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Description
BT Prime-Mover OE35 Service Manual – PDF DOWNLOAD
FILE DETAILS:
BT Prime-Mover OE35 Service Manual – PDF DOWNLOAD
Language : English
Pages : 745
Downloadable : Yes
File Type : PDF
300116-000 1989_December
301460-001 1992_February
301460-002 1993_August
301460-003 1998_January
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
BT Prime-Mover OE35 Service Manual – PDF DOWNLOAD
Front Cover.................................................................................. 2 Index........................................................................................ 4 Specifications............................................................................... 5 1.0 Electrical, Amp Draws................................................................ 5 2.0 Speeds............................................................................... 5 3.0 Hydraulics........................................................................... 6 4.0 Tires and Wheels..................................................................... 6 5.0 Fluids and Lubricants................................................................ 6 6.0 SCR Card Trimpots.................................................................... 7 7.0 Torque............................................................................... 7 Lubrication Chart............................................................................ 8 Planned Maintenance Schedule................................................................. 9 Adjustments.................................................................................. 10 1.0 Brake................................................................................ 10 3.0 Brake Interlock Switch............................................................... 10 5.0 Steering............................................................................. 10 6.0 Lift Chains.......................................................................... 11 11.0 Speed Limiting Switch............................................................... 11 12.0 SCR Card Trimpots................................................................... 11 18.0 Gate Switch......................................................................... 11 6.0 Lift Chains.......................................................................... 12 11.0 Speed Limiting Switch............................................................... 12 12.0 SCR Card Trimpots................................................................... 12 18.0 Gate Switch......................................................................... 12 19.0 Potentiometer....................................................................... 12 Load Wheel Replacement....................................................................... 13 Drive Tire Replacement....................................................................... 14 Motor Service Instructions................................................................... 15 Cleaning................................................................................. 15 Visual Inspection........................................................................ 15 Testing.................................................................................. 15 Armature................................................................................. 16 Frame and Field Service Notes............................................................ 16 Field Coil Installation.................................................................. 16 Assembly and Testing..................................................................... 17 Electric Motor Repair........................................................................ 17 Service Procedures....................................................................... 17 Disassembly.............................................................................. 17 Cleaning................................................................................. 19 Visual Inspection........................................................................ 19 Motor Troubleshooting........................................................................ 21 Drive Motor Assembly......................................................................... 22 Lift Motor Assembly.......................................................................... 23 Steering Pump Motor Assembly................................................................. 24 Electrical................................................................................... 25 2.0 Drive Motor.......................................................................... 25 3.0 Lift Motor........................................................................... 25 4.0 Steering Motor....................................................................... 25 EV100 LX/LXT SCR Controls.................................................................... 26 General Maintenance Instructions......................................................... 28 Troubleshooting Instructions............................................................. 29 Basics of Circuit Operation.............................................................. 30 Terminal Connections for LX/LXT.......................................................... 36 Troubleshooting Chart - Electrical....................................................... 38 7.1 Dead Truck....................................................................... 38 7.2 Lift............................................................................. 39 7.3 Steering......................................................................... 40 7.4 Travel........................................................................... 42 7.5 Lowering......................................................................... 43 EV100 Handset............................................................................ 45 General.............................................................................. 45 Purpose.............................................................................. 45 Operation............................................................................ 45 Function Set-Up Procedures........................................................... 46 Description of Function Numbers...................................................... 47 Status Codes............................................................................. 50 Checking Components...................................................................... 70 Replacement of EV100 Components.......................................................... 75 Instructions - EV100 Plugs............................................................... 76 General.............................................................................. 76 Procedures........................................................................... 76 Hydraulic.................................................................................... 77 1.0 Lift System Pump..................................................................... 77 2.0 Steering System Pump................................................................. 81 5.0 Solenoid Valves...................................................................... 85 6.0 Troubleshooting...................................................................... 86 Mast......................................................................................... 92 1.0 Shimming............................................................................. 92 2.0 Mast Removal, Installation, Disassembly & Assembly................................... 