 5400.1 5400.2 5400.3 6000 6000.1 6000.2 6000.3 6000.4 6000.5 6420 6420.1 6420.2 6420.3

62

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Interval in Hours

8

250

1500

Interval in Days/Weeks/Months

1d

2m

12 m

Check operation of reverse button. Battery Check cleanliness and exterior conditions. Check the battery charge. Check the battery weight. Check all connections; battery, battery and charger plugs. Check battery mounting bolt for freeplay. Battery Connector Check battery connector. Make sure all powered functions shut down when disconnected. Electrical Clean and check mounting to frame. Check ors for welded conditions. Check or tips for free movement. Hydraulic System Check hose for wear and damage. Check reservoir for cracks, leaks and mounting. Check correct oil level. Check hydraulic connections and mounting. Change hydraulic oil. Clean filters. Lift devices Check lift cylinder for leaks. Check play on pull rods. Check forks for wear and cracks.


X X X X X X X

X X X X X X X X X X X

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001

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C-code

5110 5400

5111

0300 6420

5000

3550

4100

0300

6420 5700 1700

3300 3500 1700

6000

2550


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

2.1. General The following general inspections are to be made by the operator. It is the operator’s responsibility to report any problems with the truck to the appropriate personnel. The truck should not be operated until it has been inspected and repaired by a trained, qualified, and authorized technician. The operator is ultimately responsible for the safe operation of the truck. 2.1.1. Hardware Inspect the truck for loose, damaged, or missing parts. All shields and covers must be in place and functional. Inspect truck for missing data plate or decals and make sure they are legible. Report any problems to the appropriate personnel. DO NOT operate the truck until it has been inspected and repaired by a trained, qualified, and authorized technician. Check all fasteners and connections, torque as required (see page 47.) Check the drive wheel studs. Ensure that the lug nuts and studs are tightened to the proper torque specification (see page 47.) Check torque on motor end cap bolts. 2.1.2. Noise Check for any abnormal noise coming from the truck. 2.1.3. Leaks Inspect the entire truck for leaks, especially around the hydraulic pump assembly and the lift cylinder. Any sign of oil on the floor under the truck is an indication that the truck may be leaking hydraulic oil or transmission fluid. Report any problems to the proper authorities. DO NOT operate the truck until it has been inspected and repaired by a trained, qualified, and authorized technician. Check for proper fluid level in the drive unit. When the truck is level, oil must be up to the bottom of the plug opening. If fluid is low, check for leaks (see page 99.) 64

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C-code

2.1.4. Cables and Connections Tighten connections. Check all cable insulation for damage. Check that all electrical connections are clean and tight. Plugin connectors should be unplugged and plugged back in to clean terminals. 2.1.5. Grease Location Points For location of the grease points see page 72.

2.2. Services Performed Daily or Every 8 Operating Hours Daily inspection is to be made by the operator prior to each operating shift. It is the operator's responsibility to report any problems with the truck to the appropriate personnel. The truck should not be operated until it has been inspected and repaired by a trained, qualified, and authorized technician. The operator is ultimately responsible for the safe operation of the truck. 2.2.1. Frame Check truck data plate and decals to see that data is legible. 2.2.2. Brakes Check operation of brakes. 2.2.3. Wheels/Tires Inspect wheels and tires for wear and damage. Remove any steel chips and foreign material to prevent damage to the wheels. Check for gouging and chunking of the surface. Trash that is wrapped around wheels and axles will cause premature tire wear and bearing damage. The floors should be kept clear of trash to prevent damage to the wheels and tires. 2.2.4. Steering Control Handle Check return of control handle to upper rest position.


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2.2.5. Functions/Operations Test truck for the proper operation of all functions including the speed and thumb controls (arm angle switches), lift and lower functions, brakes, steering, reverser button, horn button and the main ON/OFF switch. Devices must be operational. Report any problems to the proper authorities. DO NOT operate the truck until it has been inspected and repaired by a trained, qualified, and authorized technician. 2.2.6. Battery your battery supplier for specific instructions on care and maintenance of the battery. Determine if the battery needs to be washed down. This can only be done by a trained, qualified, and authorized technician. An average battery will have a specific gravity of 1.170 at the 80 percent discharged level. However, there are many different batteries on the market. The battery supplier can accurately determine the fully charged and 80 percent charged levels. an authorized battery supplier to determine the overall condition of the battery. The Battery Discharge Indicator (BDI) indicates the current state of charge of the truck’s battery. (See “Parameter 21” on page 178.) 1 1/2 0

Full charge battery Half charged battery Discharged battery

When the battery has reached a charge level equivalent to 70 percent discharge, a warning signal is given via flashing lights. A further 10 percent of the battery’s capacity can then be used before the battery discharge cuts out the lift function. 2.2.7. Battery Connector Inspect the negative and positive cables for breaks and wear. Check connectors for damage and to ensure proper connections of cables.

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2.3. Services Performed Every Two Months or Every 250 Operating Hours The following inspections are to be made by the operator prior to each operating shift. It is the operator's responsibility to report any problems with the truck to the appropriate personnel. The truck should not be operated until it has been inspected and repaired by a trained, qualified, and authorized technician. The operator is ultimately responsible for the safe operation of the truck. 2.3.1. Frame Check frame for crack formation and damage. Check cover screws and secure as necessary. 2.3.2. Motors WARNING When using compressed air, wear effective chip-guarding and personal protective equipment. Compressed air used for cleaning MUST be reduced to less than 30 psi (207 kPa). Check motors for improper connections due to poor connections. Check tightness on all connections. Blow carbon, copper, and plastic particle accumulations out from the motor using compressed air. Check for signs of oil on the motor air vents. Check for any damage to the air vents. For minimum brush lengths see page 51 or page 52. 2.3.3. Drive Unit Check oil in the drive housing. Check for contamination in the oil (see page 100.) 2.3.4. Brake Check brake of dust and debris. Check brake disk for wear. 1. Remove brake coil, and inspect brake disk for wear. If the brake disk is damaged or worn, replace with a new disk. 2. Before replacing the brake disk see page 112. 2.3.5. Electrical Control System Check control handle arm angle switches for adjustment (see page 220.) © BT Prime-Mover, Inc.

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Check for electrical shorts to frame (see page 157.) 2.3.6. Battery Check battery mounting bolt. Check freeplay in battery mounting area. 2.3.7. Electrical Clean and check electrical mounting to frame. Check for connections in harness connectors. Check ors for welded conditions. Check or tips for free movement. Clean operation of ors for proper operation (see page 239.) 2.3.8. Hydraulic System Check the fluid level in the hydraulic reservoir (see page 258.) Check hoses and connections on the hydraulic system for leaks. Repair or replace hoses if worn or damaged. Check oil reservoir for cracks, leaks and mounting. 2.3.9. Lifting Devices Inspect the forks and cylinder for wear.

2.4. Services Performed Annually or Every 1500 Operating Hours The following inspections are to be made by the operator prior to each operating shift. It is the operator's responsibility to report any problems with the truck to the appropriate personnel. The truck should not be operated until it has been inspected and repaired by a trained, qualified, and authorized technician. The operator is ultimately responsible for the safe operation of the truck. 2.4.1. Drive Unit Fluid from the drive unit should be drained once a year. The drain port is the lower left hand bolt holding the side cover in place. Remove bolt to drain transmission fluid. Flush transmission case with a cleaning solution. Pour clean solution into the level check plug in the side cover. With drive tire off the floor, allow solution to run out of drain port while the transmission is running. Stop flushing when the solution runs clean. Allow the solution to drain well before replacing filler/level plug. Replace drain screw. Refill transmission with proper clean oil (see page 72) before operating truck.

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2.4.2. Hydraulic System The hydraulic system should be drained, flushed and refilled. Clean the hydraulic filters when hydraulic fluid is changed. The pressure relief valve setting should be checked. WARNING Before siphoning oil from the reservoir, make certain siphon is clean. To drain reservoir, disconnect and remove the hydraulic pump assembly (see page 257.)


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70

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P3.0 Lubrication Chart

Version no

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000

SMX

C-code

Lubrication Chart Pos. No 1 2 3 4

Interval/Running Hours

Service Point

360 h

Wheel bearings Hydraulic system Drive gear Drive gear drain

720 h

L C C

L= Lubrication

1440 h

Lubricant (See “Lubricants” on page 72)

A B C A

O O O C = Check

O = Oil change

2 1

3 4


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PT P4.0 Oil and Grease Specifications Version no

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001

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Oil and Grease Specifications 1. Lubricants

Location

Lubricant Specifications

Lubricant

A Grease B Hydraulic oil C Drive gear oil D Sealant

Standard Operation Down To 32° F (0° C)

Cold Storage Continuous Operation Down To 5° F (-15° C) Intermittent Operation Down To -13° F (-25° C)

Mystik JT-6 Sunoco TH ATF Mobil-1 Synthetic Gear Lube 75W-90 or Texaco Synstar GL 75W-90 GE Weicon Silmate

Application area

Bearings and bushings Hydraulic system Gears Gear case cover

2. Grease Location Points Optional B

A

D

C

72

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S Contents, Section S T-code

000

Contents, Section S 1. Service Instructions


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NO FUNCTION GROUP

C-CODE

0

FRAME

0000

1

MOTORS

1000

2

DRIVE GEAR / TRANSMISSION

2000

3

BRAKE / WHEEL SYSTEM

3000

4

STEERING SYSTEM

4000

5

ELECTRICAL / PNEUMATIC SYSTEM

5000

6

HYDRAULIC SYSTEM / CYLINDERS

6000

10

TOOLS

10000


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000


74

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S0.1

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0300

Frame

Frame 1. Theory of Operation The carrier frame is the body section of the truck that contains the drive motor, drive unit, drive wheel, controls, and steering control handle (with electronic tiller arm card [ETAC.]) The lift frame is the section of the truck that contains the battery, pull rods, and load wheels, along with the hydraulic and electrical systems.

2. Maintenance See “Planned Maintenance Schedule” on page 61.

2.1. Inspection WARNING When using compressed air, wear effective chip-guarding and personal protective equipment. Compressed air used for cleaning MUST be reduced to less than 30 psi (207 kPa). NOTE!

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

NOTE!

Call-outs in the following procedure refers to illustration on page 78.

1. Thoroughly clean all parts and remove all nicks and burrs with emery cloth. 2. Inspect pull rods (27) for excessive wear or bending. No cracks are allowed in pull rods (27) and should be replaced as a pair. If heavy wear or bending is found replace both pull rods (27). 3. Inspect wheel fork assemblies (1) for excessive wear or cracks. If cracks are found replace both wheel forks. 4. Inspect all pins for nicks, scratches, or scoring. If heavy scoring is found, or scratches that can not be removed with emery cloth, replace pin. © BT Prime-Mover, Inc.

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5. All bushings are to be replaced with new.

3. Troubleshooting Inspect carrier frame and lift frame for crack formation and damage.

4. Repair and Rebuild NOTE!


NOTE!

Call-outs in the following procedure refers to illustration on page 78.

Extensive damage to carrier frame, lift frame, or truck in any weldment must be reported to BT Prime-Mover, Inc. Do not attempt to weld the frame without permission from BT PrimeMover.

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Frame

Truck Serial Numbers 33227001 - 34271000

3 4

8 6

7

5

32 31 29 30 20

28

19 18

17

28

27

9

11

16

10

15

13

15 26

12

14

25

21

24 23

22

Item No.

Description

Item No.

Description

Item No.

1 2 3 4 5 6 7

Wheel fork assembly Load wheel Fork, wheel Bushing Screw, set Pin Fitting, grease (optional)

12 13 14 15 16 17 18

Screw Bracket, lift limit Frame, carrier Screw Link assembly, upper Bushing Nut

23 24 25 26 27 28 29

Bushing Pin Pin Screw Pull rod assembly Bushing Screw

8

Frame, lift

19

Pin

30

Screw

9 10 11

Lift cylinder Screw Nut

20 21 22

Screw Screw Link

31 32

Pin Pin


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Description

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Truck Serial Numbers 34271001 - Up 1 2

3 4

7

6

8

5

32 35 31 29 30

20

19

10

9

33 34

28 18 17 27

16

11

15

28 13 12

15 26 25

14 21

24 23

78

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Frame

Description

Item No.

Description

Item No.

2 3 4 5 6 7 8 9

Wheel fork assembly Load wheel Fork, wheel Bushing Screw, set Pin Fitting, grease (optional) Frame, lift Lift cylinder

13 14 15 16 17 18 19 20 21

Bracket, lift limit Frame, carrier Screw Link assembly, upper Bushing Nut Pin Screw Screw

25 26 27 28 29 30 31 32 33

Pin Screw Pull rod assembly Bushing Screw Screw Pin Pin Spring, retainer

10 11 12

Screw Nut Screw

22 23 24

Link Bushing Pin

34 35

Nut Washer

1

Description

Removal NOTE!

To replace pull rods and/or bushings it is easiest to work with the truck on its side. Remove battery before turning truck over on its side.

To eliminate hydraulic leaks, remove the breather (0.6875 inch [17.46 mm] and install a plug. The bushings on the upper links of the carrier frame can be replaced by removing the links and lift cylinder. 1. Park truck on a level surface and make sure parking brake is applied and load wheels are blocked to prevent accidental movement. 2. Release pressure in hydraulic system by pressing the lowering button on steering control handle. 3. Lower the forks completely. Remove any load. 4. Press red OFF button “O” on the keypad. Depress main ON/OFF switch to the OFF position. 5. Disconnect the battery connector from the truck. If applicable, remove bolts securing the battery to the truck. Remove battery from the truck.


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6. Remove truck cover(s) [see page 84.] WARNING When using compressed air, wear effective chip-guarding and personal protective equipment Compressed air used for cleaning MUST be reduced to less than 30 psi (207 kPa). 7. Before disassembly, thoroughly clean exterior to remove all contamination. NOTE!

Turn truck on its side where the pull rod is to be repaired.

8. Turn truck on its side. 9. Remove set screw (29) and pin (32) connecting wheel fork assembly (1) to lift frame (8). This allows the wheel fork and pull rod (27) to drop.

Wheel Fork Set Screw (Top View)

10. Remove set screws (30) and pin (31) connecting the pull rod (27) to wheel fork assembly (1). 11. Remove screw (20) from pin (19). Remove pin (19). 12. Separate link (22) by removing setscrew (26) and pin (25). 13. Remove bushings (28) and (23) and discard.

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Frame

Installation WARNING When using compressed air, wear effective chip-guarding and personal protective equipment Compressed air used for cleaning MUST be reduced to less than 30 psi (207 kPa). 1. All parts should be cleaned and dried thoroughly. Metal parts should be lightly oiled prior to reassembly. 2. Press new bushing (23) into link (22). Push new bushing (28) in pull rod (27). 3. Assemble pull rods (27) on links (22) to fit in frame channel. 4. Install pins (19) and screws (20) in link (22). 5. Install pin (31) connecting pull rod (27) to wheel fork assembly (1). Secure with set screws (30). 6. Install pins (32) in wheel fork assembly (1) and lift frame (8). Secure with set screws (29). 7. If applicable, lubricate grease fitting (see page 72) before turning truck back upright. 8. Return truck to the upright position. 9. Install battery on truck. If applicable, secure battery bolts to the truck. Install truck cover(s) [see page 84.] 10. Connect the battery connector to the truck. WARNING DO NOT use your hands to check for hydraulic leakage. Use a piece of cardboard or paper to search for leaks. Escaping fluid under pressure can penetrate the skin causing injury. Relieve pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Keep hands and body away from pinholes and nozzles which eject fluids under high pressure.


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11. Turn the main ON/OFF switch to the ON position. Enter key code and press the green ON button “I” on the keypad. Test truck for proper operation before returning to service.

Cylinder Retention Trucks with serial numbers 34271001 - Up are equipped with the retainer spring (33), nut (34), and washer (35, see page 78.) To install these parts on trucks prior to these serial numbers, see drawing below. Retainer

0.25 inch (6.5 mm)

5.118 inch (130 mm)

Drill & Tap M6 x 1, MIN 12 mm Deep Use M6 Screw Hex Locking with Lock Washer Torque screw to 71-88 in-lbs (8-10 N•m)

Cylinder Retention Kit

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S0.2 0340 Inspection Covers

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000

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Inspection Covers 1. Theory of Operation The truck covers are easily removed for access to the components. During operation of the truck, the covers must be secured to the truck.


3. Troubleshooting Inspect covers for damage. Damaged covers should be replaced.

4. Repair and Rebuild When the covers become damaged and do not fit properly, replace with new as necessary.


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PT S0.2 Inspection Covers Version no

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000

SMX

0340

1

2

Item No.

84

Return

3

Description

4

1

Clip

2

Cover, upper

3

Screw

4

Cover, lower

5

Bumper

6

Lockwasher

7

Screw

5


6

7

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S0.3

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000

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0851 Decals

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

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

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


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S0.3

0851

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000

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86

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S1.0 1700 Electric Motors

Version no

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001

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Electric Motors Electric motors provide power to the transmission and hydraulic systems. Motor speed and direction are controlled by the transistor controller or or with inputs from the operator controls.

1. Theory of Operation The lift pump motor assembly consists of the pump motor, pump assembly and lift valve assembly. The pump motor and pump are an integrated unit. The drive unit assembly consists of the electromagnetic brake assembly, drive motor, transmission assembly and drive wheel. The drive motor is part of the drive unit. The steering bearing is mounted on top of the drive unit assembly.

2. Maintenance A routine maintenance schedule with recorded findings is the best way to reduce costly shut-downs and repair of equipment during operating hours. The goal of any maintenance program, long-life and trouble-free operation, is related to time spent making inspections and correcting minor problems as they occur. Inspect the motor more frequently when working in an abnormally severe or corrosive environment or if in a rigorous duty cycle. Set up and maintain a strict inspection schedule to obtain the maximum efficiency from the electrical equipment. Operating environments of truck motors varies widely. The following recommendations should be applied as actual conditions dictate: Normal Service:

Basically an eight hour day of indoor material handling.

Severe Service:

Extended operating hours, or constant usage.

Extreme Service:

Chemical processing Cold storage operation Processing plants (poultry, meat)


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PT S1.0 Electric Motors

1700

Version no

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001

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Each partial inspection of the motor must include: 1. Inspect the brushes for wear and for correct with the commutator. Record the level of wear on the brushes. This history will indicate whether a brush must be changed or if it can wait until the next inspection. For acceptable brush length see page 51 or page 52. NOTE!

Overloading a unit is ultimately reflected in the motor and brush wear. Therefore, take this into when considering brush replacement.

2. Check the brush spring tension. For acceptable brush spring tension see page 51 or page 52. 3. Clean the brushes and holders. Wipe the commutator with a dry, lint-free cloth. Do not use lubricants of any kind on or around the commutator. 4. Check the brush holders for solid connection to the mounting . Tighten the mounting screws as necessary. 5. Check the cap screws holding the brush cross connectors to the brush holder body. 6. Make sure the motor terminals are secured tightly to the motor frame. Do not strip the threads or crush the insulating parts. 7. Check all the cap screws around the frame for tightness. 8. Keep the outside frame of the motor clean and free from dirt. Maintain a free air age around the motor to permit heat radiation.

3. Troubleshooting When a motor has trouble in operation, a reasonable decision has to be made as to the proper corrective course of action.

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4. Repair and Rebuild 4.1. Motor Brushes 4.1.1. Drive Motor 1. Park truck on a level surface and make sure parking brake is applied and load wheels are blocked to prevent accidental movement. 2. Press red OFF button “O” on the keypad. Depress main ON/OFF switch to the OFF position. 3. Disconnect the battery connector from the truck. 4. Remove truck cover(s) [see page 84.] 5. Remove any shields around the motor end cover to expose the brushes. See Figure 1-1.

Brush Shield Figure 1-1: Drive Motor Brush Shield

6. Drive motor brushes are accessible by turning transmission. Remove screws holding brush lead. Lift spring off brush. Remove brush from holder. Follow the brush inspection and replacement procedures (see page 90 and page 91.)


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001

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4.1.2. Pump Motor Pump Motor

Motor End Cover

Brushes

Brushes Figure 1-2: Pump Motor

1. The pump motor will need to be removed from the hydraulic assembly before inspecting brushes. Remove screws from motor end cover. Remove motor end cover to expose the pump motor brushes. 2. Push brush back into holder to disengage the spring. Disengage the spring on remaining brushes. To remove brush assembly, remove nuts and washers from the side of the drive end head. Remove brush from holder and replace with new brush. Follow the brush inspection below and replacement procedures (see page 91.)

Spring

90

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4.1.3. Brush Inspection Brushes should be inspected for uneven wear and signs of Brush overheating such as discolored brush shunts and brush Brush springs. Check the brush holders for physical damage and Shunts make sure they are not loose on the end head or the brush holder plate. Check the brush springs for correct alignment on the brush. A brush spring that does not apply equal pressure on the center of the brush will cause the brush to wear unevenly. Check for correct clearance and freedom of brush movement in the holder. If the brushes are worn to the point that replacement is necessary, the complete brush set should be replaced (see page 91.) Master Service Manual

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4.1.4. Brush Replacement Do not replace just one or two brushes. When brush service is required on the motor, lift brush spring over holding bracket before removing brush (see the following drawing.)

Put Spring In This Position For Brush Removal

Figure 1-3: Motor Brush Removal

WARNING When using compressed air, wear effective chip-guarding and personal protective equipment. Compressed air used for cleaning MUST be reduced to less than 30 psi (207 kPa). CAUTION Do not substitute brushes. The brushes are matched to the motor type and application to provide the best service. Substituting brushes of the wrong grade can cause commutator damage or excessive brush wear. NOTE!

Blow stone dust out with dry compressed air.

After the installation of new brushes, the motor should be operated at 12 Volts, no load and brushes seated to the commutator with a dressing stone. Remove stone dust. © BT Prime-Mover, Inc.

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001

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4.2. Pump Motor Pump Motor Mounting Cylinder Assembly

or Pump Motor

Reservoir 3 1 2

Item No.

Description

1 2 3

Pump Motor Assembly Kit, brush and spring Bearing

4.2.1. Removal 1. Park truck on a level surface and make sure parking brake is applied and load wheels are blocked to prevent accidental movement. 2. Release pressure in hydraulic system by pressing the lowering button on steering control handle until lift cylinder is completely collapsed. Hydraulic Line Pump Assembly

3. Press red OFF button “O” on the keypad and depress main ON/OFF switch to the OFF position. 4. Disconnect the battery connector from the truck. If applicable, remove bolts securing the battery to the truck. Remove battery from the truck. 5. Remove truck cover(s) [see page 84.] 6. Remove hydraulic line from hydraulic pump assembly and cap end to prevent contaminants from entering the hydraulic system.

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7. Disconnect hydraulic motor power cables and mark their positions. Disconnect or wiring, noting their position. 8. Remove screws securing hydraulic pump and motor assembly to frame. Remove pump/motor assembly from truck. 9. Rebuild pump/motor as necessary. 4.2.2. Installation WARNING When using compressed air, wear effective chip-guarding and personal protective equipment. Compressed air used for cleaning MUST be reduced to less than 30 psi (207 kPa). 1. Thoroughly clean all parts with non-corrosive cleaning fluid and air dry all parts. 2. Install pump/motor assembly in truck and secure with screws to truck frame. (For torque values see page 47.)

Power Cables

3. Properly connect electrical power cables and or wiring, noting their positions recorded earlier. 4. Uncap and connect hydraulic hose to hydraulic pump assembly. 5. Fill hydraulic reservoir with new clean oil (see page 72.) 6. Remove blocks. 7. Install battery on truck. If applicable, secure battery bolts to the truck. 8. Connect the battery connector to the truck. 9. Turn the main ON/OFF switch to the ON position. Enter key code and press the green ON button “I” on the keypad. 10. Check the reservoir fluid level. Operate the truck’s hydraulic system and check operation of system as a whole. Look for leaks and tight places on the lifting linkage. 11. Install truck cover(s) [see page 84.]


