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Description
BT Prime-Mover PMX45 Master Service Manual – PDF DOWNLOAD
FILE DETAILS:
BT Prime-Mover PMX45 Master Service Manual – PDF DOWNLOAD
Language : English
Pages : 585
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
BT Prime-Mover PMX45 Master Service Manual – PDF DOWNLOAD
Front Cover............................................................................. 2 BT Standard Codes....................................................................... 4 Warning Symbols......................................................................... 16 1. Warning Levels................................................................... 16 Prohibitory Symbols..................................................................... 17 1. Ordinance Symbols................................................................ 17 Safety.................................................................................. 18 1. General Safety................................................................... 18 Battery Safety.......................................................................... 22 Static Safety........................................................................... 27 Welding Safety.......................................................................... 28 Introduction, Service Manual............................................................ 30 Contents, Section M..................................................................... 32 1. Machine Information.............................................................. 32 General Product Information............................................................. 34 1. Truck Presentation............................................................... 34 1.1. Truck Side Views........................................................... 34 1.1. Intended Truck Application................................................. 35 1.2. Prohibited Truck Application............................................... 35 1.3. Truck Data................................................................. 35 1.4. Truck Dimensions........................................................... 36 1.5. Data Plate................................................................. 37 2. Main Components.................................................................. 38 Inch and Metric (SAE) Fasteners......................................................... 42 1. Introduction..................................................................... 42 2. Nomenclature, Threads............................................................ 43 3. Strength Identification.......................................................... 44 4. Conversion of English and Metric Units........................................... 50 Technical Service Data.................................................................. 52 Ordering Spare Parts.................................................................... 54 Contents, Section P..................................................................... 56 1. Planned Maintenance.............................................................. 56 Introduction, Maintenance............................................................... 58 1. Safe Jacking Procedure........................................................... 58 2. Lubricants....................................................................... 59 2.1. Cold Storage Conditioning.................................................. 59 2.2. Electrical Component Cold Storage Conditioning............................. 59 Service Schedule........................................................................ 60 1. Planned Maintenance Schedule..................................................... 61 2. Planned Maintenance Procedures................................................... 64 2.1. Services Performed Daily or Every 8 Operating Hours........................ 64 2.1.1. Battery Discharge Indicator with slow down........................... 64 2.1.2. Hydraulic System..................................................... 64 2.1.3. Frame/Sheet Metal.................................................... 65 2.1.4. Functions/Operations................................................. 65 2.2. Services Performed Monthly or Every 120 Operating Hours.................... 65 2.2.1. Inspection........................................................... 65 2.2.2. Transmission......................................................... 65 2.2.3. Brakes............................................................... 65 2.2.4. Battery.............................................................. 66 2.2.5. Electrical Connections............................................... 66 2.2.6. Main Contactor....................................................... 66 2.2.7. Motor Brushes........................................................ 66 2.2.8. Drive Motor.......................................................... 66 2.2.9. Hydraulic Reservoir.................................................. 66 2.2.10. Frame Lube.......................................................... 67 2.2.11. Pivot Points........................................................ 67 2.3. Services Performed Quarterly or Every 360 Operating Hours.................. 67 2.3.1. Wheels/Tires......................................................... 67 2.3.2. Hydraulic System..................................................... 67 2.3.3. Lift Cylinder Mounting............................................... 67 2.4. Services Performed Semi-Annually or Every 720 Operating Hours.............. 68 2.4.1. Chassis.............................................................. 68 2.4.2. Drive Motor.......................................................... 68 2.4.3. Drive Gear........................................................... 68 2.4.4. Brake................................................................ 68 2.4.5. Steering Control Handle.............................................. 68 2.4.6. Instrument Panel..................................................... 69 2.4.7. Electrical Control System............................................ 69 2.4.8. Electrical Panel..................................................... 69 2.4.9. Electronic Card...................................................... 69 2.4.10. Hydraulic System.................................................... 69 2.5. Services Performed Annually or Every 1440 Operating Hours.................. 69 2.5.1. Inspection........................................................... 69 2.5.2. Transmission......................................................... 69 2.5.3. Battery.............................................................. 70 2.5.4. Hydraulic System..................................................... 70 2.5.5. Brakes............................................................... 70 Lubrication Chart....................................................................... 72 Oil and Grease Specifications........................................................... 73 1. Approved Oils and Grease......................................................... 73 Contents, Section S..................................................................... 74 1. Service Instructions............................................................. 74 Troubleshooting Guidelines.............................................................. 76 1. General.......................................................................... 76 2. Electrical....................................................................... 78 2.1. Shorts to Frame Test....................................................... 78 3. Hydraulic........................................................................ 