98 Jacking and Hoisting.........................................................................106 Transmission.................................................................................107 1.0 Removal..............................................................................107 2.0 Disassembly and Repair...............................................................107 3.0 Installation.........................................................................114 Back Cover...................................................................................117 Front Cover..................................................................................118 Index........................................................................................119 Specifications...............................................................................120 1.0 Electrical...........................................................................120 2.0 Speeds...............................................................................120 3.0 Hydraulics...........................................................................121 4.0 Tires and Wheels.....................................................................121 5.0 Fluids and Lubricants................................................................121 6.0 SCR Card Settings....................................................................121 7.0 Torque...............................................................................122 Lubrication Chart............................................................................123 Planned Maintenance Schedule.................................................................124 Adjustments..................................................................................125 1.0 Brake................................................................................125 3.0 Brake Interlock Switch...............................................................125 5.0 Steering.............................................................................125 6.0 Lift Chains..........................................................................126 11.0 Speed Limiting Switch...............................................................126 12.0 SCR Card Trimpots...................................................................126 18.0 Gate Switch.........................................................................126 19.0 Potentiometer.......................................................................126 Load Wheel Replacement.......................................................................127 Drive Tire Replacement.......................................................................127 Removal of Plastic Dash Panel................................................................128 Motor Service Instructions...................................................................129 Cleaning.................................................................................129 Visual Inspection........................................................................129 Testing..................................................................................130 Armature.................................................................................131 Frame and Field Service Notes............................................................132 Field Coil Installation..................................................................132 Assembly and Testing.....................................................................132 Service Procedures.......................................................................133 Troubleshooting..........................................................................134 Drive Motor Assembly.....................................................................141 Lift Motor Assembly......................................................................142 Steering Pump Motor Assembly.............................................................143 Electric Motor Specification.................................................................148 2.0 Drive Motor..........................................................................148 3.0 Lift Motor...........................................................................148 4.0 Steering Motor.......................................................................148 Instructions - EV100 LX/LXT SCR Controls.....................................................152 Basics of Circuit Operation..............................................................154 Control Features.........................................................................155 Oscillator...........................................................................155 Current Limit........................................................................155 Plugging.............................................................................156 Pedal Position Plug..................................................................156 Ramp Start...........................................................................156 Full Power Transition................................................................156 Control Acceleration and 1A Time.....................................................156 1A Current Drop Out..................................................................156 Static Return to Off.................................................................156 Accelerator Volts Hold-Off...........................................................156 Coil Driver Modules..................................................................157 1A Thermal Hold-Off..................................................................157 Must Pulse to Time...................................................................157 Pulse Monitor Trip (PMT).............................................................157 Thermal Protector (TP)...............................................................157 Low Voltage..........................................................................158 Field Weakening......................................................................158 Regenerative Braking.................................................................158 Dual Motor Operation.................................................................158 Electrical System Troubleshooting........................................................159 Control Circuits and Power Circuits..................................................160 Terminal Connection for LX/LXT Logic Cards...........................................161 Instructions - Dash Display..............................................................163 Application..........................................................................163 Function Set-Up Procedures...............................................................167 Checking Components......................................................................207 Main Logic Card......................................................................207 Capacitor 1C.........................................................................208 Contactors F, R, 1A, SP, RW, D, Regen and P..........................................208 Potentiometer in Accelerator.........................................................208 SCR's (1 Rec, 2 Rec, 5 Rec)..........................................................208 Rectifiers (3 Rec, 4 Rec, Diode Blocks)..............................................210 Thermal Protector (TP)...............................................................210 Filter Blocks........................................................................210 1X Choke and Reactor T3 - T4.........................................................211 Replacement of EV-100 Components.........................................................212 Capacitor............................................................................212 22 Rec, 23 Rec and 25 Rec............................................................212 Instructions - EV100 Plugs...............................................................213 General..............................................................................213 Procedures...........................................................................213 Troubleshooting Chart - Electrical.......................................................215 7.1 Emergency Disconnect Contactor...................................................215 7.2 Steering and Brake Release Pump..................................................217 7.3 Travel...........................................................................218 7.4 Lift.............................................................................220 