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4.3. Drive Motor 29 8 7 32 33

1 2

31

10

30 6

11

9 8

15

14 12

13

5 4

3

18

20

22

19

23 24

17 16

21

25

28

26

27

35

34 35

“EE”

94

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Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18


Return

Description Ring, retainer Gear Key Case Terminal Screw Nut

Section

PT


Version no

T-code

001

SMX

Item No. 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

Washer Field Isolator Bearing Shim Seal Armature Key Ring, retainer Hub Band, cover “E”


F-code

2006-08-04

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Description Screw Cover Plate, brush Spring Brush Nut Ring, retainer Bearing Lockwasher Screw Shoe, pole Washer Screw Lockwasher Nut Band Cover “EE” Screw “EE”

95

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1700

Version no

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001

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4.4. Drive Motor Drive Motor Mounting

Steering Bearing Carrier Frame

Steering Control Head

Drive Wheel

Drive Motor

bly sem s A e Brak

Transmission Assembly

96

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4.4.1. Removal WARNING There is no brake on the truck when the drive motor is removed from the transmission assembly. Block all wheels to reduce the risk of truck movement. 1. Park the truck on a level surface and make sure parking brake is applied and load wheels are blocked to prevent accidental movement. 2. Press red OFF button “O” on the keypad. Depress main ON/OFF switch to the OFF position. 3. Disconnect the battery connector from the truck. 4. Jack truck and block the frame (see page 58.) 5. Remove truck cover(s) [see page 84.] 6. Disconnect cable/wires from the terminal block on the transmission. 7. Remove brake assembly from drive motor. Terminal Block Connections

8. Disassemble assembly.

drive

motor

from

transmission

4.4.2. Installation WARNING When using compressed air, wear effective chip-guarding and personal protective equipment. Compressed air used for cleaning MUST be reduced to less than 30 psi (207 kPa). 1. Thoroughly clean all parts with non-corrosive cleaning fluid and air dry all parts. 2. Reassemble assembly.

drive

motor

on

transmission

3. Reinstall brake assembly on drive motor. 4. Install drive motor end cover and torque to 70.5 77.3 ft-lbs (95.6 - 104.8 N•m). 5. Unblock and lower the truck. 6. Ensure drive unit is filled to the correct level with gear oil (see page 72.) Install fill/level plug.


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1700

Version no

T-code

001

SMX

7. Connect the battery connector to the truck. 8. Turn the main ON/OFF switch to the ON position. Enter key code and press the green ON button “I” on the keypad. 9. Test truck for proper operation before returning to service. 10. Install truck cover(s) [see page 84.]

98

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Section

PT

S2.0 2550 Transmission

Version no

T-code

001

SMX

C-code

Transmission 1. Theory of Operation This transmission is of the double reduction gear type. The gears are a combination of helical and straight cut gears for strength and low noise. The final drive gear is mounted on opposing tapered roller bearings. The intermediate gear is mounted on ball bearings. Gears and bearings are enclosed in an oil filled case. The drive motor is mounted externally with the drive motor pinion gear mounted on the armature shaft. The brake is mounted on the drive motor.


2.1. Fluid Changing 1. Lower forks. 2. Press red OFF button “O” on the keypad. Depress main ON/OFF switch to the OFF position. Disconnect the battery connector from the truck. 3. Remove drain plug to drain transmission oil. 4. Flush transmission case with a safe cleaning solution and allow it to drain. 5. Clean and install drain plug.

Fill/Level Plug Drain Plug

Figure 2-1: Fill and Drain Locations

NOTE!


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When the truck is level, the oil must be up to the bottom of the fill/level opening.

2006-08-04

99

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Section

C-code

PT S2.0 Transmission

2550

Version no

T-code

001

SMX

6. Fill transmission case with oil (see page 72) through plug opening in transmission cover.

3. Troubleshooting Because of the uncomplicated nature of the transmission, troubleshooting is limited to identifying problems if they 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, if the problem is caused internally in the transmission, then metal contamination will be evident in the oil. If there is a mechanical problem outside of the transmission, then it will become evident by inspecting the drive motor and brakes. See page 111 for instructions to release the brake, if necessary.

4. Repair and Rebuild Visually inspect outside of gear case for damage, wear or cracks. Excessive damage, wear, or cracks in the gear case indicate that the transmission needs to be replaced rather than repaired or rebuilt.

100

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3 1

2

F-code

Section

PT


Version no

T-code

001

SMX

5

9 6

8

11 10

24

13 10

12

Item No.

11 14 15 16 17

18

19 20

23

21


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Transmission TransmissionMounting Mounting

7

4

22

C-code


2006-08-04

Description

1 2 3 4 5 6 7 8 9 10

Screw Cushion, upstop Screw Mount, stem Screw Clip Stem, handle Screw, set Steering control head Washer

11 12 13 14 15 16 17 18 19 20 21 22 23 24

Bushing Spring Sleeve Washer Screw Lockwasher Carrier frame Drive unit Drive motor Brake assembly Transmission assembly Steering bearing Drive wheel Pin

101

F-code

Section

C-code


2550

Version no

T-code

001

SMX

22 19

20

1

21

14 15 17

16

18

5

4

3

2

13 4 10

12 11 Item No. 1 2 3 4 5 6 7 8

102

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7

6 Transmission Assembly

8

9 Description Stud Axle Seal Bearing Spacer O ring Plug Gear

Item No. 9 10 11 12 13 14 15

Description Ring, retainer Gear Cover Plug Vent Screw Lockwasher


Item No. 16 17 18 19 20 21 22

Description Bearing Gear Bearing Retainer ring Gear Key Case

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PT


Version no

T-code

001

SMX

C-code

Removal WARNING There is no brake on the truck when the drive motor is removed from the transmission assembly. Block all wheels to reduce the risk of truck movement. NOTE!

Call-outs in the following procedure refer to illustration on page 101.

1. Lower forks. 2. Press red OFF button “O” on the keypad. Depress main ON/OFF switch to the OFF position. 3. Disconnect the battery connector from the truck. 4. Remove truck cover(s) [see page 84.] 5. If applicable, remove bolts securing the battery to the truck. Remove the battery from the truck. 6. Jack truck and block the frame (see page 58.) 7. Disconnect handle harness.

Bolts

Stem Mount

Figure 2-2: Stem Mount


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103

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Section

C-code


2550

Version no

T-code

001

SMX

Wiring Harness Connector

Arm Angle Switches Figure 2-3: Handle Harness

8. Disconnect arm angle switches. 9. Remove screws from stem mount securing steering control handle assembly to the drive unit assembly. 10. Disconnect cable/wires from the terminal block on the transmission. 11. Remove bolts (15) and lockwashers (16) securing transmission assembly and bearing assembly to frame. WARNING Transmission assembly may fall free from mounting after bolts are removed causing damage to assembly or injury to personnel. 12. Remove transmission and steering bearing assembly by lowering it through the pivot-frame mounting. 13. Feed the control wiring harness and power cables through the transmission pivot mount. 14. Drain gear case lubricant. 15. Remove drive wheel (see page 117.)

104

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001

SMX

C-code

Disassembly NOTE!

Call-outs in the following procedures refer to illustration on page 102.

Thoroughly clean the outside of the gear case with a noncorrosive cleaning fluid. Dry all parts and proceed as follows. 1. Remove screws (14) and lockwashers (15) securing gear case cover (11). Remove gear case cover (11). 2. Remove retaining ring (19) securing the top pinion gear (20). Remove top pinion gear (20) and key (21) attached to drive motor armature shaft. NOTE!

If bearing (16) does not remove with cover (11), then remove bearing (16) with a bearing puller.

3. Remove the second stage gear set (10) and (17) from the gear case (22). 4. Remove retaining ring (9) from the drive axle (2). Remove output gear (8). 5. Press drive axle (2) through the inner and outer gear case bearings. 6. Remove old bearings (4), spacer (5), and seal (3) from the gear case (22).

Reassembly NOTE!


1. Thoroughly clean gear case (22). 2. Install new bearings (4), spacer (5), and seal (3) in the gear case (22) for the drive axle (2). 3. Place the gear case (22) in a fabricated assembly base and carefully press the drive axle (2) in the gear case (22). 4. Position transmission on a work bench with gear case (22) side up. Install output gear (8) in the gear case (22) and secure with retaining ring (9). © BT Prime-Mover, Inc.

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105

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Section

C-code


2550

Version no

T-code

001

SMX

5. Install second stage gear set (10) and (17). NOTE!

The seal must be installed correctly with its open side and seal ring positioned towards the bearing. Ensure the motor end cap is installed before proceeding to the next step.

6. Install pinion gear (20), woodruff key (21), and retaining ring (19) on the armature shaft. 7. Apply sealant (GE Weicon Silmate) on the mating surface and install gear case cover (11). Install lockwashers (15) and screws (14). Torque cover screws (14) to 30 ft-lbs (42 N•m).

Installation CAUTION Make sure the main ON/OFF switch is OFF and the battery connector is removed from truck before proceeding. NOTE!


1. If removed earlier, assembly (22).

install

steering

bearing

2. Reinstall drive unit assembly through the pivot frame while feeding the harness and cables through the pivot frame mount. 3. Secure assembly lockwashers (16).

with

screws

(15)

and

4. Connect cables/wire to terminal block on the transmission. 5. Connect arm angle switches. 6. Connect stem harness to main harness and slide the connector back onto the metal tab. NOTE!

Replace any wire ties that were removed during reassembly.

7. Install stem mount.

106

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PT


Version no

T-code

001

SMX

C-code

8. Ensure drive unit contains the correct gear oil level (see page 72.) Install fill/level plug. 9. With the truck still blocked and drive unit off the ground, connect the truck to a battery. (Do not install battery on the truck at this time.) 10. Test ease of steering. Test to make sure truck powers ON and all functions on the handle head are functional. Move handle up and down to test arm angle switches. 11. Disconnect battery. 12. Install drive wheel (see page 118.) 13. Unblock and lower truck. 14. Install the battery on the truck. If applicable, secure battery bolts to the truck. 15. Install truck cover(s) [see page 84.] 16. Connect the battery connector to the truck. 17. Turn the main ON/OFF switch to the ON position. Enter key code and press the green ON button “I” on the keypad.


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2006-08-04

107

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Section

C-code


2550

Version no

T-code

001

SMX


108

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PT

Section

C-code

S3.0 3300 Parking Brake System

Version no

T-code

001

SMX

Parking Brake System 1. Theory of Operation The parking brake is an electrically released disk brake mounted on the drive motor armature for increased braking force through the transmission. The parking brake is applied when the control handle is returned to the upper rest position or in the bottom 8 degrees of the operating range. The brake may be released when the control handle is moved as little as 6 degrees and travel request is made to allow for reduced speed operation with the handle in near-vertical position for greater maneuverability. Normal stopping during truck operation is accomplished by reversing the travel controls (plugging) and activating the inductive, regenerative braking through the motor. Electromagnetic Brake

Figure 3-1: Electromagnetic Brake


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109

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C-code

PT S3.0 3300 Parking Brake System Version no

T-code

001

SMX

When the steering control handle is in the upper rest position, the parking brake is engaged. When the handle is within 6 to 41 degrees of the upper rest position and travel request is made, the brake disengages, allowing the truck to operate in slow speed. When the handle is placed beyond 41 degrees from the upper rest position, the truck can operate in fast speed. When the handle is placed in the bottom 8 degrees of the operating range, the parking brake is engaged.

6°

40° 33° 8°

Figure 3-2: Handle Positions

110

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Section

C-code


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T-code

001

SMX


2.1. Mechanical Brake Release If the brake can not be mechanically released, perform the following procedures: Mounting Bolts

1. Park truck on a level surface and load wheels are blocked to prevent accidental movement. 2. Press red OFF button “O” on the keypad. Depress main ON/OFF switch to the OFF position. 3. Remove truck cover(s) [see page 84.] 4. Loosen the mounting bolts four turns each to allow the truck to roll. 5. Move truck to desired location. WARNING Before truck is put back into service, the mounting bolts will need to be tighten. DO NOT OPERATE TRUCK WITHOUT THE BRAKE. 6. Reinstall truck cover(s).

2.2. Brake Adjustment WARNING Before adjustments are made, disconnect the battery from the truck to prevent accidental operation. 1. Park truck on a level surface and make sure parking brake is applied and load wheels are blocked to prevent accidental movement. 2. Press red OFF button “O” on the keypad. Depress main ON/OFF switch to the OFF position. 3. Disconnect the battery connector from the truck. 4. Jack the truck and block the frame (see page 58.) 5. Remove truck cover(s) [see page 84.]


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111

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Section

C-code


T-code

001

SMX

6. Loosen assembly mounting bolts on brake. 7. Turn the adjusting screws while checking the air gap at several points with a 0.008 to 0.014 inch (0.2 to 0.36 mm) feeler gauge. 8. Tighten the mounting bolts to 50 in-lb (5.6 N•m). Recheck the gap with feeler gauge. Adjusting Screw

Air Gap 0.008 - 0.014 inch (0.2 - 0.36 mm)

Mounting Bolt

Coil Housing Friction disk

Pressure Plate

3. Troubleshooting Check brake disk for wear. Replace friction disk if worn unevenly or when its total thickness is reduced to 0.20 inch (5.5 mm).

112

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Section

PT

C-code


Version no

T-code

001

SMX

4. Repair and Rebuild 2 6 3

4

7

5

1 8

Item No.

Description

Item No.

1

Transmission assembly

5

Disk

2

Brake assembly

6

Coil

3

Flange, friction

7

Screw

4

Hub

8

Retaining ring

Description

Removal 1. Park truck on a level surface and make sure parking brake is applied and load wheels are blocked to prevent accidental movement. 2. Press red OFF button “O” on the keypad. Depress main ON/OFF switch to the OFF position. 3. Disconnect the battery connector from the truck.


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T-code

001

SMX

4. Remove truck cover(s) [see page 84.] 5. Loosen and remove mounting bolts (7). Remove brake coil (6) assembly. 6. Remove friction disk (5) from hub (4). 7. Remove retaining ring (8) from hub (4). 8. Remove friction flange (3). 7 Adjusting Screw

6 5

Figure 3-3: Brake Coil Assembly

Installation 1. Inspect friction flange (3) for wear, replace if the surface is worn unevenly. Install friction disk (5) on hub (4). Place friction flange (3) on motor. 2. Install brake coil assembly on the motor end. Adjust gap (see page 111.) Torque mounting bolts to 50 in-lbs (5.6 N•m). 3. Connect the battery connector to the truck. 4. Remove blocks. Turn main ON/OFF switch to the “On” position and turn key switch ON. 5. Test truck for proper operation before returning to service. 6. Install truck cover(s).

114

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F-code

Section

PT

S3.1

Version no

T-code

001

SMX

C-code

3530 Drive Wheel

Drive Wheel 1. Theory of Operation The drive wheel is mounted on the transmission drive axle. The drive wheel is part of the drive unit assembly. Drive Wheel Specifications 10 inch X 5 inch (255 X 125 mm)


2.1. Drive Wheel Nut Inspection 1. Park truck on a level surface and make sure parking brake is applied and load wheels are blocked to prevent accidental movement. 2. Press red OFF button “O” on the keypad or turn key switch OFF. Depress main ON/Off switch to the OFF position. 3. Disconnect the battery connector from the truck. 4. Remove truck covers and bumper. 5. Hoist truck and securely block truck with drive tire approximately 1 inch (25 mm) off the floor. 6. Visually inspect lug nuts for signs of being loose. Inspect studs to see if one or more studs protrude through the lug nut farther than the others. If either condition exists, proceed as follows. 7. Loosen lug nuts to finger tight. If one or more studs turn while loosening the lug nuts, proceed as follows. 8. If any of the studs appear damaged, replace studs.


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C-code

PT S3.1 Drive Wheel

3530

Version no

T-code

001

SMX

NOTE!

The installation procedure of the studs, wheel and lug nuts must be completed in less than 0.50 hour to ensure the thread locking compound does not start to set up before the installation is complete.

9. Remove and clean studs. 10. Install two lug nuts, jammed together, to the end of the stud. This will allow the tightening of the studs using a torque wrench. 11. Apply Loctite 290® thread-locking compound to studs. 12. Install studs and torque to 23 - 28 ft-lbs (32 - 38 N•m). NOTE!

Do not overtighten studs. If studs are tightened to more to 30 ft-lbs (41 N•m) of torque, the studs will start to cut new threads and go too far hitting the lip seal. If the lip seal is damaged due to studs being installed too far, the axle will have to be replaced.

13. Remove nuts on studs, making sure studs do not rotate. 14. Install drive wheel and lug nuts. Torque lug nuts, starting with a low torque (possibly 5 ft-lbs [75 N•m]), using a star pattern. This is to make sure the lugs are centered in the mounting holes. On the final , apply 55 ft-lbs (75 N•m) of torque to nuts. 15. Remove blocking. 16. Connect the battery connector to the truck. 17. Turn the main ON/Off switch to the ON position. Enter key code and press the green On button “I” on the keypad or turn key switch ON. 18. Check operation of drive wheel. 19. Install truck covers and bumper.

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PT

S3.1

Version no

T-code

001

SMX

C-code

3530 Drive Wheel

3. Troubleshooting Inspect wheel and tire for wear and damage. Trash that is wrapped around the wheel and axle will cause premature tire wear and bearing damage. The floors should be kept clean of trash to reduce risk of damage to wheel and tire.

4. Repair and Rebuild 1

2

3

Item No. 1 2 3 4

4

Description Wheel assembly Tire Hub Nut

Removal The drive wheel can be removed without removing the transmission by the following steps: 1. Park truck on a level surface and make sure parking brake is applied and load wheels are blocked to prevent accidental movement.


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117

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Section

C-code

PT S3.1 Drive Wheel

3530

Version no

T-code

001

SMX

2. Press red OFF button “O” on the keypad. Depress main ON/OFF switch to the OFF position. 3. Disconnect the battery connector from the truck. 4. Remove truck cover(s) and bumper (see page 84.) 5. Hoist truck and securely block truck with drive tire approximately 1 inch (25 mm) off floor. 6. Remove hub (3) and nuts (4). Pull tire and wheel from transmission drive axle.

Installation 1. Install new tire and hub (3) on transmission drive axle and secure with nuts (4). In a crossing pattern, torque nuts to 55 ft-lbs (74.6 N•m). 2. Attach bumper with bolts, apply Loctite 243® to bolts, and tighten. 3. Remove blocking. Connect the battery connector to the truck. 4. Turn the main ON/OFF switch to the ON position. Enter key code and press the green ON button “I” on the keypad. 5. Check operation of drive wheel.

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F-code

Section

PT

S3.1

Version no

T-code

001

SMX

C-code

3530 Drive Wheel

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

2. Place a circular ram on press table. The length of ram must be longer than the width of the old tire to allow complete removal of old tire. The outside diameter of ram must be small enough to fit loosely in the insert of tire, but large enough to rest squarely on the flat surface on the outer edge of hub.

Circular Ram

3. If the outside edge of the hub is not flush with the edge of the metal insert in old tire, measure how far hub is recessed inside tire. The new tire must be placed in the same position the old tire was installed on the hub. A spacer (slightly smaller in diameter than the inside diameter of tire insert and the same thickness as the depth of the recess) can be used to obtain proper amount of recession.

New Tire Worn Tire

Press Table

4. Position hub assembly with the old tire on the top of circular ram so the outside of the wheel is positioned upward. The outside edge of hub has a chamfer to help guide the new tire onto the wheel. The chamfered edge must always be the leading edge when a tire is pressed onto hub. 5. Center hub assembly on the top of the ram and make sure they mate squarely. 6. Position new tire with its chamfered insert facing hub. Align new tire and hub so they are concentric.


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119

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C-code

PT S3.1 Drive Wheel

3530

Version no

T-code

001

SMX

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

If new tire does not press on with a minimum of 5 tons (68,947 kPa) force, replace hub.

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

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PT

S3.2

Version no

T-code

001

SMX

C-code

3550 Load Wheels

Load Wheels 1. Theory of Operation The load wheels are mounted on the pallet forks to the rated load at the forks fully raised height. Load wheels contain sealed bearings on both sides. Load Wheel Specifications 3.25 inch X 4.50 inch (82 X 115 mm)

2. Maintenance Inspect the wheels for wear and debris wrapped around the wheels. Check load wheel bearings for binding or excessive play. See “Planned Maintenance Schedule” on page 61.

3. Troubleshooting Inspect load wheel bearings for chunking, bond failure, and excessive or uneven wear. Make sure wheels are functioning smoothly and sufficient grease is applied to load wheel bearings and linkage.


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121

F-code

Section

C-code

PT S3.2 Load Wheels

3550

Version no

T-code

001

SMX


2

Item No. 1 2

Description Bearing Wheel, load

1

Removal 1. Park the truck on a level surface. 2. Lift forks to maximum height and block (see page 58.) 3. Press red OFF button “O” on the keypad. Depress main ON/OFF switch to the OFF position. 4. Disconnect the battery connector from the truck. 5. Remove axle set screw.

Axle Set Screw

Figure 3-4: Load Wheel Setscrew

122

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Section

PT

S3.2

Version no

T-code

001

SMX

C-code

3550 Load Wheels

6. Drive the axle out of the load arm casing with a hammer and brass drift pin. 7. Push the wheel out. 8. If bearings are to be reused, insert a brass drift pin into each of the load wheel and knock bearings out.

Installation 1. Install bearings in the new load wheel with seal side out. 2. Place the new load wheel upright on a level surface. Position the bearing over the load wheel. Put a flat metal plate over the bearing and tap the bearing in place with a plastic mallet. Make sure the bearing is fully seated in the load wheel. 3. Align the wheel with the holes in the load arm casting. 4. Install the axle through the load arm hole and wheel. Align the “dimple” in the axle with the set screw hole. 5. Install and tighten the set screw. 6. Lower truck and remove blocks. 7. Connect the battery connector to the truck. 8. Turn main ON/OFF switch to the ON position. Enter key code and press the green ON button “I” on the keypad. 9. Test truck for proper operation before returning to service.


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123

F-code

Section

C-code

PT S3.2 Load Wheels

3550

Version no

T-code

001

SMX


124

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PT

Section

C-code

S3.3 3560 Caster Wheel (Optional)

Version no

T-code

001

SMX

Caster Wheel (Optional) 1. Theory of Operation The caster assembly is mounted on the truck bumper to provide truck maximum stability.

2. Maintenance Normal maintenance includes lubricating the grease fittings on the caster assembly periodically. (See “Planned Maintenance Schedule” on page 61.)

2.1. Inspection Caster Assembly

1. Park truck on a level surface and make sure parking brake is applied and load wheels are blocked to prevent accidental movement. 2. Press red OFF button “O” on the keypad. Depress main ON/OFF switch to the OFF position. 3. Disconnect the battery connector from the truck. WARNING When using compressed air, wear effective chip-guarding and personal protective equipment. Compressed air used for cleaning MUST be reduced to less than 30 psi (207 kPa). NOTE!


4. Thoroughly clean all parts and remove all nicks and burrs with emery cloth. 5. Inspect all bearings and replace as necessary. 6. Inspect wheel(s) for flat spots or pieces of material missing from tire. 7. Fill caster wheel with grease (see page 72.)


