CLARK FORKLIFT SM577 PT5, PT7, PTT5, PTT7 SERVICE MANUALS

Service Manual

---

SM577 PT5, PT7, PTT5, PTT7

INDEX PT-5 & PT-7 and PTT-5 & PTT-7

SPECIFICATIONS Electrical ...............................................

Speeds ...................................................

Tires and Wheels .........................................

Fluids and Lubricants ....................................

SCR Card Settings ........................................

Torque ...................................................

: 2

PLANNED MAINTENANCE Schedule ............ ........*...........*................

Lube Chart .......... .......... .......*...................

3 4,5

1 1 1

ADJUSTMENTS Brakes ...................................................

Brake Solenoid ...........................................

Interlock Switch .........................................

Transmission Rollers ......................................

Caster ...................................................

DRIVE TIRE REPLACEMENT .......................................

10

LOAD WHEEL REPLACEMENT .......................................

10

ELECTRICAL Electric Motor Repair ..................... ...... .. .......

Drive Motor Specifications .......... ............ .. ...... ..

11 21

EVlOO Theory of Operation .......................... ..**........

Troubleshooting .................................*........

22 25

MASTER CONTROL SWITCH ..................*.....................

60

TRANSMISSION Removal .........*.........................................

14:l ......................................................

2211 ......................................................

64 *.. f;:

FOREWORD

Clark Equipment Company welcomes you to the growing group of professional people who own, operate and maintain Clark lift trucks. This manual will familiirtze you with service maintenance and ovefiaui information about your new truck. It has been espedaliy prepared to help yoir maintain your Clark lift truck in an efficient and safe operating condition.

Regular, corred maintenance and care of your Iii truck is not only important for full and efficient truck life; it is essential for your safety. A faulty Iii tnxk is a potential source of danger to the operator, and to other personnel working near it. The importance of maintaining your lift truck in a safe operating condition by servicing it regularly and, when necessary, repairing it promptly cannot be emphasized too strongly.

To assist you in keeping your Iii truck in good operating condition, this manual includes an outline of planned maintenance (PM) procedures that are considered essential to the life and safe performance of your truck. Brief procedures for inspections, operatianai checks, cleaning, lubrication, and adjustments are included for your reference.

Clark recommends that a planned maintenance and safety inspection program (PM) be performed by a trained and authorized mechanic on a regular basis. The PM program provides the opportunity to make thorough inspections and checks on the safe condition of your truck. Necessary adjustments and repairs can be done during the PM, which will increase the life of components and reduce unscheduled downtime. The need for major adjustments, repairs, or replacements Is found and corrections made as required; not after failure has occurred.

SAFETY

SIGNS

AND SAFETY

MESSAGES

Improper or careless techniques cause accidents. Don’t take chances with incorrect or

damaged equipment. Read and understand the procedures for safe operation and maintenance outlined in this manual.

STAY ALERT! Follow safety rules, regulations and procedures. Accidents can be avoided by recognizing dangerous procedures or situations before they occur.

DRIVE AND WORK SAFELY and follow the safety signs and their messages displayed on the truck and in this manual.

SAFETY SIGNS and MESSAGES are placed in thii manual and also on the lii truck to provide instructbns and to identify specific areas where potential hazards exist and special precautions should be taken. Be sure you know and understand the meaning of these instructions, signs and messages. Damage to the truck or death or serious injury to you or other persons may result if these messages are not followed.

NOTICE This message is used when special informatbn, instructbns or identifbation is required relating to procedures, equipment, tools, pressures, capacities and other special data.

IMPORTANT This message is used when special precautbns should be taken to ensure a correct action or to avoid damage to or malfunction of the truck or a component.

CAUTION This message is used as a reminder of safety hazards which can result in personal injury tf proper precautions are not taken.

WARNING This message is used when a hazard exists which can result in injury or death if proper precautions are not taken.

DANGER This message is used when an extreme hazard exists which will result in death or serious injury if proper precautions are not taken.

USER SAFE

MAINTENANCE

The following instructions have been prepared from current industry and government safety standards applicable to industrial truck operations and maintenance. These recommended procedures specify conditions, methods, and accepted practices that aid in the safe maintenance of industrial trucks. They are listed here for the reference and safety of all workers during maintenance operations. Carefully read and understand these instructions and the specific maintenance procedures before attempting to do any repair work. When in doubt of any maintenance procedure, please contact your local CLARK dealer.

1. Powered industrial trucks can become

hazardous if maintenance is neglected.

Therefore, suitable maintenance facilities, trained personnel, and procedures must be provided.

2. Maintenance and inspection of all powered industrial trucks shall be done in conformance with the manufacturer’s recommendations.

3. A scheduled planned maintenance, lubrication, ~ and inspection program shall be followed.

4. Only trained and authorized personnel shall be permitted to maintain, repair, adjust, and inspect industrial trucks, and in accordance with the manufacturer’s specifications.

5. Properly ventilate work area, vent exhaust fumes, and keep shop clean and floor dry.

6. Avoid fire hazards and have fire protection equipment present in the work area. Do not use an open flame to check for level, or leakage of fuel, electrolyte, or coolant. Do not use open pans of fuel or flammable cleaning fluids for cleaning parts.

PRACTICES

9. Before Starting To Drive Truck: a) Be in operating position. b) Disengage clutch on manual transmissions, or apply brake on trucks with powershift transmission and electric trucks. c) Put directional control in neutral. d) Start engine or turn on power. e) Check functioning of lift and tilt systems, directional and speed controls, steering, brakes, warning devices, and any load handling attachments.

10. Before Leaving The Truck:

a) b) c) d) e)

9

Stop truck.

Put directional control in neutral.

Apply the parking brake.

Stop the engine or turn off power.

Turn off the control or ignition circuit.

Putblocks at the wheels, if truck is on an incline.

11. Brakes, steering mechanisms, control mechanisms, warning devices, lights, guards and safety devices, and frame members must be carefully and regularly inspected and maintained in a safe operating condition.

12. Special trucks or devices designed and approved for hazardous area operation must receive special attention to ensure that maintenance preserves the original, approved safe operating features.

13. The truck manufacturer’s capacity, operation and maintenance instruction plates, tags, or decals must be maintained in legible condition.

7. Before Starting Work On Truck: a) Raise drive wheels off of floor or disconnect power source and use blocks or other positive truck-positioning devices. b) Put blocks under the load engaging means, inner-mast(s), or chassis before working on them. c) Disconnect battery before working on the electrical system.

8. Operation of the truck to check performance must be conducted in an authorized, safe, clear area.

14. Batteries, motors, controllers, limit switches, protective devices, electrical conductors and connections must be inspected and maintained in conformance with good practice. Special attention must be paid to the condition of electrical insulation.

15. To avoid injury to personnel or damage to the equipment, consult the manufacturer’s procedures in replacing contacts on any battery connection.

USER SAFE

MAINTENANCE

16. Industrial trucks must be kept in a clean condition to minimize fire hazards and help in the detection of loose or defective parts.

17. Modifications and additions that affect capacity and safe truck operation must not be done without the manufacturer’s prior written approval. Capacity, operation and maintenance instruction plates, tags or decals must be changed accordingly.

16. Care must be taken to assure that all replacement parts, including tires, are interchangeable with the original parts and of a quality at least equal to that provided in the original equipment. Parts, including tires, are to be installed per the manufacturer’s procedures.

Always use genuine CLARK or CLARK-approved parts.

19. When removing tires, follow industry safety practices.

20. Use special care when removing heavy components from the truck. Be sure that lifting and handling equipment is of the correct capacity and in good condition.

NOTICE -- You should also be familiar with additional operating and maintenance safety instructions contained in the following publications: ANSIIASME 856.1 - 1983: Safety Standard for Low Lift and High Lift Trucks (Safety Code For Powered Industrial Trucks). Published by: Society of Mechanical EngLleers, United Engineering Center, 345 E. 47th Street, New York, N.Y. 10017.

NFPA 505-1982: Fire Safety Standard for Powered Industrial Trucks: Type Designations, Areas of Use, Maintenance and Operation.