83 4. Definitions...................................................................... 84 Chassis/Lift Frame...................................................................... 86 1. Pull rod......................................................................... 87 1.1. Removal.................................................................... 87 1.2. Inspection................................................................. 88 1.3. Installation............................................................... 89 2. Carrier Frame Bushings........................................................... 91 Inspection Covers....................................................................... 92 1. General Information.............................................................. 92 Mounting Points......................................................................... 96 1. Drive Motor Brush................................................................ 97 2. Drive Motor Assembly............................................................. 97 2.1. Removal.................................................................... 97 2.2. Installation............................................................... 99 3. Pump Motor Assembly..............................................................101 3.1. Removal....................................................................101 3.2. Installation...............................................................101 Decals..................................................................................102 1. Decal with Protective Sheet......................................................102 2. Decal without Protective Sheet...................................................102 Pump Motor..............................................................................104 1. Component Repair.................................................................105 1.1. Disassembly................................................................105 2. Inspection and Troubleshooting...................................................107 2.1. Drive End Head.............................................................107 2.2. Commutator End Head........................................................107 2.3. Bearings...................................................................107 3. Brush Inspection.................................................................108 3.1. Brush Replacement Determination............................................108 3.2. Replacement Procedures.....................................................109 Motor Maintenance Schedule/Troubleshooting..............................................112 1. General Information..............................................................112 2. Operating Conditions.............................................................112 3. Troubleshooting..................................................................113 “E” Drive Motor.........................................................................120 1. Component Repair.................................................................121 1.1. Motor Disassembly..........................................................121 2. Motor Inspection.................................................................123 2.1. External Motor.............................................................123 2.2. Brush and Commutator.......................................................123 2.3. Bearings...................................................................124 2.4. Armature Electrical Check..................................................125 2.5. Commutator Undercut Guide..................................................126 2.6. Frame & Field Service Recommendation.......................................126 2.7. Assembly/Testing...........................................................127 “EE” Drive Motor........................................................................130 1. Component Repair.................................................................131 1.1. Motor Disassembly..........................................................131 2. Motor Inspection.................................................................132 Transmission............................................................................134 1. System Description...............................................................134 2. Troubleshooting..................................................................134 3. Axle Seal........................................................................135 3.1. Removal....................................................................135 3.2. Installation...............................................................135 4. Transmission Repair..............................................................137 4.1. Removal....................................................................138 4.2. Installation...............................................................138 4.3. Finger and Toe Guards......................................................140 4.4. Wrap Around Toe Guard......................................................141 5. Transmission Assembly............................................................142 5.1. Disassembly................................................................143 5.2. Reassembly.................................................................144 Parking Brake System....................................................................146 1. Brake Theory of Operation........................................................147 2. Brake Adjustment.................................................................148 3. Brake Shoe Removal / Installation................................................149 Drive Wheel.............................................................................150 1. Removal..........................................................................150 2. Installation.....................................................................151 3. Tire Pressing Procedure..........................................................152 Fork Wheels.............................................................................154 1. Removal/Installation.............................................................154 Support/Swivel Wheel....................................................................156 1. Maintenance and Adjustments......................................................158 1.1. Caster Adjustment..........................................................158 2. Troubleshooting..................................................................158 2.1. Stabilizing Caster.........................................................158 2.1.1. Caster Replacement...................................................158 Steering................................................................................160 1. Control Handle Head..............................................................161 1.1. Removal....................................................................161 1.2. Installation...............................................................161 2. Direction Control Switches.......................................................163 3. Horn, Raise, and Lower Switches..................................................167 4. Potentiometer....................................................................170 Battery.................................................................................174 1. Removal..........................................................................174 2. Installation.....................................................................175 3. Battery Maintenance..............................................................176 3.1. Battery Inspection and Care................................................176 