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2005-07-11

125

F-code

Section

C-code

PT S3.3 3560 Caster Wheel (Optional) Version no

T-code

001

SMX

3. Troubleshooting Lubricate caster swivel as necessary.

4. Repair and Rebuild 1 2 3 4 5 6

20 7 8 7 19 9

9

10

11

18

10

12

17 15

14

13

14 13 16

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2005-07-11

F-code

Section

PT

Item No. 1 2 3 4 5 6 7

Description Caster Assembly Fitting, grease Pin Cap Bearing cup Plate Washer, thrust

Item No. 8 9 10 11 12 13 14

Description Bearing, thrust Arm Washer assembly Nut Nut Washer, flat Bearing

C-code

S3.3 3560 Caster Wheel (Optional)

Version no

T-code

001

SMX

Item No. 15 16 17 18 19 20

Description Wheel Screw Screw Block, torsion Housing O Ring

Removal 1. Park truck on a level surface and make sure parking brake is applied and load wheels are blocked to prevent accidental movement. 2. Press red OFF button “O” on the keypad. Depress main ON/OFF switch to the OFF position. 3. Disconnect the battery connector from the truck. 4. Hoist truck so caster wheel is approximately 2 inches (50 mm) off the floor and securely block. 5. Before disassembly thoroughly clean exterior of the caster assembly in a cleaning solution to remove all contamination. 6. Remove caster assembly screws from bumper. Remove caster assembly and take to a suitable work area. 7. Remove nuts (11) and (12) and washers (10) from screws (16) and (17). Remove screws (16) and (17) from assembly. Remove arms (9). 8. Remove flat washers (13) and bearings (14) from wheel (15). Inspect bearings (14). 9. Disassemble housing (19) by removing pin (3), cap (4), and plate (6). Remove bearing (5) from plate (6). Remove O ring (20), thrust washers (7), and thrust bearing (8) from housing (19). Inspect bearings (5) and (8).


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Section

C-code

PT S3.3 3560 Caster Wheel (Optional) Version no

T-code

001

SMX

Installation WARNING When using compressed air, wear effective chip-guarding and personal protective equipment. Compressed air used for cleaning MUST be reduced to less than 30 psi (207 kPa). 1. All parts should be cleaned and dried thoroughly. Metal parts should be lightly oiled prior to reassembly. 2. Pack all bearings with grease (see page 72.) 3. Install O ring (20), thrust bearing (8), and thrust washers (7) in housing (19). 4. Install bearing (5) and cap (4) in plate (6). Install plate (6) on housing (19) and secure with pin (3). 5. Install bearings (14) and flat washers (13) in new wheel (15). 6. Install arms (9) on housing (19) and secure with screws (16) and (17), washer (10), and nuts (11) and (12). 7. Install caster assembly to bumper and secure with screws. 8. Connect the battery connector to the truck. 9. Remove blocks. Turn main ON/OFF switch to the ON position. Enter key code and press the green ON button “I” on the keypad. 10. Test truck for proper operation before returning to service.

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Section

C-code

S4.0 4100 Steering Control Handle

Version no

T-code

001

SMX

Steering Control Handle 1. Theory of Operation The steering control head fastens to the handle stem and mounts on the carrier frame. Ease of operator steering and the ability to right-angle stack is provided by the handle assembly.




1. Thoroughly clean all parts and remove all nicks and burrs with emery cloth. 2. Inspect all parts for excessive wear or scoring. If heavy scoring is found replace part(s). 3. Inspect handle stem for nicks or rust; clean with emery cloth or replace handle stem. 4. Inspect head harness for wear or broken wiring(s).

3. Troubleshooting Check fasteners and the ease of steering.


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129

F-code

Section

C-code

PT S4.0 4100 Steering Control Handle Version no

T-code

001

SMX

4. Repair and Rebuild 3 1

7

5

2

9 6

4 8

11 10

24

13 10

12

11 14 15 16 17

18

19 22

20 23

21

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PT

Item No.

Description

Section

Version no

T-code

001

SMX

Item No.

C-code


Description

1 2 3 4 5 6 7 8 9

Screw Cushion, upstop Screw Mount, stem Screw Clip Stem, handle Screw, set Steering control head

13 14 15 16 17 18 19 20 21

Sleeve Washer, plastic Screw Lockwasher Carrier frame Drive unit Drive motor Brake assembly Transmission assembly

10 11 12

Washer Bushing Spring

22 23 24

Steering bearing Drive wheel Pin

Removal 1. Park truck on a level surface and make sure parking brake is applied and load wheels are blocked to prevent accidental movement. 2. Release pressure in hydraulic system by pressing the lowering button on steering control handle. 3. Press red OFF button “O” on the keypad. Depress main ON/OFF switch to the OFF position. 4. Disconnect the battery connector from the truck. 5. Remove screws (1) securing lower steering control handle cover (4).


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2006-08-07

131

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Section

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001

SMX

Cover

Screw

Figure 4-1: Control Handle Cover

6. Lift cover (4) off assembly and lay to one side.

Wiring Harness Connector

Arm Angle Switches Figure 4-2: Wiring Harness

NOTE!

Make note locations of cable ties on handle harness before disconnecting wiring.

7. Disconnect wiring harness connector. CAUTION The steering control handle stem will be free to fall when cap screws are removed. 8. Remove set screw (8) located at the base of the steering control handle stem (7) and drive out pin (24) using a hammer and a brass drift pin. Hold stem securely to prevent it from dropping. 9. Carefully remove steering control handle stem (7). 132

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001

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10. Inspect stem harness and washer (10), bushing (11), spring (12), sleeve (13), and washer (14) for excessive wear. Replace if necessary.

Installation NOTE!

Make sure brake release cam assembly is in the correct position before proceeding with installation procedures.

1. Position steering control handle stem (7) on the pivot assembly. Secure with screw (5). 2. Thread wiring harness through handle base. 3. If removed, reattach steering control handle head. 4. Connect handle harness connector and arm angle switch connections. Install cable ties in their original locations on the handle harness. 5. Install lower steering control handle cover (4). Secure with screws (1).

Plastic Washer

Harness

Sleeve

Spring

Figure 4-3: Control Handle

6. Remove blocks. 7. Connect the battery connector to the truck.


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001

SMX

8. Turn main ON/OFF switch to the “On” position and enter key code and press green ON button “I” on the keypad. 9. Test operation of all steering control handle functions before returning to service.

134

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Section

C-code

S4.1 4100 Steering Control Head

Version no

T-code

001

SMX

Steering Control Head 1. Theory of Operation The steering control head is mounted to the steering control handle. For functions of the control handle assembly see “Changing Driver Accessible Parameters (P)” on page 172 or “Changing Service Parameters” on page 174.


3. Troubleshooting Check fasteners and ease of steering.


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135

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C-code

PT S4.1 4100 Steering Control Head Version no

T-code

001

SMX


13

46

14 15

45

16

44

17

43 42

20

19

18

21

41

22 25

17 29 28

26

27

24 23

30

32 31 35 38 34

38

34 33

37 36

39

31 32 40 1 3

2

4

5 6

11 8 10

136

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9

7

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SMX

Description

Item No.

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

Screw Plate Handle Screw Cover (option) Pad, key Screw Screw Relief, strain Plate Handle assembly, control Insert, blank Button, no function Button, reverser Button, horn (right) Housing Switch, horn Display Electronic Tiller Arm Card (ETAC) Spring Housing Screw Gasket

24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46

2006-08-07

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Version no

Item No.


Section

Description Spring Screw Screw Tie, cable Screw Tie, cable Thumb control assembly Screw Washer Switch, right Bearing Stop lug Arm Axle Spring Switch, left Button, horn (left) Seal Cap, transparent plastic Button, lift / lower Insert, lower Insert, lift

137

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Removal 1. Park truck on a level surface and make sure parking brake is applied and load wheels are blocked to prevent accidental movement. 2. Release pressure in hydraulic system by pressing the lowering button on steering control head. 3. Press red OFF button “O” on the keypad. Depress main ON/OFF switch to the OFF position. 4. Disconnect the battery connector from the truck. 5. Remove screw (7) from key pad. Unplug and remove key pad (6) from handle (3). 6. Holding the top cover (16) firmly, remove screws (4) and (8). 7. Disconnect the cable connected to ETAC (19). 8. Remove screws (22) from housing (21) to gain access to ETAC (19). NOTE!

Place finger between housing (21) and reverser button (14) to hold right switch (33) in place while removing housing (21).

9. Carefully lift off housing (21).

Horn Button Removal

10. Remove horn button (15) and (41). 11. Disconnect the connection for the switch on the ETAC (19). 12. Press switch out from its mounting in the top cover assembly. 13. Remove thumb wheel assembly (30). A

A

14. Remove lift/lower button (44) by placing a screwdriver in the hole.

Lift/Lower Button Removal

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Installation NOTE!

Place finger between housing (21) and reverser button (14) to hold right rocker (33) in place while installing housing (21).

1. Install thumb wheel assembly (30). 2. Install lift/lower button (44). 3. Install horn button (15) and (41). NOTE!

Do not force housing (21). Install carefully.

4. Install housing (21) and secure with screws (22). 5. Connect the stem harness to ETAC (19). NOTE!

Make sure stem harness is properly routed before installing top cover.

6. Install top cover (16) and hold firmly in place while securing with screws (4) and (8). 7. Plug in key pad (6) in handle (3). Secure with screws (7). 8. Remove blocks. 9. Connect the battery connector to the truck. 10. Turn main ON/OFF switch to the ON position. Enter key code and press the green ON button “I” on the keypad. 11. Test truck for proper operation before returning to service.


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139

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140

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PT

S4.2 4180 Steering Bearing

Version no

T-code

000

SMX

C-code

Steering Bearing 1. Theory of Operation The steering bearing is part of the drive unit assembly. The vertical and horizontal loads are carried by the steering bearing.

2. Maintenance Inspect for wear or damage.

3. Troubleshooting Probable Cause Worn or damaged steering bearing


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2004-02-13

Required Action Replace bearings

141

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Section

C-code

PT S4.2 Steering Bearing

4180

Version no

T-code

000

SMX

4. Repair and Rebuild 1 2 3

4 5

Item No.

142

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Description

1

Screw

2

Lockwasher

3

Bearing

4

Stop, steering

5

Transmission assembly


2004-02-13

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Section

PT

S4.2 4180 Steering Bearing

Version no

T-code

000

SMX

C-code

The steering bearing can not be repaired or rebuilt. Replace steering bearing with new as necessary.

Removal 1. Park truck on a level surface and make sure parking brake is applied and load wheels are blocked to prevent accidental movement. 2. Release pressure in hydraulic system by pressing the lowering button on steering control head. 3. Press red OFF button “O” on the keypad. Depress main ON/OFF switch to the OFF position. Disconnect the battery connector from the truck. 4. Jack truck and block the frame (see page 58.) 5. Remove truck cover(s) [see page 84.] 6. Disconnect all electrical connections on drive motor and brake assembly. 7. Remove transmission (see page 103.) 8. Remove screws (1) and lockwashers (2) from bearing (3). Remove bearing (3) from transmission assembly (5).


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143

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C-code

PT S4.2 Steering Bearing

4180

Version no

T-code

000

SMX

Installation 1. Install new bearing (3) and secure with lockwashers (2) and screws (1) on transmission. 2. Install transmission (see page 106.) 3. Connect all electrical connections. 4. Refill transmission with fluid as needed (see page 72.) 5. Install truck cover(s) [see page 84.] 6. Remove blocks. 7. Connect the battery connector to the truck. 8. Turn main ON/OFF switch to the ON position. Enter key code and press the green ON button “I” on the keypad. Operate the truck’s hydraulic system and check operation of system as a whole. Look for leaks and tight places on the lifting linkage.

144

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Section

C-code

S5.0 5000 Electrical Functions

Version no

T-code

002

SMX

Electrical Functions 1. Theory of Operation The travel control system on the truck is electrically controlled and monitored. The lift/lower systems are electrically controlled and hydraulically operated. All circuits are protected against overload with automatic resetting circuit breakers. Refer to the following detailed electrical circuit schematics as they apply. The complete electrical circuit schematics can be found starting on page 194. When starting the truck, the transistor controller checks the closing sequence of the micro switches in the circuit. For information on the transistor controller see page 239. Normal Operation 1. When the truck is first powered on, it displays an hourmeter (see parameter 20 on page 178) for the first five seconds. Then, it normally displays the battery state-of-charge throughout operation. 2. While a Caution error code is tripped, it is displayed 3.4 seconds out of every 5.1 seconds. The other 1.7 seconds shows normal display. 3. When battery state-of-charge is zero percent, lift is not allowed. When the battery state-of-charge is 10 percent or lower, the battery light blinks.


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PT S5.0 Electrical Functions Version no

T-code

002

SMX

C-code

5000

1.1. Battery Plugged In With Keypad With the battery connected to the truck, wire number 1 connects battery voltage to the positive side of the main or (K10), control fuse (F50), positive of the key switch jumper, electronic tiller arm card (ETAC) [A2] and positive side of resistor (PTC R1.) From resistor (PTC R1), a voltage of 1.0 to 1.5 volts less than battery voltage is provided to fuse (F51) and positive side of the main ON/OFF switch (S21.)

Pressure Oil Return Oil B+ Circuit B- Circuit Signal Pre-Charge Voltage

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Symbol

Designation

Symbol M1

Designation

A1

Drive Transistor Controller

A2

Electronic Tiller Arm Card Transistor Controller

M3

Pump Motor

F50

Keypad/Tiller Arm Circuit Fuse

S18-1

Horn Switch

F51

Main Control Fuse

S18-2

H1

Horn

S21

Drive Motor

Horn Switch Main ON/OFF Switch

J11

Handle Stem Base Wire Connection

S24

Arm Angle (A) Switch

J41

Service Key (CAN) Wire Connection

S25

Arm Angle (B) Switch

K4

Main or Relay

S36

Lift Limit Switch

K10

Main or

Y1

Brake Coil

K30

Pump Motor Solenoid

Y10

Lower Valve Coil


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1.2. Battery Plugged In With Key Switch With the battery connected to the truck, wire number 1 connects battery voltage to the positive side of the main or (K10), control fuse (F50), positive side of the key switch and positive side of resistor (PTC R1.) From the resistor (PTC R1), a voltage of 1.0 to 1.5 volts less than the battery voltage is provided to fuse F51 and positive side of the main ON/OFF switch (S21).

Pressure Oil


Designation

Symbol M1

Designation

Return Oil

A1


A2


M3

Pump Motor

B+ Circuit

F50


S18-1

Horn Switch

F51

Main Control Fuse

S18-2

H1

Horn

B- Circuit

Return

Symbol

S21

Drive Motor


J11


S24


Signal

J41


S25


K4

Main or Relay

S36

Lift Limit Switch

Pre-Charge Voltage

K10

Main or

Y1

Brake Coil

K30

Pump Motor Solenoid

Y10

Lower Valve Coil


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002

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C-code

5000

1.3. Main ON/OFF Switch/Keypad ON When the switches on wire number 22 connects to the battery voltage to the ETAC (A2) pin J11-1, this powers up the ETAC (A2) for start of communication to the transistor controller (A1). A voltage of volts from the resistor (PTC R1) 1.0 to 1.5 volts less than battery voltage is provided to the positive side of arm angle A switch (S24), arm angle B switch (S25), and the normally closed lift limit switch (S36) to the transistor controller (A1) pin J5-15.


148

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Symbol

Designation

Symbol M1

Designation

A1


A2


M3

Pump Motor

F50


S18-1

Horn Switch

F51

Main Control Fuse

S18-2

H1

Horn

S21

Drive Motor


J11


S24


J41


S25

Arm Angle (B) Switch Lift Limit Switch

K4

Main or Relay

S36

K10

Main or

Y1

Brake Coil

K30

Pump Motor Solenoid

Y10

Lower Valve Coil


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Section


T-code

002

SMX

C-code

5000

1.4. Travel, Low Speed When the steering control handle is within 6 to 41 degrees of the upper rest position and the thumb controls are rotated from neutral, the travel signal is detected via hall effect sensors. This converts into a travel instruction in the ETAC (A2) and transmitted via the CAN to the transistor controller (A1). The ETAC (A2) verifies that the reverser button is not activated before supplying the travel command to the transistor controller. The ETAC (A2) verifies that arm angle B switch (S25) is engaged for slow speed travel mode. The transistor controller provides a negative pin J5-4 to the main or coil (K10) closing the main or (K10) and to the main or relay (K4). The main or relay (K4) provides battery voltage to the positive side of pump or coil (K30), brake coil (Y1), lower valve coil (Y10) and horn (H1). The transistor controller provides a negative pin J5-5 to the brake coil (Y1) releasing the brake. The voltage at M- of the drive motor will vary from 24V to approximately 20V. The voltage is proportional to the position of the thumb controls. The drive wheel starts to rotate in the selected direction at a speed proportional of the thumb controls.

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Travel Low Speed

Pressure Oil


Return

Symbol

Designation

Symbol M1

Designation

Return Oil

A1


A2


M3

Pump Motor

B+ Circuit

F50


S18-1

Horn Switch

F51

Main Control Fuse

S18-2

B- Circuit

H1

Horn

S21

Drive Motor


J11


S24


Signal

J41


S25


K4

Main or Relay

S36

Lift Limit Switch

Pre-Charge Voltage

K10

Main or

Y1

Brake Coil

K30

Pump Motor Solenoid

Y10

Lower Valve Coil


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T-code

002

SMX

C-code

5000

1.5. Travel, High Speed When the steering control handle is between 41 to 79 degrees from the upper rest position, the ETAC (A2) verifies that both arm angle switch (S24) and arm angle switch (S25) are engaged for high speed travel mode. The voltage at M- of the drive motor will vary from 24V to 0.5V. The voltage is proportional to the position of the thumb controls. The drive wheel rotates in the selected direction at a higher speed proportional of the thumb controls.

Pressure Oil

Symbol

Return Oil

A2


M3

Pump Motor

B+ Circuit

F50


S18-1

Horn Switch

F51

Main Control Fuse

S18-2

Horn Switch

H1

Horn

S21

Main ON/OFF Switch

J11


S24


J41


S25


K4

Main or Relay

S36

Lift Limit Switch

K10

Main or

Y1

Brake Coil

K30

Pump Motor Solenoid

Y10

Lower Valve Coil

Pre-Charge Voltage


M1

Designation


Signal

152

Designation

A1

B- Circuit

Return

Symbol

Drive Motor

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002

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1.6. Reverser Pressure Oil Return Oil B+ Circuit B- Circuit Signal Pre-Charge Voltage

Symbol

Designation

Symbol M1

Designation

A1


A2


M3

Pump Motor

F50


S18-1

Horn Switch

F51

Main Control Fuse

S18-2

H1

Horn

S21

Drive Motor


J11


S24


J41


S25


K4

Main or Relay

S36

K10

Main or

Y1

Brake Coil

K30

Pump Motor Solenoid

Y10

Lower Valve Coil


Return

When the reverser button is activated with the steering control handle lowered in the travel mode, the control system provides an immediate forks-first direction travel instruction. Reverse signal is converted into a forks-first travel instruction transmitted via the CAN to the transistor controller. Travel and speed inputs are ignored. The transistor controller provides maximum torque immediately after the reverser button is pressed. Maximum rearward travel continues until the reverser button is released.


2006-12-12

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002

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C-code

5000

1.7. Lift When the lift button is pressed, the transistor controller provides a negative pin J5-4 to the main or coil (K10), closing the main or (K10) to the main or relay (K4). The main or relay (K4) provides battery voltage to the positive side of pump or coil (K30). The transistor controller provides a negative in J5-6 to the pump or coil (K30) closing the pump or.


154

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Symbol

Designation

A1


Symbol M1

Designation Drive Motor

A2


M3

Pump Motor

F50


S18-1

Horn Switch

F51

Main Control Fuse

S18-2

Horn Switch

H1

Horn

S21

J11


S24


J41


S25


Main ON/OFF Switch

K4

Main or Relay

S36

K10

Main or

Y1

Brake Coil

K30

Pump Motor Solenoid

Y10

Lower Valve Coil


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C-code


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T-code

002

SMX

1.8. Lower When the lower button is pressed, the transistor controller provides a negative pin J5-4 to the main or coil (K10), closing the main or (K10) to the main or relay (K4). The main or relay (K4) provides battery voltage to the positive side of lowering valve coil (Y10). The transistor controller provides a negative pin J5-2 to the lowering valve coil (Y10), opening the hydraulic lowering valve.

Pressure Oil


Return

Symbol

Designation

Symbol

Return Oil


A2


M3

Pump Motor

B+ Circuit

F50


S18-1

Horn Switch

F51

Main Control Fuse

S18-2

Horn Switch

B- Circuit

H1

Horn

S21

J11


S24


Signal

J41


S25


K4

Main or Relay

S36

Lift Limit Switch

Pre-Charge Voltage

K10

Main or

Y1

Brake Coil

K30

Pump Motor Solenoid

Y10

Lower Valve Coil


M1

Designation

A1

2006-12-12

Drive Motor

Main ON/OFF Switch

155

F-code

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T-code

002

SMX

C-code

5000

2. Maintenance Connections must be kept clean and tight. The electrical components should be protected from moisture. If the truck is equipped with cold storage, or corrosive environment application package, then the di-electric compound (part number 302249-000) in the plug-in connectors should be renewed periodically. This compound is available through the parts department of your authorized Prime-Mover Dealer.

2.1. Wiring Many electrical problems are caused by a bad or dirty battery. Make sure battery is clean. Check the electrolyte level and battery level. CAUTION Unless otherwise directed, disconnect battery connector when checking electrical circuits or components with an ohmmeter. Electrical current can damage the ohmmeter. Visually inspect all wiring and electrical components for the following: •

Loose connections or connectors

•

Loose or broken terminals

•

Damaged terminals, blocks, or strips

•

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

Use an ohmmeter to check for wiring continuity.

2.1.1. Definitions Continuity. A continuous and uninterrupted path between two or more locations in an electrical circuit, typically having a resistance of less than 1 ohm. Open Circuit. A lack of a continuous path between two or more electrical connections. Generally, when such a circuit is tested, it will have a resistance greater than one megohms. Pulse Width Modulation. Pulse Width Modulation (PWM), also called “chopping,” controls the speed of the motor by

156

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T-code

002

SMX

switching the battery voltage to the motor on and off very quickly. Overtemperature. Overtemperature of the transistor controller is from 185 degrees F (85 degrees C) and above. At overtemperature, the drive current limit is linearly decreased from full set current down to zero. Plug current is not reduced to provide full truck braking under all thermal conditions. Undertemperature. When the transistor controller is operating at less than -13 degrees F (-25 degrees C), the current limit is cut back resulting in reduced travel speed. Short Circuit or “Short”. A short circuit is an unspecified path in a circuit that provides unwanted full or partial continuity between two or more locations in an electrical circuit. Example: Two insulated wires are physically next to each other and the insulation has been worn off each of the wires. Because the conductors inside each wire are now touching each other, there is a short circuit. Example: A power cable from the battery to a junction post in the truck has had the insulation worn away. Because the wire conductors are touching the frame, there is a short circuit of the battery cable. 2.1.2. Shorts to Frame Test “Shorts to frame” is an industry term for unintentional current leakage paths between normally isolated electrical circuits and their metal enclosures. Shorts to frame may be metallic connections, such as a wire conductor ing metal through worn insulation. More often, shorts to frame are resistive “leakage” paths caused by contamination and/or moisture. These leakage paths can result in unwanted electrical noise on the metallic truck structure and may result in improper operation. Shorts to frame can be caused by the following:


Return

•

Accumulation of dirt

•

Battery electrolyte leakage

•

Motor brush dust


2006-12-12

157

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002

SMX

C-code

5000

•

Motor brush leads touching housing

•

Insulation breakdown

•

Bare wires

•

Pinched wiring harness

•

Circuit cards improperly mounted

Shorts to frame can occur at numerous locations on truck including the following: •

Batteries

•

Motors

•

Cables, wiring, and harnesses

•

Heat sinks

•

Bus bars

•

Solenoids

•

ors

•

Terminal strips

•

Switches

•

Power insulation

•

Circuit card mounts

To test for shorts from battery to frame: 1. Press red OFF button “O” on the keypad. Depress main ON/OFF switch to the OFF position. Disconnect the battery connector from the truck. 2. Using a voltmeter set on a 50Vdc scale, attach the leads as follows: •

Negative (-) lead to an unpainted, grounder surface on the truck frame

•

Positive (+) lead to the positive battery terminal.