Available from: National Fire Protection Assoc., Inc., Batterymarch Park, Quincy, MA 02269.

General Industry Standards, OSHA 2206: OSHA Safety and Health Standards (29 CFR 1910) Subpart N-Materials Handling and Storage, Section 1910.178 Powered Industrial Trucks. For sale by: Supenntendent of Documents, U.S. Government Printing Off ice, Washington, D.C 20402.

PRACTICES

PM - PLANNED

MAINTENANCE

PROGRAM

A planned maintenance program of regular, routine inspections and lubrication is important for long life and trouble-free operation of your lift truck. Make and keep records of your inspections.

Use these records to help establish the correct PM intervals for your application and to indicate maintenance required to prevent major problems from occurring during operation.

The periodic maintenance procedures outlined in this manual are intended to be used with the PM report form. They are arranged in groupings of maintenance work that are done in a logical and efficient sequence.

A check mark or entry is made on the PM Report Form when the PM is performed. Please note the special coding system for indicating the importance of needed repairs and/or adjustments.

When you have finished the PM inspections, be sure to give a copy of the report to the designated authority or the person responsible for lift truck maintenance.

Do not make repairs or adjustments unless authorized to do so.

NAMEPLATES AND DECALS Check to be sure all capacity, safety, and warning plates or decals are attached and legible.

Do not operate or allow a lift truck with damaged or missing decals and name plates to be operated.

They contain important information. Replace them immediately.

Be sure that safety devices are in place, undamaged, and attached securely.

For safety, it is good practice to: Remove all jewelry (watch, rings, bracelets, etc.) before working on the truck.

Always wear safety glasses when making repairs.

Be sure to: Make a record of all maintenance and operating problems you find.

WHEELS AND TIRES Check the condition of the drive wheel and rear wheels and tires. Remove objects that are embedded in the tread. Inspect the tires for excessive wear and breaks or “chunking out”, and bond failure between the tire and rim.

Check all wheels for proper tightness. Adjust if necessary.

Write the hour meter reading on the PM report form.

FUNCTIONAL

HOW TO PERFORM THE PM PERfODlC INSPECTIONS AND MAINTENANCE

To be sure that all controls and systems are functioning correctly.

Test horn and all other safety equipment and accessories. Be sure they are properly mounted and working correctly.

VISUAL INSPECTION First, perform a visual inspection of the lift truck and its components. Walk around the truck and take note of any obvious damage and maintenance problems. Check for loose fasteners and fittings.

Press the horn button to check horn function. If the horn or any other part does not operate, report the failure and have3 repaired before the truck is put back into operation.

TESTS

Operate service and parking brakes, directional controls, and steering system. Be sure all controls operate freely and return to neutral properly.

SM545 PM -1

PM - PLANNED

MAINTENANCE

TEST DRIVE THE TRUCK Check all around to be sure that your intended path of travel is clear of obstructions and

PROGRAM

check to be sure the cells are all filled. If possible, refill with distilled water to bottom of vent cap opening.

pedestrians.

Test the truck for: general correct operation drive train function steering performance brake performance by driving the truck in both the forward and reverse directions, first in a straight line and then, slowly, through a series of full right and left turns.

Listen for any unusual drivetrain or other running noises, such as wheel beating noise, vibration, etc. Note any lack of smoothness in steering.

When you have completed the operational tests, park and leave truck according to standard shutdown procedures.

BRAKES Check the service / parking brake system. Push the brake pedal all the way down and hold. The brakes should be fully released at this pedal position.

To check parking brake holding capability and adjustment, drive the truck onto a grade and release the pedal. The parking brake should hold the truck on the grade that the truck can climb with a capacity bad or a 10 % grade whichever is the lesser.

CAUTION - Do not operate a truck if the setvlce or parking brakes are not operating properly.

STEERING SYSTEM Check the steering system for abnormal looseness and damage. Check for any changes in steering action. Hard steering or looseness, unusual sounds when turning or maneuvering indicates a need for inspection and servicing.

Never operate a truck which has a steering system fault.

BATTERY Inspect the battery retainment and replace any damaged or missing parts.

Inspect the battery for any damage, cracks, leaking condition. If your battery has removable vent caps,

MECHANISM Finally, inspect all control pedals, levers, and linkages for wear and smoothness of operation.

AIR CLEANING Always maintain a lift truck in a clean condition. Do not allow dirt, dust, lint, or other contaminants to accumulate on the truck. Keep the truck free from leaking oil and grease. Wipe up all oil spills. Keep the controls and floorboards clean, dry, and safe.

A clean truck makes it easier to see leakage, loose, missing or damaged parts, and will help prevent fires. A clean truck will run cooler.

The environment in which a lift truck operates will determine how often and to what extent cleaning is necessary. For example, trucks operating in manufacturing plants which have a high level of dirt or lint (e.g., cotton fibers, paper dust, etc.) in the air or on the floor, will require more frequent cleaning.

Lift trucks should be air cleaned at every PM Interval, and otherwise as often as required.

Air cleaning should be done using an air hose with special adapter or extension having a control valve and nozzle to direct the air properly. Use clean, dry, low-pressure compressed air: restrict air pressure to 1207kPa] 30 psi, maximum.

CAUTION - Wear suitable and protective clothing.

eye protection

CRITICAL FASTENER TORQUE CHECKS Check torque of critical items, including: Drive unit mounting Drive and rear wheel mounting components.

Replace missing bolts and tightened loose bolts to the correct torque before operating the truck.

Fasteners in highly loaded (critical) components can quickly fail if they become loosened; also, loose fasteners can cause damage or failure of the component.

For safety, it is important that the correct torque be maintained on all critical fasteners of components which directly support, handle or control the load, and protect the operator.

SMS45 PM-2

PLANNED

SAFETY

PM A = B= C = D= E=

MAINTENANCE

AND

OPERATIONAL

Interval: 8 - 10 hours, or daily 50 - 250 hours, or every month 450 - 500 hours, or every 3 months 900 - 1000 hours, or every 6 months 2000 hours, or every year

SM 545 PM-3

PROGRAM

CHECKS

PLANNED

MAINTENANCE

PROGRAM

RECOMMENDED MAINTENANCE AND LUBRICATION SCHEDULE

Notes: PM Interval: *Replace As Required A = B= C = D= E=

8 - 10 hours, or daily 50 - 250 hours, or every month 450 - 500 hours, or every 3 months 900 - 1000 hours, or every 6 months 2000 hours, or every year

MAINTENANCE

AND

LUBRICATION

Test wound

Nominal Maintenance Interval

A

B

.

Clean drive unit air vent Check drive axle unit level

Drain and replace drive unit fluid Check brake condition and wear

SM 545 PM-4

C

D

E

SPECIFICATIONS 1.0

Rleotriaal PT a PTT-5 1.1 1.2

2.0

Travel Travel

amp draw unloaded amp draw loaded

E!

2.1 2.2

Pi

Travel Travel

unloaded loaded

& PlT-7

7.0 mph 5.0 mph

5.0 mph

3.0 mph

PTT-7 wl4th

Speed

8.0 mph 6.0 mph

Tire & wheel 4.11 Drive tire aire 4.12 Standard rubber 4.13 Optional 4.2

4.3

Drive

tire

10.5 x 5 x 6.5 part number 20071-01

urethane

part number

4.4

4.21 4.22

Rubber Shore A, 60-70 durometer Urethane Shore A, 80-90 durometer

Load

uheel

.

4.32 4.33

Standard rubber Optional urethane

Load

wheel

4.41 *4.42

20262.01

eompound

4.31 Size

5.0

;:

Speeds PT a PlT-5

4.0

PT & PIT-7

8 x 4.5 x 4.5 part number 24268-00

part number

24269-00

ampound

Rubber Shore A 70 durometer Urethane Shore A 90 durometer

Fluids and Lubricant8 5.1

Transmission PT 6 P-l-r-5 22:l 5.11 Type of fluid 5.12 capaelty

Aft

l

Dexron II quart

PT a PI-r-7 14:l

ATFDexron II 1 quart

6.0

SCR Card Setting

Quick Tune-up

Creep 9 C/A 6

C/L

2

1A

4

2 F.W.P.U. 6

Plug

F.W.D.O. 6

7.0 Torque PT & PTT-7 .

7.1 7.2

7.5

Drive Hub RetainingNut Wheel bolts General BOLT

SIZE

l/4-20 l/V28 5/16-18 5/16-Z+ 3/8-16 3/8-2+ 7/16-14 7/16-20 l/2-13 l/2-20 5/8-11 5/8-18

ft/lbs.