3.2. Battery Exterior Cleaning..................................................177 3.3. Charging...................................................................177 4. Storage..........................................................................178 5. Battery History Record...........................................................179 Swing Out Battery Pack..................................................................180 1. Battery Cable Routing Diagram....................................................182 2. Charger Diagram..................................................................184 3. Troubleshooting..................................................................185 3.1. Electrical Testing.........................................................185 3.1.1 . Equipment required:.................................................185 3.1.2. Instructions.........................................................185 Battery Connector.......................................................................192 1. Location.........................................................................192 2. Inspection.......................................................................193 3. Installation.....................................................................194 Battery Controller/Hourmeter/ Lift Interrupt............................................196 1. General Information..............................................................196 2. Electrical.......................................................................197 2.1. Voltage....................................................................197 3. Battery Controller (BC)..........................................................198 3.1. General Information........................................................198 3.1.1. Discharge Adjustment.................................................198 3.2. Reset......................................................................200 3.3. Key Switch.................................................................200 3.4. Hourmeter..................................................................200 4. Troubleshooting..................................................................201 4.1. Battery Discharge Indicator (BDI)..........................................201 4.1.1. No Reset.............................................................201 4.1.2. Reset After Break in Power...........................................201 4.1.3. No Discharge, Gauge Does Not Run Down................................202 4.1.4. No Lockout...........................................................202 4.1.5. No Lift..............................................................202 4.1.6. Early Lockout........................................................203 4.1.7. LEDs Do Not Light....................................................203 4.2. Hourmeter..................................................................204 4.2.1. No Display...........................................................204 4.2.2. Hourmeter Glass Icon Does Not Flash..................................204 4.2.3. Hourmeter Glass Icon Always Flashes..................................204 Battery Discharge Indicator / Hourmeter.................................................206 1. General Information..............................................................206 2. Electrical.......................................................................206 2.1. Voltage....................................................................206 3. Battery Discharge Indicator (BDI)................................................207 3.1. General Information........................................................207 3.2. Key Switch.................................................................207 3.3. Hourmeter..................................................................207 4. Troubleshooting..................................................................207 4.1. Battery Discharge Indicator (BDI)..........................................208 4.1.1. No Reset.............................................................208 4.1.2. Reset After Break in Power...........................................208 4.1.3. No Discharge, Gauge Does Not Run Down................................209 4.1.4. LEDs Do Not Light....................................................209 4.2. Hourmeter..................................................................209 4.2.1. No Display...........................................................209 4.2.2. Hourmeter Glass Icon Does Not Flash..................................209 4.2.3. Hourmeter Glass Icon Always Flashes..................................210 Start/Stop Switches.....................................................................212 1. General..........................................................................212 1.1. Test/Inspection............................................................212 2. Master Control On/Off Switch (S21)...............................................214 2.1. Inspection.................................................................214 2.2. Removal....................................................................214 2.3. Installation...............................................................214 Electrical System.......................................................................216 1. Electrical Panel Components......................................................216 2. List of Symbols..................................................................217 2.1. Circuit Diagram 1(3).......................................................218 2.2. Circuit Diagram 2(3).......................................................219 2.3. Circuit Diagram 3(3).......................................................220 3. Function Description.............................................................221 3.1. General Information........................................................221 3.2. Reference Information......................................................221 3.3. Key Switch S17 in the ON Position..........................................221 3.4. Operating Arm in Drive Position, S10, Brake Switch Closed..................221 3.5. Driving, Fork Direction....................................................222 3.6. Driving, Steer Wheel Direction.............................................222 3.7. Reversing/Motor Brake Fork Direction to Steer Wheel Direction..............222 3.8. Reversing/Motor Brake Steer Wheel Direction to Fork Direction..............222 3.9. Reverser switch............................................................222 3.10. Lifting Forks.............................................................223 3.11. Lowering Forks............................................................223 3.12. Horn......................................................................223 3.13. Lift Interrupt............................................................223 Transistor Controller...................................................................224 1. Maintenance......................................................................224 1.1. Safety.....................................................................224 1.2. Cleaning...................................................................224 1.3. Diagnostics and Troubleshooting............................................225 1.3.1. Handset Diagnostics..................................................225 1.3.2. Troubleshooting......................................................225 2. Basics Of Circuit Operation......................................................227 2.1. Control Features...........................................................229 3. Motor Circuit....................................................................231 4. Control Circuit..................................................................232 5. Diagnostics and Troubleshooting..................................................234 5.1. 