The voltmeter must shown no more than 3V. 3. Attach the leads as follows: •

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Negative (-) lead to the negative battery terminal


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Positive (+) lead to an unpainted, grounded surface on the truck frame.

The voltmeter must show no more than 3V. 4. If a reading of 3V or more is received in the previous steps 2 or 3, proceed as follows: a. If applicable, remove bolts securing the battery to the truck. Remove battery from the truck (see page 203.) b. Thoroughly clean battery (see page 200.) c. Reinstall battery. If applicable, securely fasten bolts to battery box frame on the truck. d. Repeat steps 2 and 3 to see if the problem has been eliminated. e. If excessive voltage is still found, check the battery for internal leakage. To test for shorts from components to frame: 1. Press red OFF button “O” on the keypad. Depress main ON/OFF switch to the OFF position. 2. Disconnect the battery connector from the truck. 3. Using an ohmmeter and measure the resistance to an unpainted, grounded surface on the frame at B+, B-, and all fuses: A resistance reading of less than 100,000 ohms indicates a short to the frame. If this condition exists, find the source of low resistance or short to frame using the following step 6. 4. If applicable, remove bolts securing the battery to the truck. Remove battery from the truck (see page 203.) The voltmeter must show no more than 3V. 5. Connect the battery lead to the truck. 6. Using an ammeter to measure the leakage current to the unpainted, grounded surface on the frame at B+, B-, all fuses and all motors. If the current is less than 0.001 ampere (1 mA), the truck system es. If the current exceeds 1 mA, go to step 6. © BT Prime-Mover, Inc.

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5000

7. To find the cause of the low resistance, disconnect the power cables from each motor or major subassembly one at a time, to determine if that item is causing the low resistance.

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3. Troubleshooting 3.1. Troubleshooting Flowchart Troubleshooting

Truck Fault Code

Yes

Find Code (see page 181)

No

Transistor Controller Error Code

Yes

Find Code (see page 246)

No

Yes, Traction/Overall Check Troubleshooting Chart

No

Go to charts (see page 189)

Yes, Hydraulic

Go to charts (see page 261)

General Troubleshooting (see Service Display page 169)


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5000

Troubleshooting can be broken down into two sections: (1) mechanical and (2) electrical circuits. Electrical circuits can be further broken down into control circuit and power circuit. Many hours of troubleshooting time can be saved by knowing the exact operational symptoms. Check the control switches; if they test as operating properly, the problem most likely will be in the power circuit of that function. The travel functions are controlled by the transistor controller. Lift, lower, and horn functions operate separately. To use this troubleshooting guide locate the failure symptom in the index (see Troubleshooting Chart Index” on page 188.) Then go to the expanded outline, and follow the testing procedures described. Voltage tests are made with the negative lead of the volt meter connected to battery negative. If the negative lead is connected to a negative terminal on the electrical , first the negative connection to the battery by touching the positive meter lead to the positive battery post. The battery voltage must be at least 25.2 volts for a 24 volt system. If the battery voltage is below 22 volts (no load), then the transistor controller may not operate properly. Charge the battery before starting the troubleshooting procedures. When testing voltage, the “POSITIVE SIDE” of any component refers to the terminal on that component that is closest electrically to the battery positive terminal. The “NEGATIVE SIDE” of any component refers to the terminal on that component that is farthest electrically from the battery positive terminal. It is possible and in many cases desirable to measure battery voltage on the negative side of a component. Forward direction refers to travel in the direction of the control handle with the tractor-first. Reverse direction refers to travel with the forks-first. The parking brake will automatically engage when the truck has come to a stop while the control handle is in the operating range and no travel speed is requested. Normal stopping during travel operation is obtained by reversing the travel direction controls (plugging) or moving the control handle to either the braking positions shown on page 163. The control handle and the direction control operate together to release the brake. The line or will be open when either of the parking methods are applied. 162

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6°

40° 33° 8°

Figure 5-1: Operating Range of Control Handle

After the final troubleshooting test is completed, the truck should be repaired and operating properly. If it is not, then test results and possibly re-evaluate the failure symptoms. If the truck still has not been repaired, then call your local Prime-Mover Dealer for assistance. When placing a call, the following information is required: truck model and serial number, information on hourmeter and error code, actual battery voltage at open circuit and at hydraulic operation under full load, the precise operating symptoms, and the exact results of the testing you have done. Authorized Prime-Mover Dealers may call the factory directly if necessary. The first steps of any troubleshooting procedure include: 1. Inspect truck for physical damage or mechanical malfunction. 2. Check for ground faults from the electrical system to the frame with an ohmmeter. A minimum of 100,000 ohms resistance from the frame to any and all wiring is acceptable. 3. Check that the battery is fully charged and connected. 4. Operate the truck in all modes to determine the exact symptoms. DO NOT forget that systems are equipped with circuits that reduce operation in the event of improper operating procedures.


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3.2. Main Harness Replacement NOTE!

Before removal of harness, document wire to terminal connections for main harness. Control Wires/ Wire Guard

5

26

3 6

57

4

Power Cables on Left Side Figure 5-2: Terminal Block

1. Park the truck on a level surface and make sure the parking brake is applied and load wheels are blocked to prevent accidental movement 2. Press red OFF button “O” on the keypad. Depress main ON/OFF switch to the OFF position. 3. Disconnect the battery connector from the truck. 4. Remove the truck covers and upstop (see see Figure 5-5 on page 166) to gain access to the wiring and cables.

NOTE!

Reference the electrical schematic on page 194 for location on connectors and switches.

5. Disconnect connector J11 and switches S24 and S25 inside the stem mount and all ring terminals from the drive motor terminal block (see Figure 5-2.)

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6. Remove the stem mount (see page 103) and stem handle as an assembly from the transmission (see Figure 5-3.) Remove the old harness from the truck (see page 192.) Upstop

Stem Mount

Stem Handle


Figure 5-3: Stem Handle Mounting

7. Lay the new harness into the truck. 8. Connect the truck end of the harness. For the proper harness connections, see Figure 5-3. For schematics see page 194. 9. Install the harness down through the transmission opening and connect cables and wires to the drive motor terminal block (see Figure 5-2 on page 164.) 10. Check to make sure the power wires are vertically stacked one on top of the other on the LEFT side of the transmission opening above the power terminals and the wire guard with ring terminals match on see Figure 5-3.


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11. Position cables and wires as shown in see Figure 5-3 on page 165. 12. Correctly orient the wire guards and power wires through the transmission as shown in Figure 5-4. 13. Make sure the short wire guard and wire tie are running down through the transmission as shown in Figure 5-4.

Stem Handle Wire Guard Power Cables Wire Tie

Field & Brake Wires Figure 5-4: Transmission with Harness Wiring

14. Install the stem mount and stem handle assembly.

Wire 24 Wire 51 - S25

Wire 50 - S24 Figure 5-5: Stem Mount Switch Wiring

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15. Refer to see Figure 5-3 on page 165 when installing ring terminals. Install ring terminal and secure middle nut and torque to 79 in-lbs (8.9 N•m). Install ring terminal and secure outer nut, making sure wire is out of the way, before torquing outer nut to 79 in-lbs (8.9 N•m). 16. Install the upstop (see Figure 5-4 on page 166) and truck covers. 17. Connect the battery connector to the truck. 18. Turn main ON/OFF switch to the ON position. Enter key code and press the green ON button “I” on the keypad. 19. Check all operating functions on the control handle.


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3.3. Operator Display and Programming The display is located on the top of the steering control handle arm and displays the operator and machine-specific . A

E

D

C

B

A - Numerical Field B - Hour Meter Indicator C - Parameter Control D - Battery Indicator E - Error Indicator

Operator Display 3.3.1. Special Modes To enter a special truck mode proceed as follows: 1. Hold down horn switch. 2. Enter PIN code on keypad and push green ON button (l) or turn key switch ON. 3. Release horn switch at desired display mode. Options for the display mode are follows:

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•

(H)ourmeters; use thumb control to choose, see parameter 20 on page 178 for Hourmeter options (hours shown are rounded down, i.e., 3 hours 50 minutes will display as 3.)

•

(E)rror codes log; the most recent error code will be displayed followed by the hour meter (activity time) it occurred. Use thumb control to scroll through the last 50 error codes (if no error code is logged, dashes will be displayed.)

•

(P)arameters: use thumb control to choose and the horn switch to access a parameter, the parameter light blinks (a service key is required to change some parameters (see page 174.) When the service key is used to change driver parameters and parameter 10, the driver number appears to the right of the normal


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parameter number display. All driver parameters and drivers are cycled through before Service Parameters, 0 = 10th driver.) •

(P)art (n)umbers: use thumb control to scroll through the following: •

(S)oftware (P)art (n)umber

•

(H)ardware (P)art (n)umber

•

(H)ardware (S)erial (n)umber

3.3.2. Service Display Connect the service key (see page 174) in connection point J41 (see page 194.) Push the green ON button “I” on the keypad. The battery status is displayed and the armature current symbol is lit continually. Use the horn button (S18) to toggle between display modes. No.

Flashing Symbol

Displayed Data

1

Speed reference value sent to transistor controller: -127 (FL) to +127 (FT) x parameter 2 for Fast

2

Digital inputs/outputs from transistor controller – see page 170

3

Battery voltage (V) at ETAC

4

Armature current (A)

5

Field current (A)

6

Armature PWM (%)

7

Transistor Controller System Mode – see page 171

8

Field resistance (Ohms), used for thermal cutback

NOTE!


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The first driver’s Driver Parameters are used while in Service Display.


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3.3.3. Digital Inputs/Outputs from Transistor Controller I

II

III IV

A

E

D

B

C 1A

6F

G 7

5 E 4 D

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2 B 3 C DP DP

Digit

Segment

I I I I

1 2 3 4

I

5

I

6

I

7

I

DP

II II II II II II II II

1 2 3 4 5 6 7 DP

III

1

III III III III III III III

2 3 4 5 6 7 DP

Function Input (J5-14): Arm angle B – see below Input (J5-15): Lift limit Input (J5-12): Arm angle A – see below Input (J5-2): Lower valve (lit if valve present & not powered) Input (J5-5): Brake (lit if brake is present & not released)

Output (J5-2): Lower valve Output (J5-4): Main or interlock Output (J5-7): Horn Output (J5-5): Brake Output (J5-6): Pump or

ETAC input: lift forks ETAC input: lower forks

ETAC input: horn


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3.3.4. Transistor Controller System Mode The transistor controller system mode is used only in special cases. Status 1 4 6 10 11

16

Comment Motor drive, plug or active neutral braking Field reversal (transitional) Disable (major fault, such as severe overvoltage) Regen Regen taper (transitional) No activity: main or open because no output requested for 30 seconds or an error occurred ive restraint

17 24 65 74 129 144

Active restraint while driving (overspeed) ive restraint (transitional) Reverser (drive) Reverser (regen) Emergency shutdown while in drive Emergency shutdown while in ive restraint

13

1. The system mode shows details of transistor controller activity, including during normal operation. It is different than, and does not correspond to, the code from the transistor controller Status LED. 2. Throttle requests are not allowed for any status of 32 and over. 3. Truck is in an emergency shutdown for any status of 128 and over.


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3.4. Changing Driver Accessible Parameters (P) WARNING Modify specific truck parameters will change the driving characteristics of the truck. 1. Enter special truck mode until “P” is displayed. The parameter control indicator is illuminated (see page 168.) 2. Use the thumb control to scroll to the driver parameters to locate the one to change or view the following truck parameter table. Scrolling in tractorfirst position will show parameters 1-40. scrolling in the tractor-first direction will show parameters 40-1. Press and hold horn button (S18-1 or S18-2) until “P” is displayed. 3. Press horn button once to access the parameter shown on the display. The parameter symbol (D) on the display starts flashing. 4. Change parameter value by pressing the thumb control up or down.

NOTE!

Parameters 1-7 can only be modified, see page 173. Parameters 10-40 can only be viewed.

5. Press the horn button again to confirm the change. The parameter symbol “O” on the display stops flashing and remains illuminated (see page 168.) 6. End programming by pressing the red OFF “O” key on the keypad.

NOTE!

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Moving the thumb control 1/4 - 3/8 inch (6.35 - 9.25 mm) will show the parameter display in digit “I” Releasing the thumb control to neutral position will then display the parameter value in digit III and IV, depending on if it is a single or double digit number.


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The parameter change is complete. The next time the truck is started, the new parameter will be in effect. All parameters can be viewed, however, not all parameters can be changed. Truck parameters may or may not be accessed, depending on the value of parameter 39 (see page 179.)

NOTE!

Truck Parameters Parameters 1-7 are Driver Parameters (7 parameters for each Drive PIN code entered

Parameter

Name

Unit

Range

Step

Default

Description

1

Max speed, slow mode

%

10 to 40

2

20

Maximum speed value sent to transistor controller while in Slow, except during Turtle Torque (gives torque boost if high load encountered.)

2

Max speed, fast mode

%

70 to 98

2

94

Reduces speed value sent to transistor controller while in Fast (all throttle positions.)

3

Acceleration

%

30 to 90

5

80

Defines truck’s acceleration characteristic, lower number gives less aggressive acceleration.

4

Deceleration

%

40 to 90

5

65

Defines truck’s automatic plug-braking characteristic when throttle is reduced (including to neutral); lower number gives less aggressive acceleration

5

Truck off delay (keypad only)

min

0 to 20

1

0

Sets truck off delay (energy saving feature); if truck is not used for this amount of time, the ETAC powers the truck off. When this parameter is set to 0, the truck never powers off. If parameter 39 is 1 or 2 (truck has key switch option), the truck never powers off.


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3.5. Changing Service Parameters NOTE!

A service key is required to change service parameters.

1. Connect the service key at J41.

NOTE!

With service key connected, the truck does not power ON using the keypad or key switch.

2. Enter special truck mode (see page 168.) 3. Press and hold horn button until “P” is displayed. The parameter control indicator is illuminated (see page 169.) View Parameters with Service Key Service Key

When parameters 1-7 and 10 are viewed with the service key, both the parameter (on the left side of the display, as normal) and the driver number (on the right) are shown. When the thumb control is rotated toward the forks, the parameter number increases, progresses through parameters 1 - 10, and then rolls over to the next driver (the driver number increases.) There are ten drivers 1-9, (0 = 10th driver.) If a parameter is changed, it is valid only for the driver shown. Parameter 1 for the sixth driver is shown as an example below:

01 6

Service Key

After scrolling through all drivers and driver parameters, service parameters 11-40 will be displayed. Since these parameters are valid for all drivers, no driver is shown. Parameter 39 is shown as an example below:

39

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If display/access for a service parameter is required, it is faster to initially rotate the thumb control away from the forks (go backwards through parameters/drivers.) The parameter number displays briefly, then if the thumb control is not rotated further the parameter value is displayed. Service Parameters Parameters 1-7 (driver number) and Driver Parameters, 10-40 are Service Parameters

Parameter

Name

10

Range

Step

Default

Description

Pin code (keypad only)

0 to 9999

1

1

Can set up to 10 PIN codes (need Service Key to access this.) Note: 0 disables a driver (the 2nd through 10th driver’s default PIN is 0), if all drivers are disabled the truck cannot be driven without the service key, and if two drivers have the same PIN, the higher number driver’s parameters will be used.

14

Creep speed

-10 to 10

1

-5

Defines speed at low throttle positions; a negative number enhances low speed maneuverability, a positive number makes the truck more responsive

20

Hourmeter selection

1 to 5

1

2

1 (A.) = key time 2 (b.) = activity time (drive, lift or lower) 3 (c.) = drive 4 (d.) = lift 5 (s.) = time to service (if parameter 25 = 0, the power-on 5 second hour meter display is skipped and 5(s) is not shown during Hourmeters special truck mode.) Time to service counts backward from value of parameter 25 to zero and decrements the same as 2(b.) increments.

21

Battery size (The lower the number, the deeper the discharge to the battery.)

1 to 20

1

8

Defines battery capacity; higher number represents larger capacity battery (the truck will allow the battery to become more discharged given the same displayed battery state-of-charge.) In other words, if the battery state-of-charge reaches 0% too soon (the battery still contains adequate charge to continue operation), this parameter should be increased. The battery state-of-charge is reset when the battery voltage is above 25.2V.

25

Service interval

0 to 2000

50

0

Sets service timer. C29 will display when time is up. To reset service timer, access this parameter without changing the value. To disable the service timer, set this parameter to 0. See parameter 20 on page 178.

39

Access code

1 to 4

1

3

Defines whether truck has key switch or keypad and what access level personnel will have to parameters 1=key switch/driver parameters open 2=key switch and closed 3=keypad and open 4=keypad and closed (when closed, service key is required to access driver parameters)


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3.5.1. Parameter Description Parameter 1 Maximum speed value sent to transistor controller while in Slow mode except during turtle torque (gives torque boost if high load is encountered.) Parameter 2 Reduces speed value sent from the Electronic Tiller Arm Card (ETAC) to the transistor controller while in Fast mode (all throttle positions.) Parameter 3 Defines truck’s acceleration characteristic when truck starts from a stop. A high number gives maximum acceleration, a lower number gives less aggressive acceleration. Parameter 4 Defines truck’s automatic plug-braking characteristic when throttle is reduced (including to neutral.) A lower number gives less aggressive acceleration. Parameter 5 Time until the truck is switched OFF (energy saving feature) when truck is idle and the brake is applied. Time is counted from the latest power output is requested. If truck has the key switch option, the truck never powers OFF. Parameter 10 Defines the PIN code for the driver shown. The default operator PIN-key code is “1”. Programming new key codes must be done using a service key (see page 174.) Each of the 10 key codes may be programed individually for operating parameters. If two drivers have the same PIN, the higher number driver’s parameters will be used. (EXAMPLE: If both the first and second driver’s PIN codes are 1111 and the first driver’s maximum speed is 80 percent and the second driver’s maximum speed is 90 percent, when someone logs in with 1111 the maximum speed will be 90 percent.) Setting a driver’s PIN code to 0 will disable that driver. By default, the first driver’s PIN code is 1 and all other driver’s PIN codes are 0. To enable additional drivers, change these PIN codes to numbers other than 0. To program operating parameters proceed as follows: 176

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• With the battery connected to the truck, service key connected, main ON/OFF switch turned to the ON position, press and hold down the horn button. • Enter key code and press “I” or turn on key switch. • The display will now show: H - Hour meter, E - Error Codes, P - Parameters, and Pn - Software number. These symbols will cycle continuously until the horn button is released. • Release the horn button when the display shows “P” (if the horn button is released at the wrong time, turn off the truck and start over.) • The parameter symbol below the display lights up;. • The value of parameter # 1 is shown on the display (although parameter # 1 is not functional at this time.) • Use the thumb controls to scroll to the desired parameter. When the thumb control is rotated slightly, the display changes to show the parameter number currently active. Rotating the thumb control further increments the parameter up or down according to which direction the control is rotated. • Release the thumb control to neutral when the desired parameter number is shown. (The current programmed value of that parameter is now shown on the display.) • Press the horn button once to make the parameter value displayed start to flash. • Rotate the thumb control to increment the parameter value up or down, depending upon the direction the control is rotated. • Release the thumb control to neutral when the desired parameter value is displayed. • Press the horn button once to lock in the new parameter value and this parameter has quit flashing. • Turn off truck when programming is completed.


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Parameter 14 Defines speed at low throttle positions. A negative number enhances low speed maneuverability. A positive number makes the truck more responsive. Parameter 20 Choose the hourmeter to display. • 1 = A. (key time) • 2 = b. (activity time • 3 = c. (drive motor time) • 4 = d. (pump motor time) • 5 = s. (time to service) Parameter 21 Data must be provided on the battery installed on the truck. To adjust the disconnection point of the battery discharge indicator, measure the following: WARNING The battery can be destroyed if the parameter settings are not correct. NOTE!

Acid concentration varies with different battery brands.

• The acid concentration of a fully-charged battery. To check quality of battery (must be between 1.27 - 1.29 specific gravity (SG). • At lift cutout, acid approximately 1.14 SG.

concentration

should

be

• Reset voltage is 25.2V. Lift cutout occurs when the display shows zero percent state-of-charge. See “Troubleshooting Chart Index” on page 188. Parameter 25 Used to set a time limit to the next service from 0 to 2000 hours in steps of 50 hours. When it is time for service, caution 29 will display, see page 182. To disable the service timer, set this parameter to 0. To reset service timer, access this parameter without changing the value.

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Parameter 39 Determines whether the truck has a key switch or keypad and what access level service personnel will have to the driver parameters. This parameter is adjustable as follows: • 1 = Key switch connected, driver parameters open • 2 = Key switch connected, driver parameters must be opened with service key • 3 = Keypad connected, driver parameters open • 4 = Keypad connected, driver parameters must be opened with a service key. 3.5.2. Operating Parameter Programming The following operating parameters may be programmed by the operator: • Parameter 1 - Slow speed range 10 - 40 • Parameter 2 - Fast speed range 70 - 98 • Parameter 3 - Acceleration range 30 - 90 • Parameter 4 - Deceleration range 40 - 90 • Parameter 5 - Automatic time off interval (with keypad only) - from 0 minute to 20 minutes (a setting of “0” disables automatic time off.) Additional truck parameters may be viewed but cannot be changed by the operator. 3.5.3. Display Part Numbers (Pn) 1. Enter special truck mode (see page 168.) 2. Press and hold horn button until “Pn” is displayed. 3. Use the thumb control to scroll and display the following information: •

HPn - Hardware part number

•

HSN - Hardware serial number

•

SPn - Software part number

4. End displaying the part number by pressing the red “OFF” “O” key on the keypad.


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3.6. Error Codes (E) When an error occurs on the truck, a code is displayed (see page 181.) 3.6.1. Error Code History To access the error code history, proceed as follows: 1. Enter special truck mode (see page 168.) 2. Press and hold the horn button until “E” is displayed. The error indicator (wrench icon) is illuminated (see page 169.) Use the thumb control to scroll through the last 50 error codes. The latest fault is shown first. The display first shows the error code and then the hour meter reading the fault occurred. The error codes are divided into two groups; C Caution and E - Error. The C error codes are not stored. It is only a caution and is highlighted on the display as long as the fault exists. For example, if only one fault is ed in the memory, the second empty place is shown as follows: Fault E - - - and time: - - -.hour meter reading. 3. End displaying the error code history by pressing the red OFF “O” key on the keypad.

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3.6.2. Truck Fault Codes Caution fault codes 0-49 are not logged. C codes 50-99 are logged. Code C14 - Arm Angle Reference Warning Reason

Steering control handle was not in up position at power ON or after the truck has not been used for a time.

Performance Limits

Travel is not allowed until code is cleared.

How to Clear Code

Code is cleared as soon as steering control handle is put in the Top Brake position.

Possible Causes with corrective actions/checks

1. 2.

Control handle stuck in down position. a. Check upstop. Arm angle input may be stuck ON. a. Check switch. b. Check input to transistor controller.

Code C19 - Default Parameter Warning Reason

Parameter(s) out-of-range (see page 175) or incompatible with software version.

Performance Limits

Truck functions are not allowed until after this code has been cleared.

How to Clear Code

Parameter area is automatically fixed and then code is cleared.