7.5 Lowering.........................................................................222 Hydraulic....................................................................................224 1.0 Lift System Pump.....................................................................224 2.0 Steering System Pump.................................................................228 5.0 Solenoid Valves......................................................................232 6.0 Hydraulic System Troubleshooting.....................................................233 Theory of Operation - Lift/Lower.....................................................233 Theory of Operation - Power Steering.................................................234 Theory of Operation - Brake Release..................................................234 6.1 Lift.............................................................................236 Mast.........................................................................................238 1.0 Shimming.............................................................................238 2.0 Mast Removal, Installation, Disassembly and Assembly.................................245 Jacking and Hoisting.........................................................................254 Transmission.................................................................................255 1.0 Removal..............................................................................255 2.0 Disassembly and Repair...............................................................256 3.0 Installation.........................................................................263 Back Cover...................................................................................265 Front Cover..................................................................................266 Index........................................................................................267 Specifications...............................................................................268 1.0 Electrical...........................................................................268 2.0 Speeds...............................................................................268 3.0 Hydraulics...........................................................................269 4.0 Tires and Wheels.....................................................................269 5.0 Fluids and Lubricants................................................................269 6.0 SCR Card Settings....................................................................269 7.0 Torque...............................................................................270 Lubrication Chart............................................................................271 Adjustments..................................................................................273 1.0 Brake................................................................................273 3.0 Brake Interlock Switch...............................................................273 5.0 Steering.............................................................................273 6.0 Lift Chains..........................................................................274 11.0 Speed Limiting Switch...............................................................274 12.0 SCR Card Trimpots...................................................................274 18.0 Gate Switch.........................................................................274 19.0 Potentiometer.......................................................................274 Load Wheel Replacement.......................................................................275 Drive Tire Replacement.......................................................................275 Removal of Plastic Dash Panel................................................................276 Motor Service Instructions...................................................................277 Cleaning.................................................................................277 Visual Inspection........................................................................277 Testing..................................................................................278 Armature.................................................................................279 Frame and Field Service Notes............................................................280 Field Coil Installation..................................................................280 Assembly and Testing.....................................................................280 Troubleshooting..........................................................................282 Drive Motor Assembly.....................................................................289 Lift Motor Assembly......................................................................290 Steering Pump Motor Assembly.............................................................291 Electric Motor Specification.................................................................296 2.0 Drive Motor..........................................................................296 3.0 Lift Motor...........................................................................296 4.0 Steering Motor.......................................................................296 OE-35 EV-100 with LX Card................................................................297 OE-35 with EV-100 LX Card and Dash Display...............................................298 OE35 with EV-100 LX Card and Curtis Lift Interrupt.......................................299 Instructions EV-100 LX/LXT SCR Controls......................................................300 Basics of Circuit Operation..................................................................302 Control Features.........................................................................303 Oscillator...........................................................................303 Current Limit........................................................................303 Plugging.............................................................................304 Pedal Position Plug..................................................................304 Ramp Start...........................................................................304 Full Power Transition................................................................304 Control Acceleration and 1A Time.....................................................304 1A Current Drop Out..................................................................304 Static Return to Off.................................................................304 Accelerator Volts Hold-Off...........................................................304 Coil Driver Modules..................................................................305 1A Thermal Hold-Off..................................................................305 Must Pulse to Time...................................................................305 Pulse Monitor Trip (PMT).............................................................305 Thermal Protector (TP)...............................................................305 Low Voltage..........................................................................306 Field Weakening......................................................................306 Regenerative Braking.................................................................306 Dual Motor Operation.................................................................306 Electrical System Troubleshooting............................................................307 Control Circuits and Power Circuits......................................................308 Terminal Connection for LX/LXT Logic Cards...............................................309 EV100 Dash Display.......................................................................311 Application..........................................................................311 Display Sequence.....................................................................312 Description