1307 Programmer Diagnostics................................................234 5.2. Troubleshooting Chart......................................................235 5.3. Technical Specification....................................................239 5.4. Troubleshooting Chart Using Handset........................................240 Transistor Controller Troubleshooting...................................................242 1. Troubleshooting Chart Index......................................................242 2. Troubleshooting Charts...........................................................243 Contactor Panel.........................................................................254 Hydraulic System........................................................................256 1. Hydraulic Schematic..............................................................256 2. General Information..............................................................256 3. Description......................................................................257 3.1. Lift.......................................................................257 3.2. Lower......................................................................257 3.3. Relief Pressure............................................................257 4. Maintenance......................................................................258 5. Adjustments......................................................................258 6. Lift Limit Switch................................................................258 7. Troubleshooting..................................................................260 Hydraulic Pump..........................................................................262 1. Removal..........................................................................264 2. Disassembly......................................................................265 3. Inspection.......................................................................266 4. Reassembly.......................................................................267 5. Installation.....................................................................269 6. Adjustments......................................................................271 6.1. Relief valve...............................................................271 6.2. Solenoid Operated Valve....................................................272 Lift Cylinder...........................................................................274 1. Cylinder Repair..................................................................275 1.1. Removal....................................................................275 1.2. Disassembly................................................................276 1.3. Inspection.................................................................276 1.4. Assembly...................................................................276 1.5. Installation...............................................................277 Battery Charger.........................................................................278 Handset Operation.......................................................................292 1. Operating Modes..................................................................295 2. Revert to Previous Settings......................................................298 3. Handset Self Test................................................................298 Back Cover..............................................................................303 Standard Codes..........................................................................306 Warning Symbols.........................................................................316 1. Warning Levels...................................................................316 Prohibitory Symbols.....................................................................317 1. Ordinance Symbols................................................................317 Safety..................................................................................318 1. General Safety...................................................................318 Battery Safety..........................................................................322 Static Safety...........................................................................327 Welding Safety..........................................................................328 Introduction, Service Manual............................................................330 Contents, Section M.....................................................................332 1. Machine Information..............................................................332 General Product Information.............................................................334 1. Truck Presentation...............................................................334 1.1. Truck Side Views...........................................................334 1.1. Intended Truck Application.................................................335 1.2. Prohibited Truck Application...............................................335 1.3. Truck Data.................................................................335 1.4. Truck Dimensions...........................................................336 1.5. Data Plate.................................................................337 2. Main Components..................................................................338 Inch and Metric (SAE) Fasteners.........................................................340 1. Introduction.....................................................................340 2. Nomenclature, Threads............................................................341 3. Strength Identification..........................................................342 4. Conversion of English and Metric Units...........................................349 Technical Service Data..................................................................352 Ordering Spare Parts....................................................................354 Contents, Section P.....................................................................356 1. Planned Maintenance..............................................................356 Introduction, Maintenance...............................................................358 1. Jacking Truck Off The Floor......................................................359 1.1. Elevate Rear of Truck......................................................359 1.1. Elevate Either Side of Truck...............................................359 2. Lubricants.......................................................................360 2.1. Standard...................................................................360 2.2. Corrosion..................................................................360 2.3. Cold Storage...............................................................361 Service Schedule........................................................................364 1. Planned Maintenance Schedule.....................................................364 2. Planned Maintenance Procedures...................................................368 2.1. Services Performed Daily or Every 8 Operating Hours........................368 2.1.1. Battery Discharge Indicator with lift interrupt (optional)...........368 2.1.2. Hydraulic System.....................................................368 2.1.3. Frame/Sheet Metal....................................................369 