1.

ETAC parameter area is corrupt. a. If code does not clear after 10 seconds, try restarting the truck.

Code C20 - Thumb Control Warning Reason

Thumb control was not in neutral position at power ON, or a throttle position sensor failure was detected. Also see code 160 on page 187.

Performance Limits

Truck functions are not allowed until code is cleared.

How to Clear Code

Code is cleared after problem is corrected.


1. 2. 3.


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Thumb control stuck in drive position. Bad ETAC. Bad reverser button.


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Code C28 - Main ON/OFF Switch Warning Reason

Transistor controller could not be reset via the CAN-bus at power ON or transistor controller reports main ON/ OFF switch is open.

Performance Limits

Truck functions are not allowed after code has been set.

How to Clear Code

This code can only be cleared after the problem is resolved and truck is turned OFF and back ON.


1. 2.

Main ON/OFF switch activated. Low voltage to transistor controller (especially while lifting or driving) due to overcurrent or short circuit.

a. Try driving using a known-good battery. 3.

4.

5.

6.

PTC R1 missing, bad, or tripped (very high resistance, due to excessive current while main or is open; should automatically recover.) a. Carefully check to see if R1 is hot (tripped); if so unplug battery and allow it to cool. Locate low impedance path that tripped R1 and correct. Wire #24 at OV. a. Check that J5 is connected, fuse and wiring. b. Check for 24V at J5-16. Short or open circuit in CAN wiring or electrical noise in CAN wiring due to bad connection or outside interference, both at power ON. a. Check CAN wiring. b. Try operating truck in different environment. Bad transistor controller.

Code C29 - Time to Service Warning Reason

See service parameter 25 on page 178.

Performance Limits

None.

How to Clear Code

See service parameter 25 on page 178.


1. 2.

Time for service. Service interval not reset after last service.

Code C41 - Battery Undervoltage Warning Reason

Voltage at transistor controller B+ connection less than 17V (when main or is closed.) Low voltage can also cause problems such as electrical components not powering up / staying activated and CAN errors.

Performance Limits

Truck functions are allowed unless the voltage was below 13V, in which case the truck must be restarted (Code C28) may be displayed.)

How to Clear Code

Code is cleared when voltage recovers.


1. 2. 3. 4. 5.

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Low battery voltage. a. Check for proper voltage; charge battery if necessary. Battery parameter not adjusted correctly. Circuit breaker has opened due to overloading or short circuit. a. Check brake adjustment (see page 111.) Open circuit to transistor controller B+ connection. a. Check cabling. Bad transistor controller.


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Code C42 - Battery Overvoltage Warning Reason

Voltage at transistor controller B+ connection over 30V.

Performance Limits

Truck functions are allowed unless the voltage was above 34V, in which case the truck must be restarted (error 142, see page 186, may be displayed.)

How to Clear Code

Code is cleared when voltage recovers.


1.

High battery voltage. a. Check for proper voltage; charge battery may be overcharged. Extreme regenerative motor braking. Battery charger plugged into truck.

2. 3.

Code C43 - Transistor Controller Thermal Cutback Reason

High or low temperature (such as above 185 degrees F [85 degrees C] or below -13 degrees [25 degrees C] at transistor controller heat sink.

Performance Limits

Truck functions may be allowed.

How to Clear Code

Code is cleared when transistor controller heat sink temperature recovers (see item 7 on page 191.)


1. 2.

3. 4.

Operating in extreme environment. Excessive load on truck. a. Check brake adjustment (see page 111.) b. Reduce value of parameters 2, 3 and/or 4 to help decrease motor temperature. Improper transistor controller mounting. Bad transistor controller.

Code C44 - (“Hot” is displayed) - Traction (Drive) Motor Thermal Cutback Reason

High traction motor temperature detected.

Performance Limits

Truck functions are allowed, but maximum speed value sent to transistor controller is reduced.

How to Clear Code

Code is cleared when temperature recovers.


1. 2.

3. 4. 5.

Operating in extreme environment. Excessive load on truck. a. Check brake adjustment (see page 111.) b. Reduce value of parameters 2, 3 and/or 4 to help decrease motor temperature. Air flow to motor restricted. Problem with motor wiring. Bad traction motor.

Code C46 - Severe Traction Motor Thermal Cutback Reason

Very high traction motor temperature or extreme operation detected.

Performance Limits

Same as error code 44.

Corrective Action





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NOTE!

Fault codes 100 and over are logged. The log can contain multiple faults with the same number code. Throttle is not allowed, outputs are off (brake is mechanically applied), and main or is dropped. Code is cleared when problem is resolved and truck is turned OFF and back ON (unless otherwise noted.)

Code E101 - Transistor Controller Does Not Correspond with the Type of Truck Reason

Transistor controller is not compatible with ETAC software.


1.

Incorrect transistor controller installed in truck.

Code E104 - Brake Power Error Reason

Transistor controller could not detect presence of brake coil.


1. 2. 3. 4. 5.

Open circuit in brake circuit. a. Check brake or brake coil wiring for a short or open wire. Master control relay missing or stuck open. Main or open circuit (especially after it has closed.) Bad transistor controller. Open in wire 57 or 26.

Code E106 - Digital Output or Field Overcurrent Reason

Transistor controller attempted to deliver more current than allowed to main or coil; traction motor field winding, or digital output.


1.

Short circuit in transistor controller output circuit. a. Check main or coil, traction motor field winding, digital output and associated wiring. b. Replace transistor controller.

Code E107 - or Off Reason

or probably present but transistor controller could not close it successfully.


1.

2. 3.

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Problem with main or tips. a. If or clicks prior to getting this code, try polishing or tips with a clean pencil eraser. If this does not work or there is permanent or damage, replace or. Low voltage. a. Try closing or with a known-good battery. Short in or coil. a. Replace or.


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Code E108 - or Welded or Missing Reason

Main or tips welded or missing.


1. 2. 3. 4. 5.

Main or tips welded. Open or short circuit in or circuit. a. Check or, wiring (coil) and cabling. Bad transistor controller. Low voltage. a. Try closing or with a known-good battery. Blown drive fuse.

Code E110 - Braking System Fault Reason

Transistor controller detected problem with braking functions.


1. 2.

Short circuit in brake circuit. a. Check brake and wiring. Bad transistor controller.

Code E112 - Arm Angle Sequence Fault Reason

Improper sequence of arm angle inputs.


1. 2. 3.

Arm angle input stuck on or off. Problem with arm angle input wiring. Problem with arm. a. Check for proper sequence of arm angle switches (see step 2 above.)

Code E114 - Traction (Drive) Motor Speed Fault Reason

Transistor controller detected stalled traction motor.


1. 2. 3.

Traction motor stalled. Excessive traction motor load at low speed. a. Check brake adjustment (see page 111.) Bad transistor controller.

Code E140 - Checksum Error Reason

Electronic Tiller Arm Card (ETAC) software detected that checksum was invalid.


1. 2.

Bad software. a. If applicable, try ing new software. Bad ETAC.

Code E141 - Software Problem Reason

ETAC found problem with software.


1.


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2.

Bad software. a. If applicable, try ing new software. Bad ETAC.


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Code E142 - Transistor Controller Disable Error Reason

Transistor controller detected a major fault.


1. 2.

3.

4.

Severe overvoltage (especially at main or close.) a. Check for proper voltage. High current at digital input. a. Check transistor controller outputs and wiring. b. Replace transistor controller. Open circuit in traction motor field circuit. a. Check transistor motor field wiring and field windings in motor. b. Replace transistor controller. Shorted brake coil.

Code E150 - Drive Communication Error Reason

ETAC did not receive CAN data from transistor controller.


1. 2.

3. 4.

Short or open circuit in CAN wiring. Electrical noise in CAN wiring due to bad connection, outside interference or low voltage. a. Check CAN wiring. b. Try driving using a known-good battery. c. Try driving in a different environment. Bad transistor controller. Bad ETAC.

Code E151 - Drive Communication Tx Error Reason

ETAC could not send CAN data to transistor controller.


1. 2.

3.

Short or open circuit in CAN wiring. Electrical noise in CAN wiring due to bad connection, outside interference or low voltage (especially while lifting or driving) possibly due to overcurrent or short circuit. a. Check CAN wiring. b. Try driving using a known-good battery. c. Try driving in a different environment. Bad ETAC.

Code E157 - CAN-bus Off Error Reason

ETAC detected problem with CAN-bus.


1. 2.

3. 4.


Code E159 - Over Run Error Reason

ETAC detected problem with the CAN-bus.


1. 2.

3. 4.

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Code E160 - Error In Reversing Circuit Reason

ETAC detected problem with the throttle position sensors, including the sensor used to initiate reversing. Also see code 20 on page 181.


1.

Bad ETAC.

Code E161 - Lower Valve Error Reason

Transistor controller could not detect presence of lower valve coil.


1. 2. 3. 4. 5.

Lower valve missing. Open or short circuit in lower valve or wiring. Master control relay missing or stuck open. Master control relay wired wrong. Main or open circuit (especially after it has closed.) Bad transistor controller.

Code E200 - Field Open Reason

Transistor controller detected open field.


1.

Open circuit in traction motor field circuit. a. Check traction motor field wiring and field windings in motor. b. Replace transistor controller.

Code E201 - M-Error Reason

Transistor controller detected an armature circuit fault.


1. 2.

Incorrect traction motor cabling. Bad transistor controller.

Code E202 - Transistor Controller Sensor Error Reason

Transistor controller reported an armature current sensor fault.


1. 2. 3.

Abnormal truck operation. Low battery voltage or undersized battery. Bad transistor controller.

Code E214 - Transistor Controller CAN Timeout Reason

Transistor controller did not receive CAN data from ETAC or transistor controller self-test failed.


1. 2.

3. 4.


NOTE!


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Only the first error of each type is processed (errors of the same type that happen after the first error are ignored.)


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3.7. Troubleshooting Chart Index 3.7.1. Travel (Forward / Rearward) System 1. No travel in either direction, lift/lower okay (Code E106, Digital output or field overcurrent.) 2. No travel in either direction, lift/lower okay (Code E201 M-error.) 3. No travel in either direction, lift/lower okay (Code E214, transistor controller CAN timeout.) 4. Slow travel, lift/lower okay. No fault codes. 5. No travel (Code C42, Battery overvoltage warning.) 6. Slow or no travel (Code C41, Battery undervoltage warning.) 7. Slow or no travel (Code C43, Transistor controller thermal cutback.) 8. Truck does not accelerate correctly. 3.7.2. Wiring System 1. Truck Functions Partially, some functions do work when commanded. 3.7.3. Other Possible Troubleshooting Issues 1. Green and red LEDs on keypad do not light when a button on the keypad is pushed (keypad option only.) 2. No fast travel mode. 3. No travel. 4. Horn does not sound when horn button is pushed.

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3.8. Troubleshooting Charts The following troubleshooting charts describe a course of testing and repair for each problem listed. If the given test is NOT successful, perform the repair listed with the test. If the given test IS successful, go to the next test or follow the special instructions given. For electrical legend see page 196. Travel (Forward / Rearward) System 1. No travel in either direction, lift/lower okay (Code E106, Digital output or field overcurrent.) Possible Cause

Remedy

Bad wiring between transistor controller and main or

With main ON/OFF switch OFF and battery disconnected, check wiring between transistor controller and main or (K10.)

Bad transistor controller

With main ON/OFF switch OFF and battery connector disconnected, measure resistance between J5-16 and J5-4. If resistance is approximately 50 ohms, check wires for shorts to frame, B+, B-, or other conductors. If none found replace transistor controller.

Bad main or coil

Disconnect and measure resistance of main or (K10) coil. If resistance is not approximately 50 ohms, replace coil.

2. No travel in either direction, lift/lower okay (Code E201 M-error.) Possible Cause

Remedy

Bad wiring between transistor controller and motor

With main ON/OFF switch OFF and battery disconnected, disconnect wires F1 and F2 from the transistor controller. Check wiring between motor and transistor controller.


With main ON/OFF switch OFF and battery connector disconnected, disconnect drive motor cable at transistor controller terminal M-. Connect battery connector, turn key switch ON. If Code 1,3 (see page 246) is still displayed, replace transistor controller. If Code 1,3 is not displayed, disconnect battery, remove wires F1 and F2 at transistor controller and measure resistance in wiring harness between wires F1 and F2. If less than 1.0 ohm, replace transistor controller.

Bad motor

With main ON/OFF switch OFF and battery disconnected, remove wires F1 and F2 at motor. If greater than 2.0 ohm, replace motor.

3. No travel in either direction, lift/lower okay (Code E214, transistor controller CAN timeout.) Possible Cause Bad transistor controller


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Remedy Replace transistor controller.


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4. Slow travel, lift/lower okay. No fault codes. Possible Cause

Remedy

Battery problems

Replace battery with fully-charged good battery.

Transistor controller programming changed Binding motor

drive

wheel

or

ETAC

assembly/drive

programming. If changed, reset programming. Jack and block truck (see page 58.) Disable brake (see page 111.) Check that drive wheel spins freely. If not, repair or replace (see page 117.)

Binding brake disk

Check air gap adjustment (see page 111.)

Bad drive motor (may test ok with no load, but fall under load) or worn brushes

Repair or replace motor brushes (see page 91.)

5. No travel (Code C42, see page 183), Battery overvoltage warning.) Possible Cause

Remedy

Battery problem

the correct, fully-charged good battery is installed in truck.

battery charger is not plugged into truck

Disconnect the battery charger immediately.


correct battery is installed. Replace transistor controller.

6. Slow or no travel (Code C41, see page 182), Battery undervoltage warning.) Possible Cause

Remedy

Battery problems Bad battery terminals disconnect plug

a correct, fully-charged good battery (24V) is installed in truck. or

quick

Repair or replace battery terminals.


battery voltage at key switch input. Turn main ON/OFF switch OFF and disconnect battery connector. Check for continuity and wiring shorts between B- battery to transistor controller B- and key switch circuit wiring and fuses. Repair or replace. Measure voltage at transistor controller B+. If 24V, replace transistor controller.

Bad wiring or connector

Jack and block truck. With main ON/OFF switch OFF and battery connected, while attempting travel, measure voltage between A2, transistor controller B+, B-, and F1, F2, M1, and M3. If not 24V, repair or replace wiring.

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7. Slow or no travel (Code C43 (see page 183), Transistor controller thermal cutback.) Possible Cause

Remedy

Battery problems

a correct, fully-charged good battery (24V) is installed in truck.

Binding load wheel(s)

Make sure load wheels rotate freely, If not repair or replace (see page 122.)

Bad drive wheel assembly

Jack and block truck (see page 58.) Turn main ON/OFF switch ON. Pull steering control handle down to release brake. Check drive wheel to see if it spins freely. If not, repair or replace (see page 117.)

Binding brake disk

Jack and block truck (see page 58.) Turn main ON/OFF switch ON. Pull steering control handle down to release brake. Check brake disk to see if it spins freely. If not, adjust, repair or replace (see page 111 or page 112.)

Binding drive motor

Jack and block truck (see page 58.) Turn main ON/OFF switch ON. Pull steering control handle down to release brake. Check the brake disk to see if it spins freely. Turn main ON/OFF switch OFF. Remove brake disk and check armature shaft. Remove motor and repair or replace drive unit or drive motor (see page 97.)

Worn brushes Bad drive motor (may test ok with no load, but fail under load)

Inspect brushes (see page 90.) Repair or replace drive motor (see page 97.)

Truck overloaded extreme conditions

Operate and load truck within specifications (see page 51.)

or

operating

in


Check mounting of transistor controller. Check to make sure transistor controller is secure and in with truck frame (acts as a heatsink.) If transistor controller is mounted correctly, replace transistor controller.

Bad wire or connector

Jack and block truck (see page 58.) With main ON/OFF switch ON and battery connected, while attempting travel, measure voltage between B- and transistor controller B+, B- and J5-16. If not 24V, repair or replace wiring.

8. Truck does not accelerate correctly. Possible Cause

Remedy

Battery problems Transistor controller programming not correct

a correct, fully-charged good battery (24V) is installed in truck. or

ETAC

programming.

Bad motor brushes or motor

With main ON/OFF switch OFF and battery connector disconnect, check drive motor brushes (see page 90) and motor (see page 97.)


If all possible causes check out, replace transistor controller.

Wiring System 1. Truck functions partially, some functions do work when commanded. Possible Cause

Remedy

Bad wiring in steering control handle

With main ON/OFF switch OFF and battery connector disconnect, visually inspect wiring in the handle where the wiring leaves the handle and over the brake. Repair or replace.

Bad wiring in hydraulic control area

With main ON/OFF switch OFF and battery connector disconnect, visually inspect wiring. Repair or replace.


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Other Possible Troubleshooting Issues 1. Green and red LEDs on keypad do not light when a button on the keypad is pushed (keypad option only.) Possible Cause

Remedy

Open circuit of wires that power ETAC

Check control wires, especially wires 1, 20, and 22 (red in steering control arm cable) and 40 (black in steering control arm cable.)

Bad connectors

Repair and replace bad connectors (check connector J11 at steering control arm base, connector into ETAC and connector J5 to transistor controller.)

F50 Open

Ensure control fuse has not tripped.

Keyswitch jumper not connected

Connect keyswitch jumper.

2. No fast travel mode. Possible Cause Arm angle switch “A” always off

Remedy Check for proper operation of arm angle switch “A” and correct if necessary. Check wiring, transistor controller and switch adjustment.

3. No travel. Possible Cause Arm angle switch failure

Remedy Check arm angle switch adjustment (see page 220), wiring and transistor controller.

4. Horn does not sound when horn button is pushed. Possible Cause

Remedy

Bad horn switch/wiring in handle head

Repair/replace as necessary (see page 226.)


Check and replace if necessary.

Bad horn

Replace horn.

5. No lift. Possible Cause

Remedy

Lift cut out engaged. Battery dead or did not reach reset voltage at 25.2 volts

Recharge battery or replace battery.

Lift limit switch bad or “burnt open” or disconnected.

Adjust lift limit switch (see page 221) or replace lift limit switch (see page 225.)

Lift switch not functioning.

Replace lift switch (see page 225.)

Failed ETAC.

Replace ETAC (see page 251.)

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Main Harness

3 2 1 4 7

5 8

6

or Assembly

9 I

0

O

or Power Cable

Circuit Breaker

Lift Limit Switch

Steering Control Handle Harness

Hydraulic System

Relay

10 Amp Fuse


Power Cables

Power Cables


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194

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Sh. = Sheet or page of Diagram First number = Previous page was found. Second number = Second page wire is found.

Ledger

Electrical Schematic 1(2)


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HORN SWITCH S18-1

DISPLAY A6

Sh. = Sheet or page of Diagram First number = Previous page was found. Second number = Next page wire is found.

Ledger

E.T.A.C. A2

TRUCKS WITH KEYPAD

KEYPAD A17

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Electrical Schematic 2(2)

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Electrical Legend Symbol A1 A2 A2-S1 to A2-S9 A2-S10 to A2-S18 A2-S17 A2-S19 A2-S20 A6 A17 B+ BCB1 F50 F51 H1 J11 J41 K4 K10 K30 M1 M3 S17 S18-1 S18-2 S21 S24 S25 S36 Y1 Y10

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Description Transistor controller Transistor controller Speed Ref Value Speed Ref Value Reverser Lift Lower Transistor controller Transistor controller Battery Battery Circuit breaker Fuse Fuse Horn Wire Connection Wire Connection or Relay or Solenoid Motor Motor Switch Switch Switch Switch Switch Switch Switch Coil Coil

Function Drive motor Electronic Tiller Arm Card Electronic Tiller Arm Card Electronic Tiller Arm Card Electronic Tiller Arm Card Electronic Tiller Arm Card Electronic Tiller Arm Card Operator Display Keypad Positive Negative Drive / Pump motor circuit Keypad and tiller arm circuit Main control

Remark E.T.A.C.

24 volt 24 volt 110 amp 10 amp 10 amp

Handle stem base Service key (CAN) Main Main Pump motor Drive Pump Key Horn Horn Main ON/OFF Arm angle (A) Arm angle (B) Lift limit Brake Lower valve


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Electrical Graphics Graphic


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Graphic

Description

Battery

Brake (coil)

or

Diode

Main On/Off Switch

Fuse

-

+

A1

Description

M

A2

Horn

Inductive sensor (normally closed)

Inductive sensor (normally open)

Key switch

Magnet switch (normally closed)

Magnet switch (normally open)

Motor

Potentiometer


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Electrical Graphics Graphic

Description

Graphic

Push button switch (normally closed)

Description Push button switch (normally open)

P

P

Resistor

Switch

Switch (normally closed)

Switch (normally open)

Valve

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5110 Battery

Battery 1. Theory of Operation Check the truck’s data plate for the weight of the battery required for the truck. your local battery supplier for the purchase of a proper voltage battery. A 24 volt battery may not be supplied with the truck.

2. Maintenance Information in this section does not supercede or replace information available by the battery and battery charger supplier. Read, understand, and follow the procedures available by the battery and battery charger supplier. Notify your supervisor if there are any concerns or questions regarding the battery or procedures.

2.1. Inspection and Care WARNING Battery electrolyte is a solution of sulfuric acid and water. Battery acid causes burns. Should any electrolyte come in with clothing or skin, flush the area immediately with cold water. Should the solution get on your face or in the eyes, flush the area with cold water and receive medical attention immediately. CAUTION Before working on the battery, review Battery Safety beginning on page 20. Batteries may weigh more than 200 pounds (91 kg). Use extreme care during replacement. Use a suitable replacement device or hoist for lifting. NOTE!

Read, understand, and follow procedures, recommendations and specifications available by the battery and battery charger supplier.

Batteries in industrial trucks pick up various kinds of dirt and dust depending on their surroundings and the types of


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material handled. If cells are overfilled and electrolyte collects on the covers, the following occurs: 1. The top of the battery becomes wet and stays wet, since the acid in the electrolyte does not evaporate. 2. This moist surface, in combination with certain kinds of dirt, becomes electrically conductive and permits stray currents to flow externally over the top of the battery. This degrades battery performance and truck operation. 3. The acid also causes corrosion of cell posts, nuts, connectors and the steel battery case. When inspecting batteries, check the following: 1. Wet covers can indicate overfilling, leaky seals at posts, or excessive gassing during charge. If covers are wet, determine the cause and correct the problem. 2. Make sure batteries cannot move more than 0.5 inch (13 mm) in any horizontal direction. Shim or block the batteries to restrain them.

2.2. Exterior Cleaning Refer to recommended battery supplier’s guidelines for details.

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

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5110 Battery

Read, understand, and follow procedures, recommendations and specifications available by the battery and battery charger supplier.

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

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


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

3. Troubleshooting Many electrical problems are caused by a bad or dirty battery. Make sure the battery is clean. Check the electrolyte level and battery level. Look for simple causes of problems. A trained, qualified, and authorized technician should perform testing and troubleshooting on batteries.

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4. Repair and Rebuild your local battery supplier for replacements or rebuilds. Removal 1. Park truck on a level surface and make sure parking brake is applied and load wheels are blocked to prevent accidental movement. 2. Press red OFF button “O” on the keypad. Depress main ON/OFF switch to the OFF position. 3. Disconnect the battery connector from the truck. 4. Position battery replacement device in accordance with the supplier’s recommendations. 5. If applicable, remove bolts securing the battery to the truck. Remove battery from truck onto suitable battery table or with battery lifting device. Installation 1. With a fully charged and tested battery on the battery handling device, position the handling device at truck in accordance with the supplier’s recommendations. 2. Move the battery into the compartment. Be sure the battery has no more than 0.50 inch (13 mm) of “free play” movement in the battery compartment. If applicable, secure battery bolts to the truck. 3. Move handling device from the area. 4. Connect the battery connector to the truck. 5. Remove blocks. Turn the main ON/OFF switch to the ON position. Enter key code and press the green ON button “I” on the keypad. 6. Test truck for proper operation before returning to service.