and Location.............................................................313 Operation............................................................................314 Function Set-Up Procedures...........................................................315 Description of Function Numbers......................................................319 Status Codes.........................................................................323 Checking Components......................................................................355 Main Logic Card......................................................................355 Capacitor 1C.........................................................................356 Potentiometer in Accelerator.........................................................356 SCR's (1 Rec, 2 Rec, 5 Rec)..........................................................356 Rectifiers (3 Rec, 4 Rec, Diode Blocks)..............................................358 Thermal Protector (TP)...............................................................358 Filter Blocks........................................................................358 1X Choke and Reactor T3 - T4.........................................................359 Replacement of EV-100 Components.........................................................360 Capacitor............................................................................360 22 Rec, 23 Rec and 25 Rec............................................................360 Instructions - EV100 Plugs...............................................................361 General..............................................................................361 Procedures...........................................................................361 Troubleshooting Chart - Electrical.......................................................363 7.1 Emergency Disconnect Contactor...................................................363 7.2 Steering and Brake Release Pump..................................................365 7.3 Travel...........................................................................367 7.4 Lift.............................................................................368 7.5 Lowering.........................................................................371 Hydraulic....................................................................................373 1.0 Lift System Pump.....................................................................373 2.0 Steering System Pump.................................................................377 5.0 Solenoid Valves......................................................................380 6.0 Hydraulic System Troubleshooting.....................................................382 Theory of Operation - Lift/Lower.....................................................382 Theory of Operation - Power Steering.................................................383 Theory of Operation - Brake Release..................................................383 Mast.........................................................................................387 1.0 Shimming.............................................................................387 2.0 Mast Removal, Installation, Disassembly and Assembly.................................393 Jacking and Hoisting.........................................................................402 Transmission.................................................................................403 1.0 Removal..............................................................................403 2.0 Disassembly and Repair...............................................................404 3.0 Installation.........................................................................411 Back Cover...................................................................................413 Front Cover..................................................................................414 BT Standard Codes............................................................................416 Warning Symbols..............................................................................424 1. Warning Levels........................................................................424 Prohibitory Symbols..........................................................................425 1. Ordinance Symbols.....................................................................425 Introduction, Service Manual.................................................................426 Contents, Section M..........................................................................428 1. Machine Information...................................................................428 General Product Information..................................................................430 1. Presentation of the OE35..............................................................430 1.1. Intended Application of the Trucks..............................................430 1.2. Forbidden Application of the Truck..............................................431 1.3. Truck Data......................................................................431 1.4. OE35 Dimensions.................................................................432 1.5. Data Plate......................................................................433 1.6. U.L. Construction Type..........................................................434 2. Main Components.......................................................................435 Inch (SAE) and Metric Fasteners..............................................................438 1. Introduction..........................................................................438 2. Nomenclature, Threads.................................................................439 3. Strength Identification...............................................................440 4. Conversion of Metric and English Units................................................446 Technical Service Data.......................................................................448 Ordering Spare Parts.........................................................................452 Introduction, Maintenance....................................................................454 1. Safe Jacking Procedure................................................................454 Service Schedule.............................................................................456 1. Planned Maintenance Schedule..........................................................456 Planned Maintenance Procedures...............................................................460 1. Services to be performed daily or at each 8 hour operating shift......................460 1.1. Battery Discharge Indicator with slow down......................................460 1.2. Dash Display....................................................................460 1.3. Hydraulic System................................................................461 1.4. Frame/Sheet Metal...............................................................461 1.5. Wheels/Tires....................................................................461 1.6. Functions/Operations............................................................461 2. Services to be performed monthly or every 250 operating hours.........................462 2.1. Inspection......................................................................462 2.2. Transmission....................................................................462 2.3. Brakes..........................................................................462 2.4. Battery.........................................................................462 2.5. Electrical Connections..........................................................463 2.6. Contactor Tips (NOT Sealed).....................................................463 2.7. Motor Brushes...................................................................463 2.8. Drive Motor.....................................................................463 2.9. Hydraulic Reservoir.............................................................464 2.10. Frame Lube.....................................................................464 