125 ft/lbs.

PT & PTT-5

250

80 ft/lbs.

SRE GRADE TORNJE

5

SfE 6RADE TORQUE

2

DW

LUB

DW

LUB

8 10 17 19 30 35 50 55 75 90 150 180

6 7-2 13 14 23 25 35 10 55 65 110 130

5-5 6-3

l-2 q-7 8 9 15 17 2$ 27 35 30 75 85

-2-

11 12 20 .

23 32 36 50 55 100 110

DATE PLANNEDMAINTENANCESCHEDULE Year 2.0

SerialNo. Jar Feb Mar Apr May Jur Jul Aug Sep Ott Nov Ded 100 Hour or MonthlyPM

1. Cheokconditionof batteryCharge 2. Visuallyinspectfor leaks,loose,missing,or damagedparts Cheokall operatingufunctionsand adjustments 3 4: Checktransmission oil level 5. Lubricateall greasefitti 6. Inspeotpowercablesand controlwiring Cleanwith oompressedair :: Inspeotcontactortips for pitting 3.0

I

I

I

500 Hour or Semi-AnnualPH

1. Cleanbatteryand machine 4.0

1000Hour or AnnualPM I

gear case 1. Drain,flush,and refill transmission 2. Inspectmotor brushes Grease,lube pointsand battery rollers- TexasRef. C&C 1880

LubricationSpeoifiaation Transmission - ATR DexronII

1

I I

I

I

_’

PT.5

& PT-7

LUBRICATION

CHART

1

Gear case transmission

Drain,flushAd refill

AFT Dexron

2

Load wheel axle

Use Lub. Gun & Adapterfor flush tipy fittinKs

Tex. Ref. C&C 5880

,3

Handlebearing

Cleanand oil

Motor oil

4

Frame casters

Use standardlub gun

Tex. Ref. C&C 1880

i

PTT-5

& PTT-7

LUBRICATION

CHART

1

Gear ca8e transmission

Drain,flushand refill

AFT Dexron

2

Load wheel axle

Use Lub. Gun & Adapterfor flushtipy fittings

Tex. Ref. C&C #880

3

Handlebearing

Use standardlub gun

Tx. Ref. C&C f880

4

Frame casters

Use standardlub gun

Tex. Ref. C&C X880 i

3

1.0

Mechanical

Brake - PT-5 & PT-7

Proper adjustment of the meohanioal brake is important for satisfactory operation of the truck.

The brake action of the tranmission is achieved by a pair of springs that press against a brake actuating lever which in turn grabs a brake disk.

The brake is always applied in the static (brake on) position.

To release -the brake, the actuating --lever must be pushed away -from the There are two (2) adjustments provided to permit tailoring brake disc.

The first adjustment is the brake for different operating conditions. brake release.

the

1.

Loosen the two (2) screws that hold the brake interlock slide as far left as possible.

2.

On the front

3.

Loosen the jam nut.

4.

Lower the handle all

5.

Turn the adjusting cam screw in l/3 of a revolution increments.

Adjust inward towards the brake actuating lever for less brake and outward for more brake.

6.

After each attempt at adjusting, move the actuating lever to the operation position.

Get the truck moving and release the handle to test the brake.

7.

When correctly

8.

If braking is uneven between handle up and handle down, need to center cam lobes on the brake actuation rod and adjustment nut, to center turn adjusting nut using l/16 turn increments, until braking is even at handle up and handle down.

9.

Tighten the jam nut.

cover of the transmission,

switch and

back out the brake pressure

the way to engage the brake.

adjust’with

handle down, test with handle up.

10.

Recheck the brake if the brake release drag in the operation should occur.

11.

Readjust the interlock

is properly

adjusted.

No brake

switch.

The second brake adjustment controls this adjustment:

the aggressiveness

of the brake.

To make

1.

Lower the handle to release

the brake.

2.

Turn each of the brake pressure adjusting screws (located in the front cover of the transmission) inward until resistance is felt, then turn This creates more spring pressure against the brake in & turn further. actuator lever causing it to grasp the brake disk more positively.

-6-

1.0 Mechanical Brake - PIT-5 & PIT-7

Proper adjustment of the mechanical brake is important for satisfactory operation of the truck.

The brake action of the tranmission is achieved by a pair of springs that press against a brake actuating lever which in turn grabs a brake disk.

The brake is always applied in the static (brake on) position.

To release the brake, the actuating --lever must be pushed away -from the brake disc There areTo (2) adjustments provided to permit tailoring p-0 brake for different operating conditions.

The first adjustment is the brake release.

the

1.

Loosen the four (4) cap screws that hold the brake interlock slide as far left as possible.

2.

On the front cover of the transmission, back out the brake pressure adjusting screws.

These screws control the unount of spring pressure needed by the brake actuating lever to grab the brake disks.

3.

Loosen the jam nut.

4.

De-energize

5.

Turn the adjusting cam screw in l/3 of a revolution increments.

Adjust inward towards the brake actuating lever for less brake and outward for more brake.

6.

After each attempt at adjusting, move the energize the brake solenoid to the operating posiXon. Get the truck moving and de-energize the brake solenoid to test the brake.

7.

When correctly

8.’

Recheck the brake if the brake release drag in the operation should occur.

9.

the brake solenoid

adjusted

Readjust the interlcck

tighten

switch and

to engage the brake.

the jam nut. is properly

adjusted.

No brake

switch.

The second brake adjustment controls this adjustment:

the aggressiveness

of the brake.

To make

1.

Lower the handle to release

the brake.

2.

Turn each of the brake pressure adjusting screws (located in the front cover of the transmission) inward until resistance is felt, then turn This creates more spring pressure against the brake in f turn further. actuator lever causing it to grasp the brake disk more positively.

-7-

3.

Operatethe truckand readjustif necessaryuntil the satisfaotory stopping range is achieved. of the brake pressurescrewsmay cause excessive Note: Overadjustment brakewear.

2.0 Brake Solenoid The brake on the PTT-5 & PTT-7 Is released by an electric solenoid. noid must be properly adjusted for the brake to release.

1.

The sole-

Adjustthe plungerso there is 1" of it exposedbelow the plunger by adjustingthe nut at the top of the barrel. This is acoomplished solenoid.

adjustthe clevisthat is on the 2. With the brake solenoidde-energized, plungeruntil the pin will slide thru the clevisand brake operating level.

3. Adjustthe repairspringso that there is no tensionon it when the brake is released.

3.0 InterlockSwitch The interlockswitchis locatedinsidethe motor shieldand is controlledby the brake operatinglinkage. As the brake is applied,the brakeoperatinglever oomes off the high point of the adjustingscrew. As it falls to a low point, the shaftmoves left and activatesthe interlock. Thus,when properlyadjusted, the drivemotor turns off when the brakeis applied. Any requiredbrakeadjustments shouldbe performedprior to an adjustmentof the interlock. Adjusting procedure: 1. PT & PTT-5 Loosen th$ four screwsholdingthe interlockswitchto the motor shield.

PT & PIT-7

Loosenscrewsholdingthe interlockswitchto the bracket.

2. Slide switchleft away from the brake leveras far as possible.

3.

Adjustbrake,if necessary,accordingto instructions.

4. Place brake in "braked"position.

5. Slide switchassemblyto the right until the switchsnaps. additionall/32"and tightenscrews.

6.

Move an

7.

Check that the actuatingrod makes solidcontactwith the switchlever.

8. Check that the switchsnapsnear the middleof actuatingrod movement.

-8-

7.0

Transmission Rollers The four rollerscontainingthe transmission will occasionally require adjustment.When they do, the procedureis as follows: .

.