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Swing Out Battery Pack 1. Theory of Operation The truck may be equipped with a multiple battery pack, or a maintenance-free battery and charger.

2. Maintenance WARNING Battery electrolyte is a solution of sulfuric acid and water. Battery acid causes burns. Should any electrolyte come in with clothing or skin, flush the area immediately with cold water. Should the solution get on your face or in the eyes, flush the area with cold water and receive medical attention immediately. CAUTION Before working on the battery, review Battery Safety beginning on page 20. Batteries may weigh more than 200 pounds (91 kg). Use extreme care during replacement. Use a suitable replacement device or hoist for lifting.

2.1. Electrical Testing 2.1.1. Required Equipment 1. Common hand tools. 2. AC/DC volt/ohm meter. 3. Battery connector with + to - loop (use on charger only.) 4. Battery hydrometer. 2.1.2. Instructions 1. Check condition of batteries (check each cell.) a. Specific gravity, before and after charging. Acceptable values: Dead battery - 1.180 Fully charged battery - 1.280 © BT Prime-Mover, Inc.

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Any cell that is different by more then 20 points indicates a suspect battery. b. Volts per cell, open circuit, before and after charging. Acceptable values: Dead battery - 1.9 v/cell Fully charged - 2.2 v/cell c. Charging rate DC amps, at start and finish of charge cycle. Acceptable values

Start

Finish at 2.5 VPC

24 volt system

15 amps

0.5 amps or less

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

Start

Finish

24 volt system

25.6 volts

30.0 volts

2. Visually inspect disconnected.

charger

with

all

power

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

coils

for

obvious

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

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

3. Testing the DC output circuit.

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

a. Open circuit voltage test. With batteries disconnected and the charger turned on, the DC output voltage should be 1-1/2 times the rated DC voltage. System voltage 24 volts b. Short circuit amperage test. With charger output battery connector short circuited (positive to negative jumper connector plugged into charger output connector), and the charger turned on, the DC output amps should be 80 percent of the normal DC amps. System voltage 24 volts

Short circuit output voltage approximate 12 amps

(1) With charger in the OFF position, connect AC power cord to appropriate AC power supply, connect with the + to - loop to the charger. (2) Turn battery charger on and note the amp gauge reading. It should be as stated on the chart above. Leave charger on for five minutes while watching the amp gauge. The amp gauge should remain steady. This verifies the condition of the circuit breaker and any loose connections. (3) Turn charger off before disconnecting the jumper connector. 4. Testing components


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

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On a good capacitor, the needle will deflect to the right (low resistance) and then deflect back to the left (high resistance) each time the meter leads are reversed. On a shorted capacitor, the needle will deflect to the right (low resistance) and remain there. On an open capacitor, the needle will not deflect (stationary display.) (4) Connect the capacitor leads in the charger. (5) Set AC voltmeter on a scale to read at least 500 volts AC. Connect the meter leads to the capacitor terminals. A shorted capacitor will indicate 0 volts AC. An open capacitor will indicate about 300 volts +/-20 volts AC. This is the same as the capacitor transformer winding voltage without a capacitor connected in circuit. (6) Turn on charger power. WARNING Before checking components, disconnect AC power supply, unplug batteries and discharge capacitor with insulated screwdriver. All tests should be made with the charger disconnected unless otherwise stated. Use extreme caution when a test calls for the power to be “on” at the charger. 5. Overcharging problems Most complaints about charging problems can be remedied by following the previous procedures. Overcharging problems may not be the fault of the charger. Often, overcharging is caused by bad batteries or poor connections. The following items should be checked to resolve problems of overcharging or failure of charging amps to taper down. a. Charger and battery not properly matched. Check specifications on both batteries and charger. Battery pack (GNB) has been designed for a specific size and type of battery. If another battery has been installed, be certain © BT Prime-Mover, Inc.

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that it is comparable to the original batteries. Automotive type batteries will not function properly in this application. b. Excessive battery temperatures suppressed battery voltage.

causing

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

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

4. Repair and Rebuild your local battery supplier for replacements or rebuilds.

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1

19

4 3

2

5

8

6

7 8

18 15 12 11

16

20

17

10

9

13

14

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


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Item No. 1 2 3 4 5 6 7 8 9 10

212

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Description Battery pack complete Decal Charger, battery Decal, warning Screw Cable assembly Cover Screw Decal, warning Tray, left


Item No. 11 12 13 14 15 16 17 18 19 20

Description Screw Grommet Screw , battery Nut, clip Screw Nut, clip Tray, right Decal Tray, cord

2006-08-08

F-code

Section

PT

C-code


Version no

T-code

002

SMX

Battery Cable Routing Diagram 2

4

3 11

1

5

11

9

2

1 6

1

7

2

2

2 11 10

8

11 1

11

11 1

2

9

9

2 11 1

1

2 11

9

Battery Specifications Exide type GC-3 6 volt 75-91 AMPS

Item No. 1 2 3 4 5 6 7 8 9 10 11

Description Boot Nut Tie, cable Cable Cable Battery connector Cable Cable Battery Cable Washer, flat

Trojan type T-90 or T1900


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2006-08-08

213

F-code

Section

C-code


T-code

002

SMX

Battery Pack (GNB Pallet Pro™ Start/Stop Charger) 17 1

5

15

14

6

11 4 16

3

13

9

8

10 12 7 3 2

214

Return

Item No.

Description

Item No.

Description

1 2 3 4 5 6 7 8 9

Pallet pro™ battery pack, 24 Volt Charger assembly Battery, 6 Volt Grommet Decal, Champion Decal, DANGER Cable assembly Bolt, 6x20 Lockwasher

10 11 12 13 14 15 16 17

Washer, flat Decal, serial number Bracket Tray Cable, SB175 plug Battery connector Cable, AC power Screw, securing


2006-08-08

F-code

PT

Section

C-code

S5.3 5190 Battery Connector

Version no

T-code

000

SMX

Battery Connector 1. Theory of Operation Battery Connector

The truck battery connector is located at the top of the truck cover. The battery and charger have similar battery connectors. It is necessary to connect the battery to the truck before powering ON.

2. Maintenance Visually inspect cables and connectors. Negative and positive cables should be visually inspected for breaks and wear. Check connectors for damage and to ensure proper connections of cables.

2.1. Inspection 1. Press red OFF button “O” on the keypad. Depress main ON/OFF switch to the OFF position. 2. Disconnect the battery connector from the truck. 3. Check the battery connectors for damaged cables. 4. Check to see if cables are pulling out of the connectors. 5. Check cables at battery terminals. Connections should be tight, with no corrosion. 6. Check inside connectors at internal s for damage, dirt, or corrosion. DO NOT use a metal object to clean connectors. 7. Connector housings must not be cracked or broken.

3. Troubleshooting Make sure cable wires are in good condition and connector has proper connections to cables.


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2004-03-08

215

F-code

Section

PT S5.3 Battery Connector Version no

T-code

000

SMX

C-code

5190

4. Repair and Rebuild To Battery

2

1

3

Item No.

4

9 5

1 2 3 4 5 6 7 8 9

Description Puller Cable, negative Cable, positive Nut Connector, SB-175 Cable, positive Cable, negative Screw, cap Screw, cap

8 5

7 6

216

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F-code

PT

Section

C-code

S5.3 5190 Battery Connector

Version no

T-code

000

SMX

Do not attempt to repair or rebuild the battery connector or power cables. Replace damaged parts with new. Removal, Repair, and Installation The cables to the battery connectors have a lip on the forward end. This lip snaps over a spring-loaded retainer which is part of the connector. To remove a cable from the connector, push retainer down while pushing cable towards the rear and out of the connector.


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2004-03-08

217

F-code

Section

PT S5.3 Battery Connector Version no

T-code

000

SMX

C-code

5190


218

Return


2004-03-08

F-code

Section

PT

S5.4

Version no

T-code

001

SMX

C-code

5310 Switches

Switches 1. Theory of Operation The main ON/OFF switch (S21) is provided on the truck. In the OFF position, battery power to all control functions is interrupted. In the ON position, battery potential is provided to all control functions via the transistor controller. The arm angle switches are located at the base of the steering control handle stem. The arm angles switches (S24) and (S25) determine brake activation and truck travel speed. Each switch is activated by the steering control handle position. The steering control handle must be positioned beyond 6 degrees of the upper rest position and above 8 degrees from the bottom in order for switches to close, permitting travel. When steering control handle is within 6 degrees of the upper rest position, parking brake is activated. When steering control handle is between 6 to 41 degrees of the upper rest position, arm angle B switch (S25) closes and enables slow speed operation. When steering control handle is placed beyond 41 degrees from the upper rest position, arm angle A switch (S24) also closes enabling fast speed operation. When the steering control handle is placed in the bottom 8 degrees of the operating range, arm angle switch B (S25) opens, activating the parking brake. Position

A Switch (S24)

B Switch (S25)

Function

Top 6°

Open

Open

Top Brake

6° to 41°

Open

Closed

Slow

41° plus

Closed

Closed

Fast

Bottom 8°

Closed

Open

Bottom Brake

When forks are fully raised, lift-limit switch (S36) turns the hydraulic pump motor off. This keeps the pump from trying to extend the lift cylinder beyond its maximum travel. A twoposition (ON/OFF) optional key switch (S17) is located on the main console, which energizes all truck control functions when in the ON position, provided the main ON/OFF switch is in the ON position.


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219

F-code

Section

C-code

PT Switches

S5.4

5310

Version no

T-code

001

SMX

2. Maintenance General Examine switch for signs of arcing, overheating, discoloration, cracking, or other physical damage. Replace switch if such damage is noticed. Use an ohmmeter set to a low resistance scale to measure resistance across the switch. In a closed position, the switch should be less than 1 ohm. In an open position, the switch should show a resistance greater than 10 megohms. With the battery connected, use a voltmeter to check for voltage on both the positive and negative side of the switch while in the closed position. The voltage must be the same on both sides of the switch. If not, the switch is worn or bad.

Main ON/OFF Switch Inspection

Main ON/OFF Switch

To inspect switch proceed as follows: 1. With the battery plugged in and main ON/OFF switch (S21) in the ON position, battery voltage B+ must be present on the two terminals of the switch. 2. Test main ON/OFF switch with an ohmmeter after disconnecting the battery and removing the wires from the switch terminals. 3. In the OFF position, the ohmmeter must read greater than 1 megohm. In the ON position, the ohmmeter must read less than 1 ohm. If not, replace switch.

Arm Angle Switches

Adjustment of Arm Angle Switches To adjust switches, proceed as follows: 1. Press red OFF button “O” on the keypad. Depress main ON/OFF switch to the OFF position. 2. Disconnect the battery connector from the truck. 3. Jack truck and block the frame (see page 58.) 4. Remove truck cover(s) [see page 84.] Screws

220

Return

5. Loosen screws holding the switch on the bracket. Slide the switch out as far as possible and retighten screws.


2006-08-08

NOTE!

F-code

Section

PT

S5.4

Version no

T-code

001

SMX

C-code

5310 Switches

Make sure the cam arm makes solid with switch lever. Switch S25 must operate within 6 degrees of the upper rest position or in the bottom 8 degrees of the operating range. Make sure switch does not bottom out when fully compressed.

6. Slide switch back in until the switch “clicks”. Move the switch out (approximately 0.031 inch (0.7 mm) until it “clicks” again. Retighten screws. Steering Control Handle Cover Installed

7. Install steering control handle cover. 8. Remove blocks. Connect the battery connector to the truck. 9. Turn main ON/OFF switch to the ON position. Enter key code and press the green ON button “I” on the keypad. 10. Test truck for proper operation before returning to service.

Lift Limit Switch Adjustment Raise the forks until they reach their fully raised position. If the lift-limit switch does not shut the pump down when the lift cylinder reaches it upper limit, the relief valve on the hydraulic pump will make a high-pitched squeal, indicating that the relief valve is opening. To adjust lift limit switch, proceed as follows:

Lift Limit Switches

1. Press red OFF button “O” on the keypad. Depress main ON/OFF switch to the OFF position. 2. Disconnect the battery connector from the truck. 3. Disconnect the wires on the switch. 4. Loosen bolt and slide switch bracket up or down to activate (cut power off) when the lift is 0.5 to 1.0 inch (12.7 to 25.4 mm) before its fully raised position. Tighten bolt. 5. Connect the wires to the switch. 6. Connect the battery connector to the truck.


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2006-08-08

221

F-code

Section

C-code

PT Switches

S5.4

5310

Version no

T-code

001

SMX

7. Turn main ON/OFF switch to the ON position. Enter key code and press the green ON button “I” on the keypad. 8. Test truck for proper operation before returning to service.

Key Switch (Optional) Inspection To inspect optional key switch, proceed as follows: 1. Remove truck cover(s) [see page 84.] 2. With the battery plugged in and the key switch ON, battery voltage B+ must be present on the two terminals of the switch. 3. Turn key switch to OFF. Depress main ON/OFF switch to the OFF position. 4. Disconnect the battery connector from the truck. 5. Remove wires from switch terminals. 6. Test key switch for continuity with an ohmmeter. In the OFF position, the ohmmeter must read greater than 1 ohm. If not, replace switch.

3. Troubleshooting To troubleshoot the main ON/OFF switch see page 148, arm angle switches see page 150 and/or page 152 and for the lift limit switch see page 259.

222

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F-code

Section

PT

S5.4

Version no

T-code

001

SMX

C-code

5310 Switches

4. Repair and Rebuild

2

1

3 4

15 14 9 5 10

10

6

5

7 7

8

11 12 13

Item No.

Description

Item No.

1

Switch, main ON / OFF

6

Nut

11

Screw

2

Switch, key (option)

7

Switch, arm angle

12

Switch, lift limit

3

Screw

8

Bracket

13

Nut

4

Bracket

9

Screw

14

Switch, horn

5

Screw

10

Lockwasher

15

Button, horn


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Description

2006-08-08

Item No.

Description

223

F-code

Section

C-code

PT Switches

S5.4

5310

Version no

T-code

001

SMX

The switches can not be repaired or rebuilt. Replace a bad switch with new as necessary.

4.1. Main ON/OFF Switch Removal 1. Press red OFF button “O” on the keypad. Depress main ON/OFF switch to the OFF position. 2. Disconnect the battery connector from the truck. 3. Remove truck cover(s) [see page 84.] 4. Disconnect the wires from the switch. 5. Remove main ON/OFF switch.

Installation 1. Install new main ON/OFF switch and connect the wires to the switch terminal. 2. Connect the battery connector to the truck. 3. Turn the main ON/OFF switch to the ON position. Enter key code and press the green ON button “I” on the keypad. 4. Test truck for proper operation before returning to service. 5. Install truck cover(s).

4.2. Arm Angle Switches Removal 1. Lower the forks completely. 2. Press red OFF button “O” on the keypad. Depress main ON/OFF switch to the OFF position. 3. Disconnect the battery connector from the truck. 4. Remove truck cover(s) [see page 84.] 5. Disconnect the wires on the switch. 6. Remove the screws holding the switch on the mounting bracket. Remove switch.

224

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F-code

Section

PT

S5.4

Version no

T-code

001

SMX

C-code

5310 Switches

Installation 1. Mount the switch to the mounting bracket. 2. Connect the wires to the switch. 3. Connect the battery connector to the truck. 4. Turn main ON/OFF switch to the ON position. Enter key code and press the green ON button “I” on the keypad. Test drive the truck. 5. Adjust switch if necessary (see page 220.) 6. Press red OFF button “O” on the keypad. Depress main ON/OFF switch to the OFF position. 7. Install truck cover(s).

4.3. Lift Limit Switch Removal 1. Press red OFF button “O” on the keypad. Depress main ON/OFF switch to the OFF position. 2. Disconnect the battery connector from the truck. 3. Disconnect the wires on the switch. 4. Remove truck cover(s) [see page 84.] 5. Remove lift limit switch.

Installation 1. Connect the wires to the terminal. 2. Install new lift limit switch. 3. Connect the battery connector to the truck. 4. Turn main ON/OFF switch to the ON position. Enter key code and press the green ON button “I” on the keypad. 5. Test truck for proper operation before returning to service. 6. Install truck cover(s).


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225

F-code

Section

C-code

PT Switches

S5.4

5310

Version no

T-code

001

SMX

4.4. Key Switch (Optional) Removal 1. Press red OFF button “O” on the keypad. Turn key switch OFF. 2. Disconnect the battery connector from the truck. 3. Remove truck cover(s) [see page 84.] 4. Remove wires from switch terminals. 5. Remove key switch.

Installation 1. Install new key switch. 2. Connect the wires to the terminal. 3. Connect the battery connector to the truck. 4. Turn main ON/OFF switch to the ON position. Turn key switch ON. 5. Test truck for proper operation before returning to service. 6. Install truck cover(s).

4.5. Horn Switch Removal 1. Press red OFF button “O” on the keypad. Depress main ON/OFF switch to the OFF position. 2. Disconnect the battery connector from the truck. 3. Remove truck cover(s) [see page 84.] 4. Disconnect the wires on the switch. 5. Remove horn switch.

Installation 1. Connect the wires to the terminal. 2. Install new horn switch. 3. Connect the battery connector to the truck.

226

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F-code

Section

PT

S5.4

Version no

T-code

001

SMX

C-code

5310 Switches

4. Turn main ON/OFF switch to the ON position. Enter key code and press the green ON button “I” on the keypad. 5. Test truck for proper operation before returning to service. 6. Install truck cover(s).

4.6. Converting Keypad to Key Switch Removal 1. Lift forks to maximum height. 2. Remove truck cover(s) [see page 84.] 3. Using the service key (see page 174), change parameter 39 to 1 or 2 (see page 174.) 4. Press red OFF button “O” on the keypad. Depress main ON/OFF switch to the OFF position.

Main ON/OFF Switch

5. Disconnect the battery connector from the truck. 6. Disconnect the wires from the main ON/OFF switch. Remove main ON/OFF switch. 7. Remove main ON/OFF switch mounting bracket (see page 223.)

Installation 1. Install new main ON/OFF switch and key switch mounting bracket. Keypad Cover

2. Install original main ON/OFF switch into new mounting bracket. Connect the wires that were removed earlier to the main ON/OFF switch. 3. Install key switch in mounting bracket. 4. Remove jumper wire between wire 20 and 22 (see page 194.) Connect the wires 20 and 22 to new key switch.

Keypad

5. Remove screw from keypad. Remove keypad. 6. Install new keypad cover. 7. Remove service key. 8. Connect the battery connector to the truck.


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227

F-code

Section

C-code

PT Switches

S5.4

5310

Version no

T-code

001

SMX

9. Turn main ON/OFF switch to the ON position. Turn key switch ON. 10. Test truck for proper operation before returning to service. 11. Install truck cover(s).

228

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2006-08-08

F-code

Section

PT

C-code

S5.5 5390 Fuses/Circuit Breakers

Version no

T-code

001

SMX

Fuses/Circuit Breakers

Fuse F50

Fuse F51

1. Theory of Operation The keypad and electronic tiller arm card (ETAC) circuit FU50 fuse is 10 Amps. The main ON/OFF switch circuit fuse FU51 is 10 Amps. The fuses are located on the or . •

10A, Fuse Keypad and ETAC, part number 2527512 (supplied with main harness)

•

10A, Fuse Main ON/OFF, part number 25275-12 (supplied with main harness)

•

110A, Power Circuit Breaker, part number 301890003

2. Maintenance Examine the fuse for signs of overheating, discoloration, cracking, or other physical damage. Check for blown fuse through the fuse window. If fuse is damaged replace it. To test a fuse, remove or isolate it from the electrical circuit. Do this by removing the fuse from the truck or by removing all the connections from one side of the fuse. Use an ohmmeter set to Rx1 scale and measure the resistance across the fuse. The resistance should be less than 1 ohm.

BT Prime-Mover

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229

F-code

Section

C-code

PT S5.5 5390 Fuses/Circuit Breakers Version no

T-code

001

SMX

2.1. Wiring Harness

When working on the truck, use care around the wiring harnesses. •

Do not pull on wires.

•

Carefully mate and unmate all connectors.

•

Do not pry apart connectors with unspecified tools.

•

Examine and maintain any added materials used to dress or protect wire. This includes spiral wrap, brackets, cable ties, fasteners, flexible conduit, etc.

•

Check harness wires for abrasions, scrapes, nicks in wire, damage from overheating or burns, or other general insulation damage.

•

Replace terminations with exposed wire visible at connectors. Damaged terminations, exposed wires, or damaged connectors can cause operational failure of truck.

There should be a wire marker at each termination. If marker is missing or unreadable, remark wire to allow easier identification. NOTE!

230

Return

It is normal to find unused connectors for uninstalled options that have had heat shrink applied over them and have been strapped to harness.


2006-08-08

F-code

PT

Section

C-code


Version no

T-code

001

SMX

2.2. Power Cables

Power cables should be checked for damage including:

BT Prime-Mover

Return

•

Evidence of overheating

•

Burned spots in cable

•

Nicks in insulation

•

Damaged or overheated terminal lugs

•

Damaged mounting hardware or brackets


2006-08-08

231

F-code

Section

C-code


T-code

001

SMX

2.3. Circuit Breaker

Circuit Breaker CB1

Under extreme operating conditions, the current demand on the battery may exceed the rating for the main circuit breaker (CB1) and force it open. This causes the truck to become inoperable until the circuit breaker automatically resets itself. To test a circuit breaker, remove the circuit breaker from the truck or isolate it from the electrical circuit by removing all the connections from one side. Let it cool (or reset itself.) Use an ohmmeter set to Rx1 scale and measure the resistance across the circuit breaker. The resistance must be less than 1 ohm.

232

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F-code

PT

Section

C-code


Version no

T-code

001

SMX

2.4. Master Control Relay

Wire #24

Wire #26

The master control relay should be tested regularly for proper operation. To inspect/test master control relay proceed as follows: 1. Remove truck cover(s) [see page 84.] 2. With the battery connector connected, press the green ON (I) key on the keypad. 3. Use a voltmeter to check the voltage between wire #26 (terminal 2) and wire #24 (terminal 4.) The voltmeter should read approximately 24V. 4. Move steering control handle down into the operate position. The voltmeter should now read 0V. If not, replace master control relay.

BT Prime-Mover

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F-code

Section

C-code


T-code

001

SMX

3. Troubleshooting During troubleshooting and repairs, it is sometimes necessary to unmate a connector, move a harness, cut a cable tie, or remove wire from a bracket. Note carefully the location of wire and all protective or securing attachments before moving harness. When replacing fuses, make sure fuses are installed in the proper position.

4. Repair and Rebuild Repair or replace damaged cables or mounting hardware as necessary. Power cables are marked on terminal lug with location where they belong. If marking is missing or is not readable, remark cable with correct information. The terminal lugs should be crimped tightly and securely on the wire. Replace cable if necessary. After repair, return or replace all protective and/or securing hardware to its original condition. Protective materials are necessary to provide reliable performance of interconnect system. The fuses can not be repaired or rebuilt. Replace fuses with new as necessary.

234

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2006-08-08

F-code

Section

PT

S5.6 5436 or

Version no

T-code

000

SMX

C-code

or 1. Theory of Operation The main or (K10) controls the transmission of battery power to the drive motor.

2. Maintenance Visually inspect the ors for any signs of burning or physical damage.

3. Troubleshooting 3.1. Resistance Testing 1. Press red OFF button “O” on the keypad. Depress main ON/OFF switch to the OFF position. 2. Remove truck cover(s) [see page 84.] 3. Disconnect the wires from the coil or. 4. Connect one coil lead of ohmmeter to the coil lead from or. Connect the other lead to the lead from the or. 5. The reading should be between 20 and 40 ohms. If resistance is outside that range, replace or.