2.1.4. Wheels/Tires.........................................................369 2.1.5. Functions/Operations.................................................369 2.2. Services Performed Monthly or Every 120 Operating Hours....................370 2.2.1. Inspection...........................................................370 2.2.2. Transmission.........................................................370 2.2.3. Brakes...............................................................370 2.2.4. Battery..............................................................370 2.2.5. Electrical Connections...............................................371 2.2.6. Main Contactor.......................................................371 2.2.7. Motor Brushes........................................................371 2.2.8. Drive Motor..........................................................371 2.2.9. Hydraulic Reservoir..................................................371 2.2.10. Frame Lube..........................................................372 2.2.11. Pivot Points........................................................372 2.3. Services Performed Every 480 or 960 Operating Hours........................373 2.3.1. Drive Motor..........................................................373 2.4. Services Performed Annually or Every 1440 Operating Hours..................374 2.4.1. Inspection...........................................................374 2.4.2. Transmission.........................................................374 2.4.3. Battery..............................................................374 2.4.4. Hydraulic System.....................................................375 2.4.5. Brakes...............................................................375 Lubrication Chart.......................................................................376 Oil and Grease Specifications...........................................................377 1. Approved Oils and Grease.........................................................377 2. Grease Location Points...........................................................377 Contents, Section S.....................................................................378 1. Service Instructions.............................................................378 Chassis/Lift Frame......................................................................380 1. Pull rod.........................................................................381 1.1. Removal....................................................................381 1.2. Inspection.................................................................382 1.3. Installation...............................................................383 2. Carrier Frame Bushings...........................................................385 Inspection Covers.......................................................................386 1. General Information..............................................................386 Driver Controls.........................................................................390 Decals..................................................................................392 1. Decal with Protective Sheet......................................................392 2. Decal without Protective Sheet...................................................392 Motor Maintenance Schedule/ Troubleshooting.............................................394 1. General Information..............................................................394 2. Operating Conditions.............................................................394 3. Troubleshooting..................................................................395 Pump Motor..............................................................................402 1. Mounting Points..................................................................402 1.1. Removal....................................................................402 1.2. Installation...............................................................402 2. Pump Repair......................................................................403 2.1. Disassembly................................................................404 3. Inspection and Troubleshooting...................................................405 3.1. Drive End Head.............................................................405 3.2. Commutator End Head........................................................405 3.3. Bearings...................................................................405 4. Brush Inspection.................................................................406 4.1. Brush Replacement Determination............................................406 4.2. Replacement Procedures.....................................................407 Drive Motor.............................................................................410 1. Mounting Points..................................................................410 1.1. Drive Motor Brush..........................................................411 1.2. Drive Motor Removal........................................................411 1.3. Drive Motor Installation...................................................413 2. Component Repair.................................................................415 2.1. Motor Disassembly..........................................................417 3. Motor Inspection.................................................................418 3.1. External Motor.............................................................418 3.2. Brush and Commutator.......................................................418 3.3. Bearings...................................................................421 3.4. Armature Electrical Check..................................................421 3.5. Frame and Field Service Recommendation.....................................421 3.6. Assembly/Testing...........................................................422 Transmission............................................................................424 1. System Description...............................................................424 2. Troubleshooting..................................................................424 3. Transmission Mounting............................................................425 3.1. Wrap Around Bumper.........................................................426 3.2. Guards.....................................................................427 3.3. Removal....................................................................428 3.4. Installation...............................................................429 4. Transmission Repair..............................................................430 4.1. Disassembly................................................................431 4.2. Reassembly.................................................................432 5. Axle Seal........................................................................434 5.1. Removal....................................................................434 5.2. Installation...............................................................434 Parking Brake System....................................................................436 1. Brake Theory of Operation........................................................437 2. Brake Adjustment.................................................................438 3. Brake Shoe Removal / Installation................................................439 Drive Wheel.............................................................................440 1. Removal..........................................................................440 2. Installation.....................................................................441 3. Tire Pressing