2.11. Pivot Points...................................................................464 3. Services to be performed annually or every 1200 operating hours.......................465 3.1. Inspection......................................................................465 3.2. Transmission....................................................................465 3.3. Battery.........................................................................465 3.4. Hydraulic System................................................................466 3.5. Brakes..........................................................................466 Lubrication Chart............................................................................468 Oil and Grease Specifications................................................................470 1. Approved Oils and Grease..............................................................470 Contents, Section S..........................................................................472 1. Service Instructions..................................................................472 Inspection Covers............................................................................474 1. Removal Of Plastic Dash Panel.........................................................475 Drive Motor..................................................................................478 1. General Information...................................................................478 2. Operating Conditions..................................................................478 3. Troubleshooting.......................................................................478 Drive Motor 24 Volt..........................................................................484 1. Component Repair......................................................................485 2. Inspection and Troubleshooting........................................................486 2.1. Drive End Head..................................................................486 2.2. Commutator End Head.............................................................486 2.3. Bearings........................................................................486 2.4. Brush and Commutator............................................................487 2.5. Armature........................................................................487 2.6. Frame and Field Assembly........................................................488 2.6.1. Testing...................................................................488 2.6.2. Frame and Field Service Notes.............................................489 2.7. Assembly........................................................................490 2.7.1. Field Coil Installation...................................................490 2.7.2. Bearing Installation......................................................490 2.7.3. After Assembly............................................................491 3. When changing brushes.................................................................491 Drive Motor 36 Volt..........................................................................492 1. Component Repair......................................................................493 1.1. Disassembly.....................................................................493 2. Inspection and Troubleshooting........................................................494 2.1. Drive End Head..................................................................494 2.2. Commutator End Head.............................................................494 2.3. Bearings........................................................................494 2.4. Brush and Commutator............................................................495 2.5. Armature........................................................................495 2.6. Frame and Field Assembly........................................................496 2.6.1. Testing...................................................................496 2.6.2. Frame and Field Service Notes.............................................497 2.7. Assembly........................................................................498 2.7.1. Field Coil Installation...................................................498 2.7.2. Bearing Installation......................................................498 2.7.3. After Assembly............................................................499 3. When Changing Brushes.................................................................499 Transmission.................................................................................500 1. System description....................................................................500 2. Troubleshooting.......................................................................500 3. Removal...............................................................................501 Transmission Disassembly / Assembly..........................................................504 4. Disassembly...........................................................................505 5. Installation..........................................................................512 Drive Wheel..................................................................................514 5.1. Removal.............................................................................514 5.2. Installation........................................................................515 Load Wheels..................................................................................516 Stabilizing Caster Spring Loaded.............................................................518 1. Removal...............................................................................519 2. Inspection............................................................................521 3. Disassembly...........................................................................522 3.1. Installation....................................................................522 Torque Generator.............................................................................524 1. Disassembly...........................................................................526 2. Assembly..............................................................................531 Steering System Pump.........................................................................538 1. General Information...................................................................539 2. Removal...............................................................................539 3. Installation..........................................................................540 4. Disassembly...........................................................................542 5. Inspection............................................................................543 6. Assembly..............................................................................543 Steering System..............................................................................546 1. General Information...................................................................546 Electrical System with TX and TT Card........................................................548 1. Electrical Schematic Part 1...........................................................548 2. Electrical Schematic Part 2...........................................................549 3. Basics Of Circuit Operation...........................................................550 4. Control Features......................................................................552 4.1. Oscillator......................................................................552 4.2. Current Limit...................................................................553 4.3. Plugging........................................................................553 4.4. Pedal Position Plug.............................................................553 4.5. Ramp Start......................................................................554 4.6. Full Power Transition...........................................................554 4.7. Control Acceleration and 1A Time................................................554 4.8. 