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2004-03-10

235

F-code

Section

C-code

PT S5.6 or

5436

Version no

T-code

000

SMX


4 1 3 2

17 16

6

18

7

15

8

14

10 9 11 12 13

236

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2004-03-10

Item No.

Description

F-code

Section

PT

S5.6 5436 or

Version no

T-code

000

SMX

Item No.

C-code

Description

1

Drive controller

10

Screw

2

Screw

11

Control cable / harness

3

or

12

Horn

4

13

Screw

5

Battery connector

14

Relay

6

Nut

15

Screw

7

Decal, breaker

16

Breaker, circuit

8

Decal, fuse

17

Bar, bus

9

Lockwasher

18

Screw

Replace main or if coil resistance is outside a range between 20 and 40 ohms.

Removal 1. Press red OFF button “O” on the keypad. Depress main ON/OFF switch to the OFF position. Disconnect the battery connector from the truck. 2. Remove truck cover(s) [see page 84.] X and Y Terminals

Bus Bar

Figure 5-6: Main or

3. Disconnect the wires from the X and Y terminals on the or (3) coils.


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2004-03-10

237

F-code

Section

C-code

PT S5.6 or

5436

Version no

T-code

000

SMX

4. Remove screws (15) securing the bus bar (17) and cables to the or (3), noting the location for assembly later. 5. Remove screws (2) holding the or (3) assembly to the electrical (4).

Installation 1. Secure or (3) to the electrical (4) with screws (2). 2. Secure bus bar (17) and cable to the or (3) with screws (15). 3. Connect the wires to the X and Y terminals. 4. Connect the battery connector to the truck. 5. Turn main ON/OFF switch to the ON position. Enter key code and press the green ON button “I” on the keypad. 6. Test truck for proper operation before returning to service. 7. Install truck cover(s).

238

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2004-03-10

F-code

PT

Section

C-code

S5.7 5460 Transistor Controller

Version no

T-code

001

SMX

Transistor Controller 1. Theory of Operation WARNING Interchanging the transistor controller with another truck model could cause internal failure to the transistor controller. The warranty will be void if the transistor controller is interchanged from one truck to another! The transistor controller is programmed specifically for this truck. It is microprocessor based and programmable designed for separately excited motors. The transistor controller provides smooth control of the traction (drive) motor utilizing four distinct operating modes. An LED is built into the transistor controller that communicates controller status.

1.1. Basics Of Circuit Operation The transistor controller provides both armature and field outputs. Through these outputs, it regulates the voltage and current applied to the motor according to it’s programmed motor control algorithm. This programmable motor control algorithm allows the to optimize truck performance based on their application. The polarity and magnitude of the field is controlled to provide solid state, or-less direction control and plug braking. As the transistor controller is powered up, it performs an internal self test. •

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

•

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

Selecting either tractor-first or forks-first travel selects the direction of current flow in the field. The voltage and current in the armature circuit raises when the throttle increases. The field current will then follow a predetermined current map to match the armature current. In this manner, the motor is kept © BT Prime-Mover, Inc.

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2006-12-12

239

F-code

Section

PT S5.7 Transistor Controller Version no

T-code

001

SMX

C-code

5460

in its optimal commutation range and arcing on the commutator is minimized. As the throttle is increased and the motor speeds up, the armature voltage will approach the battery. Top speed is limited by confining the minimum allowable field current. Plug braking involves reversing the travel control to the opposite direction causing the truck to decelerate smoothly. The operator may choose to continue holding the travel controls in the opposite direction. This will start the truck moving in that direction or the operator may release the handle and allow the truck to come to a complete halt. The parking brake is automatically applied when released. When using plug braking the operator may regulate, within the programmed capabilities, the degree of the plugging force and distance travelled during plugging. For the lightest plugging force, and the longest distance, the travel control should be operated in the opposite direction. For the strongest plugging power, and the shortest distance, the travel control should be operated to full speed in the opposite direction. Plug braking may be regulated with the steering control handle at any point between full speed.

1.2. Interface The direction control section controls the drive motor direction by manipulating the drive motor field polarity according to the directional signal inputs from the Electronic Tiller Arm Card (ETAC). The thumb control section controls the drive motor speed and torque by monitoring the position change of the arm angle A and arm angle B switches. Variable motor speed is accomplished by separate control of field and armature currents. The reverser circuitry in the ETAC provides the directional travel control commands to the transistor controller. The control circuit section controls all truck inputs and outputs (excluding steering control handle head inputs.) The ETAC controls. The transistor controller is the slave.

240

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F-code

Section

PT

C-code


Version no

T-code

001

SMX

1.3. Control Features • Reversing without the use of direction ors permitted with full bridge control of motor field. • Controlled and limited truck speed at top end through separate field and armature control. • Fully protected inputs and outputs. • Active power on self test and continuous diagnostics during operation. • Internal watchdog circuits ensure proper software operation.

1.4. Motor Circuit

Control wire plug 16-pins M-

B-

B+

F1 F2


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2006-12-12

241

F-code

Section


T-code

001

SMX

C-code

5460

The transistor controller has three terminals for the high current circuits B-, M-, and B+. Two quick connect terminals are provided for the field winding connections F1 and F2. Terminal BB+

MF1 F2

Connecting Negative connection to battery Overcurrent protected and K10 switched positive connection to the battery and motor armature Motor armature Motor field Motor field

1.5. Control Circuit The transistor controller has an integrated 16-pin connector to provide the low power logic control connections. The designation of the pins are according to the following table.

242

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F-code

PT

Section

C-code


Version no

T-code

001

SMX

Pin number 1 is located in the back row right side when viewing the logic connector. Pin No P1 P2 P3 P4 P5 P6 P7 P8 P9 P10 P11 P12 P13 P14 P15 P16

Connecting CAN High IN/OUT Lower Valve Not Used Out Main or IN/OUT Brake OUT Pump or OUT Horn CAN Low Not Used Not Used Not Used IN Arm Angle A Not Used IN Arm Angle B IN Lift Limit IN +24 VDC

1.6. Definitions Overtemperature. Overtemperature of the transistor controller is from 185 degrees F (85 degrees C) and above. Overheating is unusual, but can occur if the transistor controller is installed incorrectly or overloaded. At overtemperature the drive current limit is linearly decreased from full set current down to zero. Plug current is not reduced by any thermal conditions to allow full plugging strength at all times. Undertemperature. When the transistor controller is operating at less than −13 degrees F (−25 degrees C), the current limit is cut back resulting in reduced travel speed and acceleration. Pulse Width Modulation. Pulse Width Modulation (PWM), also called “chopping,” controls the speed of the motor by switching the battery voltage to the motor on and off very quickly. © BT Prime-Mover, Inc.

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243

F-code

Section


T-code

001

SMX

C-code

5460

Thermal Cutback. Thermal cutback of the transistor controller is below -13 degrees F (-25 degrees C) or above 185 to 203 degrees F (85 to 95 degrees C), the PWM drive current limit is linearly decreased from full set current down to zero. At -13 to -40 degrees F (-25 to -40 degrees C), the current limit is reduced to approximately half the set current, resulting in reduced travel speed. Below -40 degrees F (-40 degrees C) or above 203 degrees F (95 degrees C), the allowed PWM is zero percent.

2. Maintenance There are no serviceable parts inside the transistor controller. No attempt should be made to open the transistor controller. OPENING THE TRANSISTOR CONTROLLER WILL VOID THE WARRANTY!

2.1. Safety WARNING Because there is a risk of short circuits, remove all watches and jewelry; always use insulated tools. The transistor controller is essentially a high-power device. When working around any battery powered vehicle, proper safety precautions should be taken. These include, but are not limited to the following: proper training, wearing eye protection, avoiding loose clothing, removing watches and jewelry, and using insulated tools.

2.2. Cleaning It is recommended that the transistor controller exterior be cleaned periodically with an approved and regulated air supply (blower.) Although the transistor controller virtually requires no maintenance if properly installed, the following is recommended on a regular basis of 250 hours for cold storage and 1500 hours for standard environment. 1. Remove power by disconnecting the battery at the battery connector. 2. Discharge capacitors in the transistor controller by connecting a load (such as a or coil or horn) across the transistor controller’s B+ and B-

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Section

C-code


Version no

T-code

001

SMX

terminals before doing any work on the transistor controller. 3. Remove dirt or corrosion from the bus bar area. The transistor controller should be wiped clean with a moist rag. Allow to dry before reconnecting the battery. 4. Make sure the connections to the bus bars are tight. Use two well insulated wrenches for this task in order to avoid stressing the bus bars.

3. Troubleshooting 3.1. Diagnostics and Troubleshooting The transistor controller provides diagnostic information to assist technicians in troubleshooting drive system problems. The information can also be obtained by looking at the status LED built in the transistor controller that is visible through the window label.

3.2. Fault Codes

Transistor Controller

J5 Connector

Figure 5-7: Transistor Controller

An internal microcontroller automatically checks the function of the transistor controller. When this microcontroller detects a fault, it signals the appropriate fault code through the diagnostic LED on the bottom of the transistor controller. These are not the codes that appear on the display. Under normal operation, the LED flashes a single flash at approximately one flash per second. A two-digit flash code © BT Prime-Mover, Inc.

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C-code

5460

signals the transistor controller has detected a fault within itself. The following table list some transistor controller codes that are okay (normal.) Error Code

Program LCD Display

OFF

N/A

ON

N/A

0,1

No known faults

1, 1

Current shunt

1, 2

Hardware failsafe

1, 3

M- shorted

1, 4 2, 1

SRO Throttle Fault 1 EMR REV Wiring HPD Throttle Fault 2

2, 2 2, 3 2, 4

3, 1

246

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CONT COIL/ FLD Short

Probable Cause

Explanation

Open circuit at transistor controller Transistor controller does not have +24VDC logic input due to wire, fuse or voltage at +24VDC logic power supply bad transistor controller. input. Transistor controller is not functioning Bad transistor controller. properly. N/A Normal “hearbeat”, everything is okay. See truck error code 202 (see page 187.) If ETAC does not display this code, there may be a problem with CAN See truck error code 202 (see page 187.) communication, transistor controller or ETAC. • If ETAC is not keyed on; the controller is reporting it is not receiving CAN messages from ETAC, which is normal. • If ETAC is keyed on and ETAC is displaying an error code; see truck error code (see page 181) for possible Transistor controller is reporting that it is causes. not receiving CAN messages from the • If ETAC is keyed on and ETAC is not ETAC or its self-test failed. displaying any error code, there may be a problem with CAN communications, transistor controller or ETAC. This code may take a few seconds to clear after ETAC key-on. See truck error code 201 (see page 187.) If ETAC does not display this code, there may be a problem with CAN See truck error code 201 (see page 187.) communication, the transistor controller or ETAC. Bad transistor controller or ETAC. Bad transistor controller or ETAC. Transistor controller is not setup or Bad transistor controller or ETAC. functioning properly. Bad transistor controller or ETAC. Bad transistor controller or ETAC. See truck error code 106 (see page 184.) If ETAC does not display this code, there may be a problem with low battery See truck error code 106 (see page 184.) voltage, CAN communication, transistor controller or ETAC.


2006-12-12

F-code

PT

Error Code

Program LCD Display

3, 2

Main CONT Welded

3, 3

3, 4

4, 1

4, 2

4, 3

4,4

Section

Version no

T-code

001

SMX

Probable Cause

C-code


Explanation

Bad transistor controller or ETAC.

Transistor controller is not setup or functioning properly.

See truck error code 200 (see page 187.) If ETAC does not display this code, there may be a problem with CAN See truck error code 200 (see page 187.) Field Open communication, transistor controller or ETAC. Missing Transistor controller is not setup or Bad transistor controller or ETAC. or functioning properly. See truck error code 41 (see page 182.) If ETAC does not display this code after a Low battery few seconds, there may be a problem with See truck error code 41 (see page 182.) voltage CAN communication, transistor controller or ETAC. See truck error code 42 (see page 183.) If ETAC does not display this code after a few seconds, there may be a problem with See truck error code 42 (see page 183.) Overvoltage CAN communication, transistor controller or ETAC. See truck error code 43 (see page 183.) If ETAC does not display this code after a Thermal cutback few seconds, there may be a problem with See truck error code 43 (see page 183.) CAN communication, transistor controller or ETAC. Transistor controller is not setup or Anti-Tiedown Bad transistor controller or ETAC. functioning properly.

4. Repair and Rebuild There are no serviceable parts inside the transistor controller. No attempt should be made to open the transistor controller. OPENING THE TRANSISTOR CONTROLLER WILL VOID THE WARRANTY! Replace transistor controller with new as necessary.


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247

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T-code

001

SMX

C-code

5460


248

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Section

C-code

PT S5.8 5700 Electronic Tiller Arm Card (ETAC) Version no

T-code

000

SMX

Electronic Tiller Arm Card (ETAC) 1. Theory of Operation The programmable motor control functions are performed by the ETAC housed within the steering control handle. The ETAC controls. The transistor controller is the slave. The basic function of the ETAC include the following:


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•

Monitor relative positioning of the thumb controls to 18 Hall effect sensors for speed and direction control.

•

Monitor position of reverser button for reversing of the truck direction.

•

Monitor truck performance and provide input data and commands to the service display.

•

Provide lift/lower input commands to the transistor controller.

•

Monitor horn switches S18-1 and S18-2 for horn operation.

•

Monitor and define truck performance parameters.

•

Fully compatible for programming, diagnostic and test information.

•

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

•

Automatic neutral braking: adjustable plugging force.

•

Truck acceleration and response controlled through programmable parameters.

•

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

•

Interlock features ensure proper start-up sequence.

•

Integral fault LED provides a “transistor controller operating properly” signal and flashes error code information when a fault occurs.


2004-03-10

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T-code

000

SMX


3. Troubleshooting See “Error Codes (E)” on page 180.

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Section

C-code


T-code

000

SMX

4. Repair and Rebuild A bad ETAC must be replaced with a new card.

Reverser Button

Push Button

Electronic Horn Button Tiller Arm Right Card (ETAC)

Lift/Lower Button

Display Horn Button Left

Housing

Horn Button/ Switch

Speed Control

Steering Control Handle


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Keypad

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251

F-code

Section

C-code


T-code

000

SMX

Removal 1. Press red OFF button “O” on the keypad. Depress main ON/OFF switch to the OFF position. 2. Disconnect the battery connector from the truck. 3. Remove screw from keypad. Unplug and remove keypad. 4. While holding the top cover firmly, remove screws securing the top cover assembly to the handle. 5. Disconnect the ETAC cable. CAUTION To avoid risk of static discharge that can damage the electronics, make sure to take the necessary precautions before working with electronics (see page 25.) NOTE!

Place fingers between the housing and reverser button to hold the thumb control in place.

6. Remove screws securing housing to gain access to the ETAC board. Carefully lift off the housing.

Installation CAUTION Do not use excessive force when prying on the button or damage could result to the locking tabs. 1. Install new ETAC board with screws. 2. Connect the cable to ETAC. 3. Install keypad and secure with screw. Connect the keypad plug. 4. Connect the battery connector to the truck. 5. Turn the main ON/OFF switch to the ON position. Enter key code and press the green ON button “I” on the keypad. 6. Test truck for proper operation before returning to service.

252

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F-code

Section

PT

S6.0 6000 Hydraulic System

Version no

T-code

001

SMX

C-code

Hydraulic System 1. Theory of Operation The hydraulic system consists of a compact hydraulic unit, including a electric solenoid valve, pressure relief valve and a cylinder for lifting the forks. The hydraulic solenoid activates the hydraulic lowering valve that releases pressure on the lift cylinder to lowing the forks. The hydraulic system is protected by a relief valve installed in the adapter body.

Lift Cylinder

Component Enclosure Hydraulic Lines ing Motor (Electric) Hydraulic Pump

Solenoid Valve

Filter Check Valve

Reservoir (Vented)

1.3 GPM

Cylinder (Single Acting) Cylinder (Double Acting)

3000 PSI

Check Valve Hydraulic Lines Crossing

Orifice

M3

1.25 CC

Filter Reservoir


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253

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Section

PT S6.0 Hydraulic System Version no

T-code

001

SMX

C-code

6000

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


1.3 GPM

3000 PSI

M3

254

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1.25 CC

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PT


Version no

T-code

001

SMX

C-code

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

Pressure Oil Return Oil B+ Circuit B- Circuit

1.3 GPM

Signal Pre-Charge Voltage

3000 PSI

M3


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1.25 CC

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255

F-code

Section


T-code

001

SMX

C-code

6000

1.3. Relief Pressure The relief valve is set by the manufacturer to open at a specified pressure of 3000 psi (20684 kPa).


1.3 GPM

3000 PSI

M3

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1.25 CC

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Section

PT


Version no

T-code

001

SMX

C-code

2. Maintenance To prolong the life of the truck, keep all fittings and connections tight to prevent leaks. To avoid damage or distortion, do not over-tighten brass fittings. Before removing any component from the hydraulic system, wash the component and surrounding area with cleaning solution to prevent foreign matter from entering the system. Cap and plug all openings immediately. Whenever removing fitting with a pipe thread, use a sealing compound on the outside of threads before reinstalling. (Do not use Teflon® tape.) Make sure all parts are clean. When installing a hose assembly, make sure that it is not twisted when fittings are tightened. Always use two wrenches on a swivel-type fitting, one to hold the fitting and the other to tighten the hose.

2.1. Changing Hydraulic System Fluid Hydraulic fluid level must be checked periodically (see “Planned Maintenance Schedule” on page 61.) If the reservoir regularly requires additional oil to maintain proper level, a leak is indicated and must be repaired. When scheduled, the reservoir should be removed and drained for cleaning and replaced with new oil. After refilling, check lift, lower and other hydraulic functions for proper operation. If the truck will not lift a full load, the pressure relief setting should be checked and adjusted. During normal operation, pressure relief setting will not change. As the lift pump wears with age, some loss of performance will be experienced. When this loss becomes severe, the lift pump should be replaced. WARNING Fluid is under pressure and may spray or splash. Point hose away from you body and hold firmly in waste fluid container. NOTE!

Be sure truck is in a clean area, away from possible contaminating elements that could enter the hydraulic system during the changing process.

Contaminated hydraulic fluid is the major cause of hydraulic system failures. Keep any service equipment, such as containers, funnels, and hand pumps clean at all times by covering when not in use. © BT Prime-Mover, Inc.

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257

F-code

Section


T-code

001

SMX

C-code

6000

1. Lower forks. 2. Press red OFF button “O” on the keypad. Depress main ON/OFF switch to the OFF position. 3. Disconnect the battery connector from the truck. 4. Remove truck cover(s) [see page 84.] Lift Cylinder Hose

5. Disconnect lift cylinder hose at the hydraulic cylinder. NOTE!

Wear protection eye and face gear when draining oil.

6. Insert hose in a waste fluid container. 7. Connect the battery connector to the truck. 8. Turn the main ON/OFF switch to the ON position. Enter key code and press the green ON button “I” on the keypad. 9. Run hydraulic pump by pressing the lift button until all hydraulic fluid is pumped from the system. 10. Press red OFF button “O” on the keypad. Depress main ON/OFF switch to the OFF position. 11. Disconnect the battery connector from the truck. 12. Connect the lift cylinder hose. 13. Remove vent plug and fill reservoir to within 1 inch (25.4 mm) below the filler port elbow with recommended fluid (see page 72.) The usable reservoir capacity is 0.8 quart (0.75 liter). Replace vent plug. 14. Install truck cover(s). 15. Connect the battery connector to the truck. 16. Turn the main ON/OFF switch to the ON position. Enter key code and press the green ON button “I” on the keypad. 17. Raise and lower forks several times to purge air from the system. 18. Properly dispose of waste fluid.

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Section

PT


Version no

T-code

001

SMX

C-code

2.2. Hydraulic Pump Pressure Relief Valve The hydraulic system is protected by a relief valve installed in the adapter body. The relief valve is set by the manufacturer to open at specific pressure (3000 psi [20684 kPa]). There is no need to ever adjust the relief valve on this truck.

3. Troubleshooting NOTE!

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

If the hydraulic pump assembly does not operate properly, the following preliminary checks should be made: 1. Proper oil level 2. All electrical connections tight 3. Battery fully charged When checking voltage at ors, make sure hydraulic lines and components are fully installed. When possible, keep the main ON/OFF switch OFF and battery connector disconnected. After the preliminary check is accomplished, install a 0-5000 psi (0-34473 kPa) pressure gauge in the 0.375 inch (9.525 mm) NPTF outlet port near the relief valve in the adaptor. The installation of a pressure gauge is required to insure proper observation of what is occurring in the unit during trouble shooting. Start pump and raise lift cylinder to its upper limit stops to develop maximum pressure of the unit, which will normally be ing all flow over a relief valve. Pressure gauge should be reading the set pressure of the relief valve. Remove pressure on hydraulic system by actuating the solenoid operated lowering valve. Normal trouble that may occur with pump assembly have been grouped under three headings: Failure to (A) Raise (B) Hold (C) Lower load. One or more of the listed trouble


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Section


T-code

001

SMX

C-code

6000

sources may be causing improper operation. Refer to the proper heading (relief valve) for detailed instructions for disassembly and check parts to remedy the trouble. 1. If pump operates but will only develop low pressure or slow lift: a. Relief valve seat scored, foreign particles under ball. b. Dirt in hydraulic lowering valve. c.

Pump worn, replace pump.

2. If pump develops pressure but will not hold: a. Dirt in hydraulic lowering valve. b. Relief valve seat scored, foreign particles under ball. 3. If pump develops pressure but will not release load: a. No electrical to hydraulic lowering valve. b. Solenoid in hydraulic lowering valve coil burned out. c.

Relief valve bottomed causing pressure to go beyond the unloading limit of the hydraulic lowering valve.

3.1. Troubleshooting Chart Index 1. No lift, lift motor does not run, travel is okay. 2. No lift or slow lift, lift motor does run. 3. No lower, lift and travel okay. 4. Unable to pick up a load. 5. Slow lower. 6. Load drifting/settling.

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Section

PT


Version no

T-code

001

SMX

C-code

3.2. Troubleshooting Charts The following troubleshooting charts describe a course of testing and repair for each problem listed. If the given test is NOT successful, perform the repair listed with the test. If the given test IS successful, go to the next test or follow the special instructions given. For electrical legend see page 196. 1. No lift, lift motor does not run, travel is okay. Possible Cause

Remedy

Bad ETAC (A2)

With main ON/OFF switch in the ON position, the pin key code entered in the keypad, the green ON button “I” pressed on the keypad, and the lift switch depressed, does main or (K10) and pump or (K30) energize (click)? If not, check “Service Display” on page 169. If no signal is detected, check mechanical problems in the steering control head. Replace electronic tiller arm card ETAC (A2) as a last alternative in resolving problem.

Bad lift pump or

With main ON/OFF switch in the ON position, the pin key code entered in the keypad, the green ON button “I” pressed on the keypad, and the lift switch depressed, does main or (K10) and pump or (K30) energize (click)? If not, measure voltage between pump or coil terminals. If B+ voltage is present, replace the pump or.

Bad wiring continuity or wiring shorts

With main ON/OFF switch OFF and battery connector disconnected, check for continuity and wiring shorts in wiring harness or cables.

Bad lift-limit switch

With main ON/OFF switch OFF, battery connector disconnected, and forks lowered, check continuity through the lift-limit switch. Replace if necessary.

Bad lift pump motor brushes

With main ON/OFF switch in the ON position, the pin key code entered in the keypad, the green ON button “I” pressed on the keypad, and the lift switch depressed, does pump or (K30) energize (click)? If yes, measure voltage between B- and lift pump motor terminal. If okay, check lift motor brushes (see page 91.)