Procedure..........................................................442 Support/Swivel Wheel (Optional).........................................................444 1. Maintenance and Adjustments......................................................446 1.1. Caster Adjustment..........................................................446 2. Troubleshooting..................................................................446 2.1. Stabilizing Caster.........................................................446 2.1.1. Caster Replacement...................................................446 Fork Wheels.............................................................................448 1. Removal/Installation.............................................................448 Steering................................................................................450 1. Control Handle Head..............................................................451 1.1. Removal....................................................................451 1.2. Installation...............................................................451 2. Driver Protection (Reverser) Assembly Replacement................................452 3. Direction Control Switches.......................................................454 3.1. Removal....................................................................454 3.2. Installation...............................................................454 4. Raise, Lower, and Horn Switches..................................................456 4.1. Removal....................................................................456 4.2. Installation...............................................................457 5. Potentiometer....................................................................458 5.1. Removal....................................................................458 5.2. Installation...............................................................459 6. Steering Stem....................................................................463 6.1. Removal....................................................................463 6.2. Installation...............................................................463 Electrical Functions....................................................................464 1. General..........................................................................464 1.1. Adjustable Settings:.......................................................464 1.2. References.................................................................464 1.3. Key Switch S17 in the ON Position..........................................464 1.4. Operating Arm in Drive Position, S10, Brake Switch Closed..................465 1.5. Travel Request, Fork First.................................................465 1.6. Travel Request, Forks Trailing.............................................465 1.7. Reversing/Motor Brake Forks First Direction to Forks Trailing Direction....465 1.8. Reversing/Motor Brake Forks Trailing Direction to Forks First Direction....466 1.9. Reverser switch............................................................466 1.10. Lifting Forks.............................................................466 1.11. Lowering Forks............................................................466 1.12. Horn......................................................................467 1.13. Lift Interrupt............................................................467 Electrical Panel Components.............................................................468 Electrical Symbols......................................................................470 Electrical Schematics...................................................................474 Circuit Diagram 1(3)....................................................................474 Circuit Diagram 2(3)....................................................................475 Circuit Diagram 3(3)....................................................................476 Battery.................................................................................478 1. Removal..........................................................................478 2. Installation.....................................................................478 3. Battery Maintenance..............................................................479 3.1. Battery Inspection and Care................................................479 3.2. Battery Exterior Cleaning..................................................480 3.3. Charging...................................................................480 4. Storage..........................................................................481 5. Battery History Record...........................................................481 Swing Out Battery Pack..................................................................482 1. Battery Cable Routing Diagram....................................................484 2. Charger Diagram..................................................................486 3. Troubleshooting..................................................................487 3.1. Electrical Testing.........................................................487 3.1.1. Equipment required:..................................................487 3.1.2. Instructions.........................................................487 Battery Connector.......................................................................494 1. Location.........................................................................494 2. Inspection.......................................................................494 3. Installation.....................................................................495 Battery Controller/Hourmeter/ Lift Interrupt (Optional).................................496 1. General Information..............................................................496 2. Electrical.......................................................................497 2.1. Voltage....................................................................497 3. Battery Controller (BC)..........................................................498 3.1. General Information........................................................498 3.1.1. Discharge Adjustment.................................................498 3.2. Reset......................................................................500 3.3. Key Switch.................................................................500 3.4. Hourmeter..................................................................501 4. Troubleshooting..................................................................501 4.1. Battery Discharge Indicator (BDI)..........................................501 4.1.1. No Reset.............................................................501 4.1.2. Reset After Break in Power...........................................501 4.1.3. No Discharge, Gauge Does Not Run Down................................502 4.1.4. No Lockout...........................................................502 4.1.5. No Lift..............................................................503 4.1.6. Early Lockout........................................................503 4.1.7. LEDs Do Not Light....................................................503 4.2. Hourmeter..................................................................504 4.2.1. No Display...........................................................504 4.2.2. Hourmeter Glass Icon Does Not Flash..................................504 4.2.3. Hourmeter Glass Icon Always Flashes..................................504 Battery Discharge Indicator / Hourmeter.................................................506 1. General Information..............................................................506 