1. Loosenthe locknutand bolt holdingbearingassembly. . firmlyagainstthe non-adjustable rollers.

2. Wedge the transmission 3*

Turn the eccentricadjustersso the two adjustablerollersare firm and even with each other.

4.

Retightenthe boltsand locknuts.

makingsure it rotatesfreely.

5. Rotatetransmission 10.0 Caster

The stabilizercastershouldbe adjustedso thereis l/8"preloadon the castersprings. The procedurefor this adjustmentis as follows: 1.

Place l/8”

shim under the drive tire.

2. R move casterfrom carrierframe.

3*

Installshims betweencarrierframeand caster,so that casterjust touchesthe floor.

12.0

See Section7.4 of this manual for SCR card Adjustment.

-9-

DRIVE TIRE REPLACEMENT To replace 1.

the drive wheel, the following

steps should be taken.

Disconnectthe battery.

2. Hoist the truck approximately

one foot

(5) bolts holding

and block truck.

3.

Remove the five

4.

Tap the drive wheel off the shoulder and remove the tire

5.

Press on new tire, the wheel.

6.

Install ft/lbs.

make sure tire

wheel and lug bolts. on, PE.

the wheel. and wheel.

is flush with the lug bolts

Torque bolts

to 125 ft/lbs.

side of

on BT and 80

LOAD WHEEL PLACEMENT 1. Park machine on level

I

surface

and disconnect

battery.

2.

Hoist oi- jack machine just high enough so that the particular wheel barely clears the floor.

Block machine securely.

3.

Remove hub cap. Bend back locking ring tabs and remove retaining nut, locking ring, locating washer and outer bearing.

At this time the wheel can be removed.

4.

Remove inner seal anh bearing.

5.

If the new wheel is beingpressed,make sure that the tire flush on the outer edge of the wheel.

6.

Clean and inpsect

wheel bearings and replace

if

necessary.

load

ring is Repack

bearingsand installinner bearingand seal.

7.

Slidewheel on axle shaft,installouter bearing,locatingwasher, lockingring and retainingnut.

8.

Tightenretainingnut to 25 ft. lbs. while spinningwheel. Loosenwheel and retroqueto 2-6 in. lbs. or untilall free play is removedfrom bearing.

9.

Bend lockingtabs in place aroundretainingnut and installhub cap.

Greasewith standardadapter. Lowermachineand checkoperation.

-lO-

1.0

PRESTOLJTE MOTOR SERVICE INSTRUCTIONS

(General

whenever the motor is overhs&d.

The oil seal seat an the armature shaft should be checked for rough spots, grooves, or scm3.

Notes)

CLEANING

4.

Bearings Check bearings by turning them with your fingers. Feel for binding or gritty effects and for excessive looseness or wobble. A good bearing should also have a small amount of drag or stiffness caused by the lubrication. If the bearing turns very freely, it should be replaced.

5.

Frame and field assembly Check the condition of all insuIation. If the insulation on the field coils appears blackened or charred, the serviceability of the coils is questionable. Burned or charred insumion is a result of coils over-heating due to overloading conditions, ’ grounded or shorted coil windings. Check condition of all other insulation such as brush rigging, under coil connections, and around terminal

Prior to any testing or inspection, the motor components, except bearings and armature, should be thoroughly cleaned with a good grade petroleum base cleaning solvent and dried with compressed air.

AD

Be extremely careful when working with solvent. Even a sms.lI explosion or fire could cause injury or death.

AWARNING Wear eye protection and be

sure to comply with OSIIA or other maximum air pressure requirements.

The armature should be blown off with compressed air to remove brush dust and dirt from around the commutator and windings.

studs.

Bearings shouId be wiped clean with a cloth and never submerged in a solvent.

Submerging bearings in a solvent wiII deteriorate internal lubrication which cannot be replaced.

6.

VISUAL INSPECTION After the motor components have bzn thoroughly cleaned and dried, they should be inspected for the folIowing:

Armature Check the shaft bearing journals, splines or keyways for wear. Check windings, commutator connections and commutator bars for any signs of burning. If deep burned sections are evident, either in the brush track or on the rider end of the commutator bars, an. open circuit in the armature winding is indicated. .

Drive end head Check bearings recess for any signs of wets. Check mounting h&s -for any stripped or crossed threads or broken studs.

TEST’ING

2.

Commutator end head Check bearing recess for any signs of wear. Check bearing holder insulation for cracks or any signs Check brush holders of burning. and springs for wear.

After thorough inspection, the frame and field assembly should be checked for grounded, open, or shorted circuits. Grounded and open circuits can be checked tsing 110 volt A.C. test leads with a SO watt bulb in series.

3.

Oil seal Oil seal, if upon disassembly of the motor, the field coils or cummutator are oily. A faulty oil seal is indicated. A good service practice is to replace the oil seal

1.

1.

-ll-

Frame and Field Assembly

Grounded circuit Touch one test lead to a clean bare metal spot on the frame and check aU terminals with the other lead.

If a grounding condition exists, the test light lights.

2.

Open circuit

fails to light, indicated.

3.

1.

Check between all connecting terminals with test leads. If the bulb

an open circuit is

Shorted circuit Shorted windings in series coils are very difficult to detect.

Generally,. if the coil insulation is sound there are no signs of overheating, the coil can be presumed good. The individual pages in your Prestolite service manual lists the series winding resistance. The resistance of the series coils is usually so low a special ohmeter or ohmeter attachment is needed to check it.

Shunt coils can ‘be ohmeter for proper with a battery, of voltage, for proper

tested with an resistance or the specified currant draw.

NOTE: The resistance in shunt field coils may cause the test light to be dimly lit.

Standard winding connections -These armatures are tested on a growler using a steel strip or

hacksaw blade to locate any shorted windings. Rotate the armature in the growler while holding the strip or blade over the armature so that it passes over each armature core slot.

If a winding is shorted, or blade will vibrate.

2.

the strip

Equalizer winding connections This tvne of armature cannot be tested-b a growler like the standard winding connection armatures.

The equalizer connections are made between commutator bars and will cause the armature to test shorted.

The only practical method of testing these armatures is to perform a light load test after the motor has been completely assembled. If the motor does not meet or exceed aR parts .of the light load specification, replace the armature.

FRAME AND FIELD SERVICE NOTES

ARMATURE Check the armature for grounded cir. cuits by placing one test lead of the 110 volt A.C. test lamp on the commutator and the other test lead on the armature shaft. If the test light lights, the armature is grounded.

There are two different dectrically connected types of armatures trsed in motors. Each type requires a different method of testing for shorted circuits.

The individual pages in your Presolite Service Manual specify the type of armature used in that particular motor series.

NOTE: If the armature has been turned and undercut prior to testing, check for and remove any copper buildup or fii between commutator bars and the commutator riser. This condition will cause an armature to check shorted and usually results from a dull undercutting tool.

-12-

If the inside of the motor is exceptionally dirty and there is evidence of a grounding condition caused by dirt, the inside of the motor can be given an additional cast of insulating varnish.

Red glyptol can be wed ‘if a better material is not available, however, we recommend using a Class “F” Polyurethane air drying insulating varnish. This is readily available under various brand names from electrical repair or parts houses in aerosal type dispensers.

Before spraying field coils, make sure they are absolutely clean and dry. Keep varnish off of brush rigging, pole shoe faces; and end head seats.

FIELD COIL INSTALLATION Good solder connections are important due to the vibration characteristics encountered by these motors which can cause cold or poorly soldered connections to break. Prior to installing the field coils, the connections which

require soldering should be buffed or wire brushed clean to remove any oxidi28 tion . The connections should then be tinned with a 90% tin solder sing a soldering iron.

NOTE: We do not recommend using a soldering gun or torch.

Soldering guns cannot provide the heat concentration required and soldering torches can damage the insulation. .

ELECTRIC MOTOR REPAIR

..

SERVICE PROCEDURES The service procedures are basically the same for all motors regardless of size.

DISASSEMBLY 1.

After field coil installation, connect the solder joint, making sure the solder is flowing properly to avoid a cold soldered joint.

Remove the cover band from the commutator end of the motor (if equipped).

Cover Band

There is an optional method of connecting field coils which provides a mechanical connection prior to soldering. This method facilitates soldering and results in a stronger connection for added vibration protection.