Bad lift pump motor

If lift motor brushes are okay, test pump motor.

Bad pump

If motor is okay, remove motor from the pump and rotate pump shaft by hand. Replace pump if not okay.

2. No lift or slow lift, lift motor does run. Possible Cause

Remedy

Battery problems

Replace battery with fully-charged battery.

Mechanical binding in lift mechanism

Repair lift mechanism.


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261

F-code

Section

C-code


T-code

001

SMX

6000

Possible Cause

Remedy

Low hydraulic pressure

Check hydraulic pressure setting and adjust if necessary (see page 259.)

Relief valve contaminated or bad. (Unable to get the correct hydraulic pressure)

When main ON/OFF switch OFF, and battery connector disconnected, remove pressure relief valve and check for damage or contamination. Replace valve or flush system and replace the hydraulic fluid (see page 257.)

Bad lift brushes

Check lift motor brushes (see page 91.) If brushes are okay, replace lift pump.

pump

motor

or

Contamination found in pump

Flush system and replace hydraulic fluid (see page 257.)

Bad pump

If motor is okay, remove motor from the pump and rotate pump shaft by hand. Replace pump if necessary.

3. No lower, lift and travel okay. Possible Cause

Remedy

Bad lower solenoid valve

With main ON/OFF switch in the ON position, cycle the lower switch. Does the lower solenoid valve energize (click)? If yes, disconnect the battery connector, then slowly loosen, but DO NOT REMOVE the hydraulic line at the hydraulic pump assembly. Have drain pan and rags ready and allow the forks to slowly lower.

If forks do not lower, check for mechanical binding in lift cylinder or fork mechanism

Replace lift cylinder or repair lift mechanism.

If forks lower, remove and inspect hydraulic lowering valve

Inspect for free movement and signs of contamination. Clean solenoid valve or flush system, clean filter and replace hydraulic fluid. If not contamination is found, repair or replace hydraulic lowering valve or pump assembly.

Check for bad ETAC (A2)

With main ON/OFF switch in the ON position, the pin key code entered in the keypad, the green ON button “I” pressed on the keypad, and the lower button depressed, check “Service Display” on page 169. If no signal is detected, check mechanical problems in the steering control handle head. Replace ETAC (A2) as a last alternative in resolving problem.

4. Unable to pick up load. Possible Cause

Remedy

Load too large for lift truck capacity

Check load weight. Check lift pressure setting.

Battery problems

Replace battery with fully-charged battery.

Incorrect lift pressure adjustment

Check and adjust lift pressure setting.

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Possible Cause

F-code

Section

PT


Version no

T-code

001

SMX

C-code

Remedy

Contaminated or bad pressure relief valve

Check for contamination in hydraulic fluid. If contamination is present, flush, fill and bleed the hydraulic system and clean relief valve. If no contamination is found, replace relief valve.

Bad lift pump

Replace lift pump (see page 270.)

Bad lift motor

Replace lift motor (see page 92.)

5. Slow Lower. Possible Cause

Remedy

Bad lift/lower solenoid valve or wiring

Repair or replace valve or wiring.

Plugged or malfunctioning flow hydraulic lowering valve

Check for contamination in hydraulic fluid. If contamination is present, flush, fill and bleed hydraulic system and clean valve. If no contamination is found, replace flow control valve.

Contamination solenoid valve

Inspect solenoid for contamination or binding.

in

Mechanical binding mechanism

lowering in

lift

Bad or mid adjusted lift-limit switch

Adjust or replace mechanism. Adjust lift limit switch (see page 221) or replace lift limit switch (see page 225.) Pump should not hit relief if lift limit switch is operating properly.

NOTE: If pump hits relief and lower is attempted, lowering will be slow. Release lower button momentarily, then continue to lower. Normal lower speed should resume.

6. Load Drifting/Settling. Possible Cause

Remedy

Incorrect lift pressure adjust

Check and adjust lift pressure setting (see page 259.)

Contamination or bad check valve

Check for contamination in hydraulic fluid. If contamination is present, flush, fill and bleed hydraulic system and clean check valve. If no contamination is found, replace check valve.

Leaking or contaminated hydraulic lowering valve

Check for contamination in hydraulic fluid. If contamination is present, flush, fill and bleed hydraulic system and clean hydraulic lowering valve. If no contamination is found, replace hydraulic lowering valve.

Load too large for lift truck capacity

Check load weight. Check lift pressure setting.


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2006-08-08

263

F-code

Section


T-code

001

SMX

C-code

6000

4. Repair and Rebuild The lift motor solenoid, hydraulic reservoir, lowering valve, adapter body and lift pump can be repaired or rebuilt. Replace items as necessary.

2

4

3

5

6

1

39 38

37

40 7

5 6

4

36 35 34 33 32

8 9 10

8

12

31 30

14 15 16 17

13

11

18 19

41

20 21 29

22 23 24 25

28

27

264

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26

2006-08-08

Item No.


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Description

F-code

Section

PT


Version no

T-code

001

SMX

Item No.

Description

1

Pump and motor assembly

22

Tube

2

Pump motor

23

Magnet

3

Solenoid

24

Strainer

4

Washer, flat

25

Clamp, hose

5

Lockwasher

26

Reservoir

6

Screw

27

Elbow, 90 degrees

7

Fitting, male tap 45 degrees

28

Breather

8

Plug

29

Tube

9

Plug

30

O Ring

10

Spool, flow control

31

O Ring

11

Hydraulic lowering valve assembly

32

Adapter

12

Valve, relief

33

Seat, relief

13

Coil, 24 Volt

34

Plunger

14

Spring

35

Spring

15

Coupler

36

O Ring

16

O Ring

37

Cap

17

Pump assembly

38

Gasket

18

Washer

39

Cable

19

Screw

40

Nut, adjustment

20

Seal, washer

41

Insert, tube

21

Fitting


2006-08-08

C-code

265

F-code

Section


T-code

001

SMX

C-code

6000

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

4.1. Hydraulic Unit Removal 1. Lower forks to the floor. 2. Press red OFF button “O” on the keypad. Depress main ON/OFF switch to the OFF position.

Pump Motor

3. Disconnect the battery connector from the truck.

Lift Motor Solenoid

4. Remove truck cover(s) [see page 84.] 5. Remove and tag all wires and cables connected to the pump motor (2). 6. Remove and cap hydraulic line from the hydraulic unit. Disconnect or control wires.

Lowering Valve Adapter Body (Pump)

Fill/Vent Plug

7. Remove bolts attaching hydraulic unit mounting bracket to truck. 8. Remove hydraulic unit from truck.

Hydraulic Reservoir

266

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2006-08-08

F-code

Section

PT


Version no

T-code

001

SMX

C-code

Installation 1. Install hydraulic unit on the truck and bolt bracket. 2. Install hydraulic line on hydraulic unit. 3. Fill reservoir with specified fluid (see page 72.) Use a funnel with a flexible neck. Fill reservoir to within 1 inch (25.4 mm) below filler plug elbow. Use up to 0.8 quart (0.75 liter). 4. Install vent plug. 5. Connect the wires and cables to the pump motor. 6. Connect the battery connector to the truck. Turn the main ON/OFF switch to the ON position. Enter key code and press the green ON button “I” on the keypad. 7. Raise and lower forks. Check hoses and fittings for leaks. 8. Check hydraulic fluid level in the reservoir (see page 257.) 9. Install truck cover(s).

4.2. Hydraulic Solenoid Removal 1. Lower forks to the floor. 2. Press red OFF button “O” on the keypad. Depress main ON/OFF switch to the OFF position. 3. Disconnect the battery connector from the truck. 4. Remove truck cover(s) [see page 84.] 5. Remove wires from terminals on the solenoid (3). 6. Remove nut holding solenoid coil (13) to the hydraulic lowering valve (11). 7. Lift solenoid coil (13) off the relief valve (12) stem. 8. Remove relief valve (12) from the adapter (32) body.


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2006-08-08

267

F-code

Section


T-code

001

SMX

C-code

6000

Inspection 1. Inspect seat where hydraulic lowering valve stem seals against the adapter body. The sealing surface must be completely clean and free from any nicks or damage. Installation 1. Thread adapter body into the adapter (32) and torque to 204 - 240 in-lbs (23 - 27 N•m). 2. Install solenoid coil (13) and torque nut to 48 to 60 in-lbs (5 to 7 N•m). 3. Connect the wires to the terminals. 4. Install truck cover(s). 5. Connect the battery connector to the truck. 6. Turn the main ON/OFF switch to the ON position. Enter key code and press the green ON button “I” on the keypad.

4.3. Reservoir Removal 1. Remove hydraulic unit from truck (see page 266.) 2. Remove hose clamp securing hydraulic reservoir to the adapter (32) housing. 3. Tap reservoir (26) lightly to loosen. Wiggle reservoir sideways while pulling up on the pump and motor at the same time to remove. 4. Remove reservoir (26) and properly dispose of old hydraulic fluid. 5. After fluid has drained, flush the inside of the reservoir with a suitable cleaning solution. 6. Dry the inside of the reservoir with clean, dry compressed air. Inspection 1. Inspect the reservoir O ring and inside leading edge for defects. Replace if necessary. 268

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2006-08-08

F-code

Section

PT


Version no

T-code

001

SMX

C-code

Installation 1. Lubricate O ring with hydraulic fluid. Install O ring. 2. Carefully install reservoir on adapter (32) housing and attach with hose clamp. Torque clamp to 48 60 in-lbs (5.5 - 7 N•m). 3. Install hydraulic unit on truck (see page 267.)

4.4. Filter Screen and Inlet Tube Removal 1. Remove reservoir (see page 268.) 2. With pump assembly inverted, unthread and remove inlet tube fitting and sealing washer from pump housing.

Filter Screen

3. Clean filter screen at the bottom of the inlet tube with a suitable cleaning solution. Inlet Tube

Inspection 1. Inspect filter screen and inlet tube for defects. Replace if necessary. Installation 1. Install inlet tube sealing washer and fitting in the pump housing. Torque to 245 - 275 in-lbs (27 - 31 N•m). 2. Install hydraulic reservoir to gain access to the pump. 3. Install hydraulic unit on truck (see page 267.)


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2006-08-08

269

F-code

Section


T-code

001

SMX

C-code

6000

4.5. Lift Pump Removal 1. Remove hydraulic unit from truck (see page 266) and put on a clean bench for disassembly. 2. Remove reservoir to gain access to pump (see page 268.) 3. Remove inlet tube with filter screen from pump housing (see page 269.) 4. Remove pump mounting bolts. Remove pump from adapter (32) body. Installation 1. Stand motor assembly on end, with adapter (32) body facing up. 2. Lubricate O ring and install on adapter (32) body facing up. 3. Insert pump drive coupling on the end of the motor armature shaft and fill the cavity with lubricant. 4. Align splines on the motor drive and pump shaft. Gently push pump pilot on the adapter (32). 5. Secure pump with mounting bolts and torque to 40 to 45 in-lbs (4.5 to 5 N•m). 6. Install hydraulic reservoir (see page 269.) 7. Install hydraulic unit on truck (see page 267.)

270

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2006-08-08

F-code

Section

PT

S6.1

Version no

T-code

000

SMX

C-code

6420 Lift Cylinder

Lift Cylinder 1. Theory of Operation The lift cylinders are the positive displacement type, meaning there are NO seals on the inner end of the cylinder rod.

2. Maintenance Inspect cylinder for leakage. Inspect cylinder rod for gouges or pits. Fluid leakage indicates that the seal is worn. Replace seal, wiper and lock ring when fluid leakage becomes excessive.



NOTE!


1. Press red OFF button “O” on the keypad. Depress main ON/OFF switch to the OFF position. 2. Inspect cylinder rod (2) for nicks, scratches, or scoring. If heavy scoring is found replace cylinder rod (2). 3. Inspect hydraulic hose and replace if worn.

3. Troubleshooting Check cylinder for leakage.


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2006-12-12

271

F-code

Section

C-code

PT S6.1 Lift Cylinder

6420

Version no

T-code

000

SMX

4. Repair and Rebuild 1 6 5 4

3 2

Item No.

Description

Item No.

1 2 3

Cylinder assembly Rod, cylinder Ring, retaining

4 5 6

Description Wiper, rod Seal, rod Tube

If the cylinder contains gouges or pits it can not be repaired. The rod wiper, rod seal, and retainer ring are replaced as new in the seal kit available for this cylinder. DANGER HOT OIL under pressure may be present. Be certain truck is safely blocked and pressure is released. Some spillage of hydraulic oil may occur. WARNING When using compressed air, wear effective chip-guarding and personal protective equipment. Compressed air used for cleaning MUST be reduced to less than 30 psi (207 kPa).

272

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2006-12-12

NOTE!

F-code

Section

PT

S6.1

Version no

T-code

000

SMX

C-code

6420 Lift Cylinder


Removal 1. Raise and block lift frame. Release pressure in cylinder by activating lowering valve.

Lift Frame

2. Press red OFF button “O” on the keypad. Depress main ON/OFF switch to the OFF position. 3. Disconnect the battery connector from the truck. 4. Remove truck cover(s) [see page 84.] 5. Thoroughly clean outside of cylinder before removing hydraulic hose. Lift Cylinder

6. Remove hydraulic line and pivot cylinder out of pocket. 7. Remove cylinder and place on a clean bench for disassembly. 8. Clean exterior of lift cylinder. 9. Push cylinder rod (2) in until the end of rod and retaining ring (3) can be seen through inlet port. 10. Insert screwdriver in inlet port and slide retaining ring (3) in deep groove in cylinder rod (2). 11. Remove cylinder rod (2) from cylinder tube (6). 12. Remove wiper (4) and seal (5) from the inside diameter of cylinder tube (6).

Inspection 1. Clean and dry all parts thoroughly. Remove all nicks and burrs with an emery cloth. 2. Inspect inside surface of cylinder tube (6) for excessive wear or scoring. 3. Inspect outside surface of cylinder rod (2) for nicks, scratches or scoring.


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2006-12-12

273

F-code

Section

C-code


6420

Version no

T-code

000

SMX

Assembly 1. Using seal tool, install new seal (5) on the inside diameter of cylinder tube (6). Install new wiper (4) with lips facing inward to bottom on cylinder tube (6).

Seal Tool

NOTE!

Refer to the Parts Book for the correct tool part number based on seal size.

2. Install new retaining ring (3) in deep groove of cylinder rod end. 3. Oil outside of cylinder rod (2) and carefully insert in tube assembly (6). 4. Push cylinder rod (2) in cylinder tube (6) until retaining ring (3) areas of cylinder rod can be seen through port. 5. Using a screwdriver through port, move retaining ring (3) to lock position. 6. Extend cylinder rod (2) to the fully out position to make sure retaining ring (3) is locked in place.

Installation 1. In order to prevent air from filling the cylinder assembly, it is recommended that the cylinder rod (2) is fully retracted. 2. Install upper mount first and hold in place with shoulder bolt. 3. Connect the hydraulic hose and use the pump to extend the cylinder. 4. Place bottom of cylinder in line with lower pocket. 5. Raise and unblock lifting frame of unit. 6. Install truck cover(s) [see page 84.] 7. Connect the battery connector to the truck.

274

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2006-12-12

NOTE!

F-code

Section

PT

S6.1

Version no

T-code

000

SMX

C-code

6420 Lift Cylinder

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

8. Turn the main ON/OFF switch to the ON position. Enter key code and press the green ON button “I” on the keypad. 9. Test operation of cylinder and look for leakage around fitting and cylinder rod.


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2006-12-12

275

F-code

Section

C-code


6420

Version no

T-code

000

SMX


276

Return


2006-12-12

Index Index

A Application Intended Truck Application Prohibited Truck . . . . . . .

. . . . . . . . . . . .33 . . . . . . . . . . . .34

B Battery . . . . . . . . . . . . . . . . . . . . . . . . . .199

Interface . . . . . . . Legend . . . . . . . . Normal Operation . Service Display . . Service Parameters Special Modes . . . Truck Fault Codes Wiring . . . . . . . .

. . . . . . . . . . . . . . . . 240 . . . . . . . . . . . . . . . . 196 . . . . . . . . . . . . . . . . 145 . . . . . . . . . . . . . . . . 169 . . . . . . . . . . . . . . . 175 . . . . . . . . . . . . . . . . 168 . . . . . . . . . . . . . . . . 181 . . . . . . . . . . . . . . . . 156

Electrical Functions

. . . . . . . . . . . . . . . . . . . . .111 . . . . . . . . . . . . . . . . . . . . .111 Brake Disk . . . . . . . . . . . . . . . . . . . . . . .112

. . . . . 147 . . . . . 146 . . . . . 154 . . . . . 155 . . . . . 148 . . . . . 153 . . . . . 150 Electrical Schematic . . . . . . . . . . . . . . . . 194 Error Codes . . . . . . . . . . . . . . . . . . . . . . 180 ETAC . . . . . . . . . . . . . . . . . . . . . . . . . . 249

C

F

. . . . . . . . . . . . . . . . . . . . . . . . . .20 Battery Connector . . . . . . . . . . . . . . . . . .215 Safety

Battery Pack Swing Out

. . . . . . . . . . . . . . . . . . . . . .205

Cable Routing Diagram . . . . . . . . . . .213 Brake Adjustment Release . .

Fasteners

Caster

. . . . . . . . . . . . . . . . . . . . . . . . .125 or . . . . . . . . . . . . . . . . . . .236 Conversion Formulas . . . . . . . . . . . . . . . .48 Wheel

Cylinder

Lift . . . . . . . Retention Kit

. . . . . . . . . . . . . . . . . . . .271 . . . . . . . . . . . . . . . . . . . . .82

D Decals . . . . . . . . . . . . . . . . . . . . . . . . . . .85 Definitions Electrical . . . . . . . . Transistor Controller

. . . . . . . . . . . . . . .156 . . . . . . . . . . . . . . .243 Drive Motor Brush Replacement . . . . . . . . .89 Drive Wheel Specifications

. . . . . . . . . . . . . . . . . . . .115

Drive Wheel Nut Inspection . . . . . . . . . . .115

E Electric Motors . . . . . . . . . . . . . . . . . . . . .87 Electrical Di-electric Compound Error Code History . Error Codes . . . . . . Functions . . . . . . . Graphics . . . . . . . .


Return

Battery Plugged In With Key Switch Battery Plugged In With Keypad . . Lift . . . . . . . . . . . . . . . . . . . . . . Lower . . . . . . . . . . . . . . . . . . . . Main ON/OFF Switch/Keypad ON . Reverser . . . . . . . . . . . . . . . . . . Travel, Low Speed . . . . . . . . . . .

. . . . . . . . . . . . . .156 . . . . . . . . . . . . . . .180 . . . . . . . . . . . . . . .180 . . . . . . . . . . . . . . .145 . . . . . . . . . . . . . . .197


Designations . . . . . . Strength Identification Torque Values . . . . .

. . . . . . . . . . . . . . . 42 . . . . . . . . . . . . . . . 41 . . . . . . . . . . . . . . . 46

Fault Codes

. . . . . . . . . . . . . . . 245 . . . . . . . . . . . . . . . 181 Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Fuses/Circuit Breakers . . . . . . . . . . . . . . 229 Transistor Controller Truck . . . . . . . . . .

G Grease Location Points . . . . . . . . . . . . . . . 72

H Hydraulic

. . . . . . . . . . 269 . . . . . . . . . . 254 . . . . . . . . . . 255 . . . . . . . . . . 256 . . . . . . . . . . 268 Hydraulic Schematic . . . . . . . . . . . . . . . . 253 Filter Screen and Inlet Tube Lift Schematic . . . . . . . . . Lower Schematic . . . . . . . Relief Pressure Schematic . Reservoir . . . . . . . . . . . .

Hydraulic System

Changing Fluid . . . . . . . . . Pump Pressure Relief Valve Troubleshooting Charts . . .

2004-03-19

. . . . . . . . . . 257 . . . . . . . . . . 259 . . . . . . . . . . 261

277

Index

I Interface ETAC and Transistor Controller

. . . . . . . . . . 25 . . . . . . . . . . 27 Service Key . . . . . . . . . . . . . . . . . . . . . . 174 Spare Parts, Ordering . . . . . . . . . . . . . . . . . 1 Steering Bearing . . . . . . . . . . . . . . . . . . 141 Steering Control Handle . . . . . . . . . . . . . 129 Static Discharge Precautions Welding . . . . . . . . . . . . . .

. . . . . . . .240

J

Switch

Jacking Truck off the Floor . . . . . . . . . . . . .58

L Lift Pump . . . . . . . . . . . . . . . . . . . . . . . .270 Load Wheel

. . . . . . . . . . . . . . . . . . . .121 Lubricants . . . . . . . . . . . . . . . . . . . . .59, 72 Cold Storage . . . . . . . . . . . . . . . . . . . . .59 Standard . . . . . . . . . . . . . . . . . . . . . . . .59 Lubrication Chart . . . . . . . . . . . . . . . . . . .71 Specifications

Arm Angle . . . . . . . . . . . . . . . . Converting Keypad to Key Switch Horn . . . . . . . . . . . . . . . . . . . Key . . . . . . . . . . . . . . . . . . . . Lift Limit . . . . . . . . . . . . . . . . . Master Control ON/OFF . . . . . . .

Symbols

Caution . . Danger . . . Ordinance . Prohibitory Warning . .

. . . . . . . . . . . . . . . . . . . . . . 13 . . . . . . . . . . . . . . . . . . . . . . 13 . . . . . . . . . . . . . . . . . . . . . . 14 . . . . . . . . . . . . . . . . . . . . . . 14 . . . . . . . . . . . . . . . . . . . . . . 13

T

M Motor

. . . . . . . . . . . . . . . . . . . . . . . . . .96 . . . . . . . . . . . . . . . . . . . . . . . . . .92 Motor Brush Inspection and Replacement . .89 Drive Pump

Technical Service Data . . . . . . . . . . . . . . . 51 Transistor Controller . . . . . . . . . . . . . . . . 239 Control Circuit Interface . . . . Motor Circuit .

Transmission

O

Fluid Changing

. . . . . . . . . . . . . . . . . . . 242 . . . . . . . . . . . . . . . . . . . 240 . . . . . . . . . . . . . . . . . . . 241

. . . . . . . . . . . . . . . . . . . . 99

Troubleshooting

Oil and Grease . . . . . . . . . . . . . . . . . . . . .72 Operator Display and Programming . . . . .168

. . . . . . . . . . . . . . . . . 161 . . . . . . . . . . . . . . . . . 261 Truck Torque Specifications . . . . . . . . . . . 47 Electrical System Hydraulic System

P

W

Parameters

. . . . . . . . . . . . . . . . .174 . . . . . . . . . . . . . . . . .172 Planned Maintenance Schedule . . . . . . . . .61 Pump Motor Brush Replacement . . . . . . . .90 Changing Service Changing Truck .

S Safety Battery

278

Return

. . . . . . 224 . . . . . . 227 . . . . . . 226 . . . . . . 226 . . . . . . 225 . . . . . . 224

. . . . . . . . . . . . . . . . . . . . . . . . .20

Wheels Caster (Optional) Drive . . . . . . . . Load . . . . . . . .

Wiring

. . . . . . . . . . . . . . . . . 125 . . . . . . . . . . . . . . . . . 115 . . . . . . . . . . . . . . . . . 121

Circuit Breaker . . . . Harness . . . . . . . . Master Control Relay Power Cables . . . .


. . . . . . . . . . . . . . . 232 . . . . . . . . . . . . . . . 230 . . . . . . . . . . . . . . . 233 . . . . . . . . . . . . . . . 231

2004-03-19

Return

Back Cover

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

Return

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