1A Current Drop Out.............................................................554 4.9. Static Return to OFF............................................................555 4.10. Accelerator Volts Hold-OFF.....................................................555 4.11. Coil Driver Modules............................................................555 4.12. 1A Thermal Hold-OFF............................................................555 4.13. Must Pulse to Time.............................................................555 4.14. Pulse Monitor Trip (PMT).......................................................556 4.15. Thermal Protector - (TP).......................................................557 4.16. Low Voltage....................................................................557 4.17. Top Speed (Motor volts) Limit..................................................557 4.18. Steer Pump Contactor Time Delay................................................557 4.19. Constant Current Coil Drivers and Internal Coil Suppression....................558 4.20. Hourmeter Readings.............................................................558 4.21. Internal Resistance Compensation...............................................558 4.22. Stored Status Code.............................................................558 4.23. On-board Diagnostics...........................................................558 4.24. Battery Discharge Indication...................................................559 4.25. Handset........................................................................559 5. General Maintenance Instructions......................................................560 6. Trouble-shooting Instructions.........................................................561 Battery Controller / Hourmeter / Lift Interrupt..............................................564 1. General Information...................................................................564 2. Electrical............................................................................564 2.1. Voltage.........................................................................564 2.1.1. The Contact Voltage and Current Ratings for Switching Resistive Loads.....565 2.1.2. Memory Retention..........................................................565 3. Battery Controller (BC)...............................................................565 3.1. General Information.............................................................565 3.1.1. Discharge Adjustment......................................................565 3.2. Reset...........................................................................567 3.3. Key Switch......................................................................567 3.4. Hourmeter.......................................................................568 4. Troubleshooting.......................................................................568 4.1. Battery Discharge Indicator (BDI)...............................................568 4.1.1. No Reset..................................................................568 4.1.2. Reset After Break in Power................................................568 4.1.3. No Discharge, Gauge Does Not Run Down.....................................569 4.1.4. No Lockout................................................................569 4.1.5. No Lift...................................................................569 4.1.6. Early Lockout.............................................................570 4.1.7. LEDs Do Not Light.........................................................570 4.2. Hourmeter.......................................................................570 4.2.1. No Display................................................................570 4.2.2. Hourmeter Glass Icon Does Not Flash.......................................570 4.2.3. Hourmeter Glass Icon Always Flashes.......................................571 Dash Display.................................................................................572 1. General Information...................................................................572 2. Location..............................................................................573 3. Operational Checks....................................................................573 3.1. Checking Hourmeter..............................................................573 3.2. Checking Battery Condition (BDI)................................................573 3.3. Checking Status Code (wrench)...................................................573 4. Status Codes..........................................................................574 EV100 LX Control Status Codes................................................................576 SCR Component Checks.........................................................................594 1. Main Logic Card.......................................................................594 1.1. Instructions for Removal of Control Card........................................594 2. Capacitor 1C..........................................................................595 3. Contactors Forward, Rearward, 1A, Power Steering, and Pump............................595 4. Potentiometer in Accelerator..........................................................595 5. SCR’s (1REC, 2REC, 5REC)..............................................................595 6. Rectifiers (3REC, 4REC, Diode Blocks).................................................597 7. Thermal Protector (TP)................................................................597 8. Filter Block (23FIL, etc.)............................................................598 9. Filter Block (23FIL, etc.)............................................................598 10. 1X Choke and Reactor T3-T4...........................................................598 11. Replacement of EV100 Components......................................................598 11.1. 1REC, 2REC or 5REC.............................................................599 11.2. Capacitor......................................................................599 11.3. 22REC, 23REC and 25REC.........................................................600 12. Instructions - EV100 Plugs...........................................................600 12.1. General........................................................................600 12.2. Procedures.....................................................................600 12.3. Reference......................................................................601 Direction Contactor..........................................................................602 1. General Information...................................................................603 2. Remove / replace contact tips.........................................................603 1A Speed Contactor...........................................................................608 1. General Information...................................................................609 2. Disassembly...........................................................................609 3. Assembly..............................................................................611 Electrical System Troubleshooting............................................................614 1. Control Circuits and Power Circuits...................................................616 Electrical System Troubleshooting Charts.....................................................618 Pump Contactor...............................................................................630 1. General Information...................................................................631 2. Disassembly...........................................................................631 3. Assembly..............................................................................633 Steering Pump Contactor......................................................................636 1. General Information...................................................................637 2. Disassembly...........................................................................637 