After tinning and installing the &Id coils in the frame, align the coil straps and drill an U/64” hole (P18 Drill) thru both straps. Insert a 88-32 brass screw and nut or a brass pop rivet and solder the connection. After the connection has been made, check the clearance between it and the end head to prevent grounding the connection when the end head is instaIled.

2.

Use a brush hook to reach into the motor and lift the brush springs.

Pull the brushes out of the brush holders. Either position the brushes outside the motor or remove the brush retaining screws and remove the brushes from the motor.

ASSEMBLY AND TESTING Commutator end head retaining screws

After the motor components have been thoroughly cleaned, tested, and repaired or replaced, assemble the unit. Refer to the individual motor page of your Prestolite Service Manual for specific assembly information.

After assembly, the motor should be connected as SpeCifkd in test connections, and tested to the specifications contained on the Presolite service individual motor page.

.

Some motors are tested at a voltage different from the SpeCified or routed voltage of the motor. This is done to avoid excessive current draw and, or excessive free running R.P.M.

Brush retaining screws

When testing motors, the voltmeter connections must be made at the motor terminals.

-13-

3.

Scribe or center punch locating in the end head and the frame. Although locating marks are not always necessary because of locating pins in some motors, they can save a lot of time when the motor does not have locating pins. marks

4.

Remove the commutator end head retaining screws. Almost aII motors have a slip fit bearing at the commutator end, and the end head can be removed with very lit.tle trouble.

When a puller is used, protect the end of the armature shaft with a nut or a thick flat washer. If the shaft, coupling, or spline is damaged when removing the end head, the armature or the drive spline usually has to be replaced. Use caution ana do not damage the armature.

On motors that have a shaft extension on both ends of the armature, the attachment on the commutator end of the shaft must be removed before the end head can be separated from the motor.

5.

Remove the drive end he+ retaining screws, if necessary. Some of the slndler pump motors retain the drive end head with the motor through bolts. Separate the armature and drive end head as an assembly from the frame and field coil assembly .

7.

Separate the bearing from the end head. On larger motors, the bearing is retained with a snap ring.

Remove the snap ring. Then press the bearing out of the end head.

End head /

Drive end head retaining screws

assembly Press Ram T Aramature and

Bearing Inner Race

Pipe (same

dnve end head assembly

site

as

inner Race)

Snap Ring

6.

Separate the armature from the drive end head. This operation is usually done by pressing the armature out of the drive end bearing.

On some of the larger motors, .the end head and bearing will have to be removed with a puller.

End head

-

Armature shaft

PRESSING END BEAD BACK ON ARMATURE SHAE’T -14-

8.

The ventilating

CLEANING

fans are cast ah-

minum. Once these fans have been

Prior to any testing or inspection, the motor components, except bearings and armature, should be throughly cleaned with a good grade petroleum base cleaning solvent and dried with compressed air.

pressed onto the armature, they must be heated to be removed without damage.

A puller is installed and a slight pressure exerted against the fan.

Use a small propane torch to heat the area of the fan around the When the fan becomes loose shaft. on the shaft, as evidenced by the puller becoming loose, it should be removed as quickly as possible.

a

WARWlMG

Be extremely careful when working with solvent. Even a small explosion or fire could cause injury or death.

AWARNING

Wear eye protection and be sure to comply with OSHA or other maximum air pressure requirements.

The armature should’ be blown off with compressed air to remove the brush dust and dirt from around the commutator and windings.

Bearing should be wiped clean with a cloth and never submerged in a solvent.

Submergingbearings in a solvent will deteriorate internal lubrication which cannot be replaced.

9.

When the fan is reassembled on the shaft, make sure it is a tight fit.

Use “Loctite Retaining Compound 40” or equivalent on the inside of the fan hub when reassembling fan.

VISUAL INSPECTION After the motor components have been thoroughly cleaned and dried, they should be inspected for the following: 1.

Drive end head Check bearing recess for anv signs of wear. Ch&k mounting’ h&es lor any stripped or crossed threads or broken studs.

34.

Commutator end head Check bearing recess for any signs of wear. Check bearing holder &Ilation for cracks or any signs of burning. Check brush holders and springs for wear.

3.

OiI SC-al --

Use “locae” on ths area of shaft

If upc#n disassembly of the motor, the field coils or cummutator are oily. A faulty oil seal is indicated. .A good service practice is to replace the oil seal whenever the motor is. overhauled. The oil seal seat on the armature shaft should be checked for rough spots, grooves, or scars.

10. After the motor has been separated into all its major subassemblies, the components should be cleaned and inspected for wear or damage.

-15-

4.

Bearings Check bearings by turning them with your fingers. Feel for binding or gritty effects and for excessive looseness or wobble. A good bearing should also have a small amount of drag or stiffness caused by the lubrication. If the bearing turns very freely, it should be replaced.

Place the armature in lathe and clean the commutator with PO00 or finer sandpaper to determine whether or not the commutator needs resurfacing.

Light pitting and wear can be removed with the sand-paper* Excessive pitting and wear will have to be removed by turning and undercutting the commutator.

Ball bearings that have been pulled off of shafts, pressed out of end head, or side Ioaded in such a way as to apply pressure on the balls and races must be replaced.

Although the bearing may appear to feel good, the bearing races have been brine&d and will fail within a relatively short period of service.

5.

Frame and field assembly Check the condition of aU insulation. If the insulation on the field coils appears blackened or charred, the serviceabilfty of the coils is questionable. Burned or charred insulation is a result of coils over-heating due to overloading conditions, grounded or shorted coil windings. Check condition of all other insulation such as brush rigging, under coil connections, and around terminal studs.

6.

Armature Check the shaft bearing journals. splines or keyways for wear. Check windings, commutator connections and commutator bars for any signs of burning. If deep burned sections are evident, either in the brush track or on the rider end of the commutator bars, an open circuit in the armature winding is indicated.

Loose commutator bars will usually be indicated by excessive wear or burning on one bar. The commutator can be checked for loose bars by lightly tapping all of the bars with the handle of a plastic or wooden handle screwdriver. A contrasting dull thud or vibration will indicate a loose bar in which case the armature must be replaced.

16-

MOTOR TROUBLESHOOTING

.POSSIBLECAUSE

SYMPTOM I.

BIOWS circuit

breaker

Bad

Bearing

Replace bearing (also check armature 1

and shaft tums very .2. Blows circuit breaker 3.

Blows circuit breaker and armature roasted

4. Does not run

Shorted armature coil

Replace mature

Check for machine

Replace armature and possibly rear end bell assembly

overload

Worn brushes or brush hung up

Replace or reiease brushes and check commutator

5.

Doesnotrunorruus fast

Open armature connection

Replace armature

6.

Motor runs in wrong direction

Reverse motor connections

Correct. connections

-17-

PT & PTT-5

DRIVE

(TRACTION)

MOTOR

- 24 VOLT

ibg Band, Cover Head Assembly

wwset,~

2 1 1

srushset,.@rvice Holder,Brush

:

h3hef, sprltlg Bearing, Ball TerminalStud Package coil. FieldPackage

: 1 1

SCW,POltdbOPaElcage

scmw,Poleshoepackage

: : 1 Y

:: 13 14

-18-

PT & PTT-5

DRIVE

(TRACTION)

MOTOR

- 12 VOLT 9

Rem # 1 f

4 B” 8’ 8A 0 ::

12 13 14

#for

NW

A-Y*

Band, Ccvw Head Assembly Washer, Spring kminal Stud Pkg. Plate, BNsh Bnah Set Spring Set, Brush Beating Cover, Bearing Coil Field Package Screw, PoleshoePkg. Annawe Seal, Oil Head Assembly Bearing

-19-

1 1 1 : 1 1 1 ‘1 1 : 1 1 1

PT & PTT-7 DRIVE (TRACTION) MOTOR - 24 VOLT

Item # 1 3 5” 6 7 8 9 10 11 12 13 14 15

It for

Name

J-Y.