2. Electrical.......................................................................507 2.1. Voltage....................................................................507 3. Battery Discharge Indicator (BDI)................................................507 3.1. General Information........................................................507 3.2. Key Switch.................................................................507 3.3. Hourmeter..................................................................508 4. Troubleshooting..................................................................508 4.1. Battery Discharge Indicator (BDI)..........................................508 4.1.1. No Reset.............................................................508 4.1.2. Reset After Break in Power...........................................509 4.1.3. No Discharge, Gauge Does Not Run Down................................509 4.1.4. LEDs Do Not Light....................................................509 4.2. Hourmeter..................................................................510 4.2.1. No Display...........................................................510 4.2.2. Hourmeter Glass Icon Does Not Flash..................................510 4.2.3. Hourmeter Glass Icon Always Flashes..................................510 Start/Stop Switches.....................................................................512 1. General..........................................................................512 1.1. Test/Inspection............................................................512 2. Master Control On/Off Switch (S21)...............................................514 2.1. Inspection.................................................................514 2.2. Removal....................................................................514 2.3. Installation...............................................................514 Transistor Controller...................................................................516 1. Basics Of Circuit Operation......................................................516 1.1. Control Features...........................................................518 2. Maintenance......................................................................519 2.1. Safety.....................................................................519 2.2. Cleaning...................................................................519 3. Motor Circuit....................................................................520 4. Control Circuit..................................................................521 5. Troubleshooting Guidelines.......................................................522 5.1. General....................................................................524 6. Shorts to Frame Test.............................................................525 7. Definitions......................................................................529 8. Diagnostics and Troubleshooting..................................................530 8.1. Handset Diagnostics........................................................530 8.2. Troubleshooting............................................................530 8.3. Troubleshooting Chart......................................................532 8.4. Technical Specification....................................................537 8.5. Troubleshooting Chart Using Handset........................................538 Transistor Controller Troubleshooting...................................................540 1. Troubleshooting Chart Index......................................................540 2. Troubleshooting Charts...........................................................541 Hydraulic System........................................................................552 1. General..........................................................................552 2. Troubleshooting..................................................................552 3. Schematic........................................................................554 4. Description......................................................................555 4.1. Lift.......................................................................555 4.2. Lower......................................................................555 4.3. Relief Pressure............................................................555 5. Maintenance......................................................................556 6. Lift Limit Switch................................................................556 Hydraulic Pump..........................................................................558 1. Removal..........................................................................560 2. Disassembly......................................................................561 3. Inspection.......................................................................562 4. Reassembly.......................................................................563 5. Installation.....................................................................565 6. Adjustments......................................................................566 6.1. Relief valve...............................................................567 6.2. Solenoid Operated Valve....................................................567 Lift Cylinder...........................................................................568 1. Cylinder Repair..................................................................569 1.1. Removal....................................................................569 1.2. Disassembly................................................................570 1.3. Inspection.................................................................570 1.4. Assembly...................................................................570 1.5. Installation...............................................................571 Battery Charger, Optima Pack............................................................572 Handset Operation.......................................................................574 1. Operating Modes..................................................................577 2. Revert to Previous Settings......................................................580 3. Handset Self Test................................................................580 A...................................................................................582 B...................................................................................582 C...................................................................................582 D...................................................................................582 E...................................................................................582 F...................................................................................582 G...................................................................................582 H...................................................................................582 I...................................................................................582 L...................................................................................582 M...................................................................................583 O...................................................................................583 P...................................................................................583 S...................................................................................583 T...................................................................................583 W...................................................................................583
S.S 06/24