3. Assembly..............................................................................639 EV100 Handset Operation......................................................................642 1. General Information...................................................................642 2. Purpose...............................................................................643 3. Operation.............................................................................644 4. Function Set-Up Procedures............................................................645 5. Description and Location..............................................................647 6. Function Numbers for Controllers......................................................648 6.1. Function 1......................................................................648 6.2. Function 2......................................................................648 6.3. Function 3......................................................................648 6.4. Function 4......................................................................649 6.5. Function 5......................................................................649 6.6. Function 6......................................................................649 6.7. Function 11.....................................................................650 6.8. Function 12.....................................................................650 6.9. Function 13.....................................................................650 6.10. Function 14....................................................................651 6.11. Function 15....................................................................652 6.12. Function 16....................................................................652 6.13. Function 17....................................................................653 6.14. Function 18....................................................................654 Hydraulic System.............................................................................656 1. Hydraulic Schematic...................................................................656 2. General Information...................................................................657 2.1. Lift/lower......................................................................657 2.2. Power Steering..................................................................658 2.3. Brake Release...................................................................658 3. Maintenance...........................................................................659 4. Adjustments...........................................................................659 Hydraulic Troubleshooting....................................................................660 1. Troubleshooting Chart.................................................................660 Lift Pump Assembly...........................................................................664 1. Removal...............................................................................665 2. Disassembly...........................................................................666 3. Inspection............................................................................669 4. Assembly..............................................................................671 Mast, 2 Stage................................................................................674 1. Shimming Mast on Truck................................................................675 1.1. Shimming the Platform...........................................................675 1.2. Shimming the Rails..............................................................676 2. Two Stage Mast........................................................................679 2.1. Removal.........................................................................679 2.2. Installation....................................................................680 2.3. Disassembly.....................................................................681 2.4. Assembly........................................................................682 Mast, 3 Stage................................................................................684 1. Shimming Mast on Truck................................................................685 1.1. Shimming the Platform...........................................................685 1.2. Shimming the Rails..............................................................686 2. Three Stage Mast......................................................................690 2.1. Removal.........................................................................690 2.2. Installation....................................................................691 2.3. Disassembly.....................................................................692 2.4. Assembly........................................................................693 Lift Cylinder, 2 Stage.......................................................................696 1. Cylinder Repair.......................................................................697 1.1. Removal.........................................................................697 1.2. Disassembly.....................................................................698 1.3. Assembly........................................................................698 1.4. Installation....................................................................698 Freelift Cylinder, 3 Stage...................................................................700 1. Freelift Cylinder Repair..............................................................701 1.1. Removal.........................................................................701 1.2. Disassembly.....................................................................702 1.3. Assembly........................................................................702 1.4. Installation....................................................................702 Staging Cylinder, 3 Stage....................................................................704 1.1. Removal.............................................................................705 1.2. Disassembly.........................................................................705 1.3. Assembly............................................................................705 1.4. Installation........................................................................706 Micro 70 Wire Guidance Important Information.................................................708 1. Powering Up:..........................................................................708 2. Powering Down:........................................................................708 Micro 70 Wire Guidance.......................................................................710 1. Electrical Schematic Part 1...........................................................710 2. Electrical Schematic Part 2...........................................................711 3. Electrical Schematic Part 3...........................................................712 4. Electrical Schematic Part 4...........................................................713 5. Cautions and Warnings.................................................................714 6. Operation Information.................................................................716 6.1. Modes of operation..............................................................716 6.2. Acquiring the guide wire........................................................716 6.3. Daily operational checks........................................................719 7. Component Function and Relationship...................................................720 8. Truck Set Up On Site..................................................................722 9. Troubleshooting Information...........................................................725 10. Troubleshooting Charts...............................................................728 Back Cover...................................................................................745
S.S 06/24