Cover, band Cover End head assembly Spring, brush Brush holder Washer, spring Bearing Field coil package Terminalstud package Brush set Armature and f&n zzer band seal, ‘oil Befiring

-2o-

2.0

Drive Motor - PT & PTT-5 12v

2.2 Minimum Brush Length 2.3 Minimum Commutator Diameter 2.4 Brush SpringTension

2.5 Field Coil Resistance 2.6 Part numberof:

2.0

24V

g/16”.

. g/16" 2.875 2.75" 30-36oz.

30-36oz. .0062-.0070 ohms .0076-.0086 ohms

Drive Motor - PT 8 PTT-7

2.2 2.3 2.4 2.5 2.6

MinimumBrush Length MinimumCommutatorDiameter Brush SpringTension Field Coil Resistance Part numberof:

91i6”

2.75" 30-36oz. .0076-.0086 ohms

-21-

6 .O

EV-100 OPSRATION.

BASICS OF CIRCUITOPERATIONS The control circuit is energixed by closing the key switch, seat switch and moving the forward or reverse lever to either position and then depressing the accelerator closing the start switch.

This applies power to the control card turning on the PET driver, which will close the selected directional contactor and complete the circuits to the drive motor. (See elementary drawing. > The control card then supplies a Sate pulse to 2RECturning it on to a conducting state, allowing current to flow from the battery through lC, 1X, 2REC, motor field, motor armature, sensor, and back to the battery.

After 1C charges, 2REC shuts off, due to lack of holding current.

The control card checks that 1C is charged and unlocks the gab to 1RECand SEC. The control card then supplies a gat8 pulse to 1FEC turcing it on to a conducting state, allowing current to flow from the battery through WC, and allows current to flow T4-T3,lC, lREC, WC, to T4-T5. This current charges the bottom of 1C positive with respect to the battary positive bus. This charging cycle 0ccurS in 1eSS t&n 1 BIilliS8COnd ( .OO 1 see. > and 5RECshuts off.

This charge is now stored on the capacitor until it is time to turn off 1REC. Current continues to flow in 1RECuntil the control tiara fires 2REC. WhenZREC .conducts, capacitor ?C discharges around the circuit composed of lC, 2REC, 1X, and 1REC. This diSCharge Current opposes the battery current through 1RECso t&at theresultant current is zero.

With reverse voltage across lREC, 1RECis turned.off.

Current continues to flow in the 2REC, lC, motor and battery loop until the capacitor (card terminal 14) is fully charged negative.

This charge exceeds battery voltage by an amount which is a function of peak motor current, and ZXEC turns off l

During the off time, the energy stored in the motor, by virtue of the motor ( s inductance, uill cause current to circulate through the motor around the loop formed by 3REC, Thus,providing at is called “flyback current”.

It should be noted that the average motor current measured will be greater than the average battery current.

The SCR control, in effect, COnVertS battery current at battsry volts into a higher motor current and a lowermotor volts.

The time for the next ON and OFF cycle to start is deterxined by the time that the control card takesto oscillate.

This frequency of oscillation is

controlled by the potentiometer in the accelerator and automatic circuitry in *Slow speed is obtaIned by having maximumohms in the potentiometer. the card.

As the resistance in the potentiometer decreases, the speed of the motor The SCR circuit is capable of delivering For full speed operation, the 18 contactor is closed voltage across the motor.

increases.

approximately 95% speed. to apply full battery

CONTROL FEATURES OSCILLATOR- the Oscillator section of the card has two adjustable features and one fixed feature. With the accelerator potentiometer .at maxiam ohms, the creep speed can be adjusted by tha “creep” trlmpot on the card. Top speed is flxed by card design, and is Obtained with the accelerator potentiometer at The S ON time has a range of approximately 5 to 95 percent.

The minimum ohms. ctnter operating condition of the oscillator is at 50 percent ON time with a

-22-

nominal 1.8 milliseconds ON time and 1.8 millisecond OFF time. This corresponds to a maximumoperating frequency of about 300 hertz.

At creep the ON time will decrease to approximately 0.8 milliseconds while OFF time will become in the order of M milliseconds.

At full SCR operation, this condition will he reversed (short OFF time, 'long ON time). This variation of ON and OFF time of the oscillator produces the optimum frequencies through the SCR range.

The rate at which the oscillator may increase its percent ON time is limited by Wontrolled Acceleration”.

The minimumtime required to go from creep apeed to 80-852 on time point may be varied by trimpot (C/A) on the card, adjustable from approximately 0.5 seconds to 3.54.5 seconds. .

CURRENT LIMIT - This circuit monitors motor current by utilizing a sensor in series with the armature.

The information detected across the sensor is fed back to the card ao -current may be Umited to a preset mlue.

If heavy load currents are detected, this circuit overrides oscillator snd llmlta the average current to a Palue set by the C/L adjustment pot.

The C/L setting is baaed on the maximumthermal rating of 1RECand the peak voltage on the capacitor.

Because of the flyback current through 3REC, the motor current usually runs 2 to 3 times battery current.

The current limit is set with the V/Lo trimpot on the card.

PLUGGIBG - Slow down ia accomplished when reversing by providing a small amount of retarding torque for deceleration.

If the vehicle is moving the directional lever is moved from .One direction to the other, the motor field la reversed’.

The plug signal la initiated by the fact that the directional switch has moved from one directfon to the other.

The motor srmature, driven by the inertia of the vehicle, acts aa generator.

This generated current passes through 4REC and The oscillator circuit regulates at a plug current limit level aa the sensor. set by the plug trimpot on the control card. This controls the pulse rate 1REC to. regulate the generated motor current and bring the truck to a amooth atop and The accelerator potentiometer input will modulate plugging current. reversal.

With the accelerator potentiometer at minimumresistance, the plugging trimpot will enable adjustment of .plugging current from max to min. current level.

With the accelerator potentiometer at maximumresistance, the’ plugging current will be reduced. full SCRtorque to restart a vheicle on an RAMP START- this feature protides incline.

The memory for this function is the directional switch. When stopping on a0 incline, the directional switch must be left in its original or off position to allow the control to assure full power when restarted.

The accelerator potentiometer input will modu.late ramp start current.

PULLPOWER TRANSITION - this feature provides bypass. This is accomplished the contactor

smooth transition

has two modes of control:

this feature with potentfometer the acceleraWhen the accelerator potentiometer la activated so that accelerator? tor. voltage is reduced to 0.5 volt or leas, the 1A time is enabled. The time delay pickup of lA is provided by a circuit in the card. This allows the truck to accelerate through the SCR range until 1A picka up, even if the accelerator potentiometer is actuated immediately.

The time delay is ad justable by means of a 18 time trfmpot on the card.

-23-

2.

If motor current is reduced during cutback to a point uhcra 1A pickup would cause a severe torque increase, the 18 timed pickup function will be disabled.

STATIC RETURN To OFF - this built-in featti of the control is set up to make the driver return the directional lever to neutral anytime he leaves the vehicle and returns.

If the seat switch or key switch is opened, the control will shut off and cannot b8 restarted uutil directiodal lever is returutd to neutral.

A time delay is built into the seat switch input, .75 second, to allow momentary opehing of the saat witch if a bump is encountered.

COIL DRIVERMDDULRS - these modules are’located typically on the contactor portion of the control.

They are the power devices that operate F, R, 18, FU and These modules open or close these coils on commandfrom the RR contactor coils. control card. All qodules are equipped with reverse battery protection in that if the battary is conuected incorrectly, non8 of the contac?xrs controlled m be closed electrically.

THERMAL PROTRCTGR - (TP) - this temperature stnsitfve device is mounted in the 1REC h8at sink.

If the 1RECtemperature begins to exceed the design limits, the them protector will lower the maximumcurrant Unit and not allow 1RRCto exceed its temperature Wts. Even at a reduced current limit, the vehicle till uomally be able to reach sufficient speed for full 18 operation, thereby allOWinS the -81 t0 COOl. As the panel cools,-the thermal protector will ~autoamtically return the control to full power.

18 TRERMAL BOLDOFF - this feature prevents 18 contactor from closing uhen the truck is in aever thermal cutback to avoid torque juntas. When t&e control goes into sBver8 cutback, the. must pulse to time witi inhibit the 1A timer.

