BT Prime-Mover TCB ELECTRIC TUGGER CAR BODY CARRIER Repair Manual PDF

Front Cover 2
Index 4
Specifications 6
1 0 Electrical 6
2 0 Speeds 6
4 0 Tire & Wheel 6
5 0 Fluids and Lubricants 6
6 0 SCR Card Setting 7
7 0 Torque 7
Planned Maintenance Schedule 8
Lubrication Chart 9
Adjustments 10
1 0 Mechanical Brake 10
2 0 Brake Solenoid 12
3 0 Interlock Switch 12
4 0 Lift Limit Switch 12
7 0 Transmission Rollers 14
12 0 SCR 14
Drive Tire Replacement 15
Load Wheel Replacement 15
Electric Motor Specification 16
2 0 Drive Motor 16
3 0 Lift Motor 16
4 0 Steering Motor 16
Electric Motor Service Instructions 17
Visual Inspection 17
Testing 18
Armature 19
Frame and Field Service Notes 19
Field Coil Installation 19
Assembly and Testing 20
Electric Motor Repair 20
Service Procedures 20
Drive Motor Assembly 21
Disassembly 22
Troubleshooting 26
Table # 1 27
Table # 2 31
EV-100 Operation 33
Basics of Circuit Operations 33
Control Features 34
Oscillator 34
Current Limit 34
Plugging 34
Ramp Start 35
Full Power Transition 35
Static Return to Off 35
Coil Driver Modules 35
Thermal Protector (TP) 36
1A Thermal Hold Off 36
Must Pulse to Time 36
Field Weakening (optional) 36
Low Voltage 36
Troubleshooting Chart – Electrical 38
7 1 Emergency Disconnect Contactor 38
7 2 Electric Brake TCB – Control 40
7 3 Electric Brake – TCB pull in power 41
7 4 Lift 42
7 5 Lowering – Control Circuits 43
7 6 EV-100 Maintenance Instructions 45
Trimpot Location for EV-100 Logic Cards 47
EV-100T Customer Terminal Functions 48
Troubleshooting 50
Maintenance Instructions 53
Directional Control Switch 62
Removal 62
Installation 62
Master Control Switch 62
Disassembly 62
Assembly 63
Troubleshooting 64
Hydraulics 66
1 0 Lift System Pump 66
5 0 Solenoid Valve 68
How To Adjust Release Valve 69
6 0 Troubleshooting – Hydraulic 71
Cylinder Assembly Removal Installation 72
Lift Frame Removal/Shimming/Installation 74
Transmission 75
1 0 Removal 75
2 0 Disassembly and Repair 76
3 0 Installation 82
Back Cover 84