MUSTPULSEMTIME - this feature prevents the 18 timer from timing if the oscillation pulse rate has not reached a particular level of operation.

FIELD UEAIERIRG(optional) - if the vehicle is supplied with a field .weakening circuit, the FU PU and FU DG trimpot adjustments will be on the SCR control Field weakening is a method of attaining higher zmning speed for the card. vehicle in level operation.

The normal settings for this feature are: pickup of FU contactor from 125 to 150 percent of normal full-load running current (la), and dropout of FU contactor from 275 to 300 percent current.

The dropout puts the motor back to the 1A range to climb ramps and inclines.

VCLTAGE - batteries uuder_load, particularly if undersizedor more than 80 percent discharged, will produce low voltages at the SCR control terminals.

The W-100 control is designed for use down to 50 percent of the nominal battery Lou battery volts may cause the control to not operate correctly but the volts.

PMTshould open the F or R contactor in the event of a commutation failure.

LOU

-24-

7.0

Troubleshooting

- Electrical

l?ote: Troubleshooting chart is to be used in conjunction with wiring schematic for the individual truck.

Battery must be fully charged before testing.

Unless otherwise specified, all-tests measure voltage with the volt meter negative lead connected to the battery negative cable.

7.1

Dead Truck 7.11 Nothing operates.

7.111

Condition

for test:

Check battery

voltage

Battery plugged in,

key switch on.

at:

1.

Positive side of control circuit breaker or fuse. ’ 0 volts - repair open wire from battery to circuit breaker.

2.

Negative side of control circuit breaker or fuse.

0 volts - replace control circuit breaker or fuse.

3.

Positive side of key switch.

0 volts - repair open wire from control breaker to key switch.

4.

Negative side of key switch.

0 volts - replace key switch.

5.

Positive side of lift, lower, horn, foot switches, and brake switches.

0 volts - repair open wire from key switch to the respective switch.

6.

Negative side of lift, lower, horn, foot switches and brake switch. faulty switch.

0 volts - replace respective

-2%

circuit

7.2

Electric Brake Control - PTT-5 8 PTT-7

7.21 Brakewill not release,horn works.

7.211 Condition.for test: Batterypluggedin, key switoh alosed,foot switchclosed. .

.

Test for batteryvoltageat: 1.

Positiveside of foot switch.

0 volts - repairopen wire from key switchto foot switch.

2. Negativeside of foot switch.

0 volts - replacefoot switch.

7.22

3.

Positiveterminalof time module.

0 volts - repairopen wire or replaoeopen diode from foot switohto time module.

4.

B terminalof time module.

Battery*volts for 5 secondsafter closingof foot switch,if not replacetime module.

Note: In the proceedingtest you will have battery volts for 5 secondsafter closingof foot switch, after 5 secondsit will go to 0 volts.

5.

Positiveside of brakecontactorcoil.

0 volts - repairopen wire from time module to brake contactorcoil.

6.

Negativeside of brake contactorcoil.

0 volts - replacebrake contactor.

Batteryvolts - repairopen wire from brake contactor to batterynegative.

Brake released,then appliesafter 5 seconds 7.221

Conditionsfor test: Batterypluggedin, key switch closed,foot switchclosed.

Test for batteryvoltageat: 1. A terminalof time module.

0 volts - replacetime module.

2.

Positiveside of brakesolenoidhold in coil.

0 volts - repairopen wire from time module to brake solenoidhold in coil.

39

Negativeside of brake solenoid.

0 volts - replacebrake solenoid.

Batteryvolts - repairopen wire from brake sole&id to batterynegativeor replacetime module.

-26-

7.3

Electric Brake Pull-In Power - PTT-5 & PTT-7 7.31

Condition for test: foot switch closed.

Test for battery 1.

voltage

key switch closed,

at:

Positive side of power circuit breaker.

0 volts - repair open wire from battery cuit

2.

Battery plugged in,

to

power

cir-

.

Negative side of power circuit breaker. volts - replace power circuit breaker.

0

Positive side of brake contactor.

0 volts - repair open wire from circuit brake contactor.

breaker to

4.

Negative side of brake contactor.

0 volts - replace brake contactor.

5.

Positive side of brake solenoid pull in coil.

0 volts - repair open wire from brake contactor brake solenoid pull in coil.

6.

Negative side of brake solenoid pull in coil.

0 volts - replace brake solenoid.

Battery volts - repair open wire from brake solenoid to battery negative, or replace time module.

-27-

to

7.4

Travel Control - PT Resistor Trucks 7.41

No forward- oontactordoes not pick up.

7.411

Conditionfor test: Batterypluggedin, key switch closed,brake switchclosed,master switchactivatedto forward.

1.

Positiveside of brake switch.

0 volts - repairopen wire from key switchto brake switch.

2.

Negativeside of brake switch.

0 volts - replaoebrake switch.

3.

Positiveside of reverserswitch.

0 volts - repairwire from brake switchto reverser switch.

4.

Negativeclosedside of reverserswitch.

0 volts - replaoereverserswitch.

5.

Positiveside of forwarddirectionalswitch.

0 volts - repairopen wire from reverserswitchto forwarddirectionalswitch.

6.

Negativeside of forwarddirectionalswitch.

0 volts - replaceforwarddirectionalswitch.

7.

Positiveside of forwardcontactorcoil.

0 volts - repairopen wire from forwarddirectional switchto forwardcontactorcoil.

0.

Negativeside of forwardcontactorcoil.

0 volts - repairmechanicalbindingof contactor.or replacefaultycontactorcoil.

Batteryvolts - repairopen wire from negativeside of forwardcontactorcoil to batterynegative.

7.42 No reverse- contactordoes not pickup- forwardoperatesok.

7.421 Conditionfor test: Batterypluggedin, key switch closed,brake switchclosed,masterswitchactivatedto reverse.

Test for batteryvoltsat: 1. Positiveside of reversedirectionalswitch.

0 volts - repairopen wire from brake switchto reverse directional switch.

2. Negativeside of reversedirectionalswitch. switch.

0 volts - replace reversedirectional 3.

Positiveside of reversecontactorcoil.

0 volts - repairopen wire from reversedirectional switchto reversecontactorcoil.

-28-

Negative side of reverse contactor coil.

0 volts - repair mechanical binding of contactor replace faulty reverse contactor coil.

Battery volts - repair open wire from negative side of reverse contactor coil to battery negative.

4.

7.43

No second speed - forward and reverse 7.431

volts

at:

1.

Positive side of second speed switch.

0 volts - repair open wire from brake switch to second speed switch.

2.

Negative side of second speed switch.

0 volts - replace second speed switch.

3.

Positive side of second speed time delay (if equipped 1.

0 volts - repair open wire from second speed switch to second speed time delay.

4.

5.

6.

No third 7.441

ok.

Conditions for test: Battery plugged in, key switch closed, brake switch closed, directional switch closed, second speed switch activated.

Test for battery

7.44

operates

.

Negative side of second speed time delay.

0 volts - replace second speed time delay.

Positive side of second speed contactor coil.

0 volts - repair open wire from second speed time delay to second speed contactor coil. . Negative 0 volts

side of second speed contactor coil.

- repair mechanical binding of second speed contactor or replace faulty second speed contactor coil.

speed - forward,

reverse

second speed operator

ok.

battery plugged in, key switch Conditions for test; closed, brake switch closed, directional switch closed, second speed contactor closed, foor switch (3rd speed switch w/optional 4th speed) activated.

Test for battery 1.

2.

volts

at:

Positive side of foot switch (3rd speed switch w/optional 4th speed).

0 volts - repair open wire from key switch to third speed switch.

Negative side of foot switch (3rd speed switch w/optional 4th speed).

0 volts - replace third speed switch.

-29-

7.45

3.

Positive side of third speed time delay.

0 volts - repair wire from third speed switch to third speed time delay.

4.

Negative side of third speed time delay.

- replace third speed time delay.

0 volts

5.

Positive side of second speed interlock switch.

0 volts - repair open wire from third speed time delay to second speed interlock switch.

6.

Negative side of second speed interlock switch.

0 volts - repair mechanioal operation or replace faulty second speed interlock switch.

7.

Positive side of third speed contactor ooil.

0 volts - repair open wire from second speed interlock switch to third speed oontactor coil.

8.

Negative side of third speed contactor coil.

0 volts - repair mechanical binding of third speed contactor or replace faulty third speed coatactor coil.

No fourth speed - forward, operator ok.

7.451

reverse,

second speed,

third

speed

Conditions for test: Battery plugged in, key switch closed, brake switch closed, directional switch closed, second speed contactor closed, third speed contactor closed, fourth speed switch activated.

Test for battery

volts

at:

1. Positive side of foot switch.

0 volts - repair open wire from key switch to fourth speed switch .

2.

Negative side of foot switch.

0 volts - replace fourth speed switch.

3.

Positve side of fourth speed time delay.

0 volts - repair wire from fourth speed switch to fourth speed time delay.

4.

Negative side of fourth speed time delay.

0 volts - replace fourth speed time delay.

5.

Positive side of third speed interlock 0 volts - repair open wire from fourth delay to third speed interlock switch.

6.

Negative side of third speed interlock switch.

0 volts - repair mechanical operation or replace faulty third speed interlock switch.

-3o-

switch. speed time

side of fourth speed contactor c?oil.

0 volts - repair open tire from third speed interlock suitch to fourth speed contactor coil.

7.

Positive

8.

Negative side of fourth speed contactor coil.

0 volts - repair mkoiianlcal binding of speed contactar or replace faulty fourth speed aontactor coil. attery volt8 - repair open wire from negative side of fourth speed contactor aoil to battery negative.

-31-

ELECTRICAL SCHEMATIC

am

,oo

i -

-32-

PT-5

ELECTRICAL

SCHEMATIC

Ir

-

I

--

I L

-33-

/

I

PTT-5

RESISTOR

ELECTRICAL

carrrn-

BATTERY

I

m . .. .

-

II WM

A

I

SCHEMATIC

PTT-7

RESISTOR

BATTERY

ELECTRICAL

SCHEMATIC

4

. . .

P

cma -

OPTIONAL

1 I :> I J

!

1

7.4

EV-100 Maintenance Instructions The SCR oontrol, like all electrical apparatus, does have some thermal The semiconductor junctions have finite temperature limits losses. above which these devioes may be damaged. For these reasons, normal maintenance should guard against any-action which will expose the components to excessive heat, such as steam cleaning; or which will reduce heat dissipating ability of the control, such as restricting air flow.

The following

DO‘S and DONT’S should be observed:

Any controls that will be used in ambients of lOOoF (SOOC) or over should be brought to the attention of the truck manufacturer.

All external components having inductive coils must be filtered.

Refer to vehicle manufacturer for specifications.

The oontrol

should not be steam cleaned.

In dusty areas, use the control.

In oily or greasy areas, a mild solution of detergent or denatured alcohol can be used to wash off the control and then blow completely dry with low-pressure air.

The control oan also be cleaned with Freon TF degreaser .

low-pressure air to blow off

For the SCR panel to be most effective, it must be mounted against the frame of the truck.

The truck frame, acting as an additional heat sink, will give improved truck performance by keeping the SCR control package cooler.

The use of a heattransfer grease (Dow Corning 340) is recommended.

Terminal boards and other exposed SCR control parts should be kept free of dirt and paint that might change the effective resistance between points.

CAUTION : The truck should not be plugged when the truck is jacked up and the drive wheels are in a free wheeling position.

The higher motor speeds can create excessive voltages that can be harmful to the control.

Do not hipot (or megger) the control.

Unless the terminals of each semiconductor and card are connected together, the control may be damaged. Refer to control manufacturer before hipotting.

Use a lead-acid battery with the voltage and ampere hour rating specified for the vehicle.

Follow normal battery maintenance procuedres, recharging before 80 percent discharged and with periodic equalizing charges.

-36-

TROUBLE-SE?GOTING INSTRUCTIONS The pulsing of the main SCR is too fastfor conventional instruments to measure.

When the controlis functioning properly, a low burp can be heard.

Malfunctions

of the SCR will generallyfallinto one of tm categories.They are either00 power (Table1) or fullpower(Table21, when operatingin the SCR range.

These simple and’

easy-to-follow tables corrective actionto be taken.

outlinethe varioussymptomsand the

The same devicedesignations have beenmaintained on different controlsbut the wire numbersmay vary. Referto the elementary and wiringdiagramsfor your specificcontrol. The wire numbersshownon the elementary diagramwill have identical numbers on the corresponding wiring diagram for a specific truck,but thesenumbersmay be different from the numbersreferenced in thispublication.

WARNING: Beforetrouble-shooting, jack up wheels,disconnectthe batteryand dischargecapacitor1C. Reconnect the batteryas needed for the specificcheck.

If capacitor IC terminals are not accessible, discharge capacitor by connecting from SCR POS terminalto 2REC anode. Checkresistance on Rx1000 scale irom. 'frameto SCR power;ufrd control terminals.

A resistance of less than 20,000 O&IS can cause misleading mptoms.

Resistance.less than 1000ohms should be corrected first.

Before firoceeding,

visually check for loose wiring, maladjusted linkageto the accelerator switch,sign of.overheating of co~onents,etc.

Toolsand testequipment required are: (a) 6-voltlamp, 6-voltvattery,two At4 diodes(1 Amp SOOV),clip leads,volt-ohmmeter (20,000ohms per volt) and general hand tools.

-37-

FUNCTION OF EVIOO CARD’ (Dl) TERMINALS FOR CLARK PART NUMBER 913783 (Voltage measurements with respect to NEGATIVE, SCR Power Terminal) [ Dl CARD ONLY ]

Term SCR TBl

SCR TB2

Condition

DescriRtion

aad accelerator at creepspeed Key on and accelerator at top speed

Accelerator Potentiometer input

Key on

Key or suat Switchopen

SRO input, accelerator start and brake suitch

input. nustbe high afterTB4 and TB3 are at batteryvoltsand while TBS and TB6 low.

Key or

mat

Key switch open Key closed

SCBTB4

Card power supply inputmustbe low tc satisfyPMT reset

Key

PB1 PB2

Directional'switch input frompositiveside of "F" coil.

0

0 B.V. 0.

Key closed

B.V.

Key open

0

brake and directional ‘F” switch closed

B.V.

Key open

0

Key,

brake,

and

directional "R= switch closed

B.V.

Creepspeed speed

2.5 6.5

I?0current 500 amps average motor current

1.80 3.30

on time output (seenote 11

%

Motor current sensor

open

Key,

Directional switchInput f'rom positiveside of "R" cofl.

output

0.5-O

B.V.

Key switch input

SCR TB6

3-4.0

Switchclosed

SCR TB3

SC8 TB5

Voltaue

Top

-38-

TCZI PB3

rkscriutfdd

Condition

Fv Driver Output

Pu

contactor open

1A closed

PB4

PBS

outputto 1A drive

Pm

Driven

Key Key,

U&x

speed

orr

seat and SaO satisfis

IA Contactor

Output

Voltaqt

Open

Top SCB speed PB6

Plugging.

PA2

Not Presently

Used

PA6

Not Presently

Used.

TRIMPOT

output

Not plu&ng mode Plugging Mode

LOCATION FOR EVlOO LOGIC (Di) CLARK PART NUMBER 913783

-39-

0.0 S-10

u-&up

0.0 s-10

b!-Amp

0.0 s-10

K-Amp

‘0.0 v 12 volt

CARDS

TRIMPOT LOCATION FOR EVIOO LOGIC CLARK

PART

NUMBER

(Rl)

CARDS

912079

Panels are factory adjusted for a particular motor,and truck and should not need adjustment. The card is suppied with single turn potentiometers,with internal stops and the box is marked with "dial" settings.

The vehicle manufacturer should supply the "combination" setting for the particular model truck.

With a new card, turn all pots fully CCW to "1". Then set each pot to the setting for the particular truck.

Turning pots CU increases the particular function (i.e., CW adjustment increases creep speed, acceleration rate [C/Al, C/L, 1A TIME, stiffness of plug, FW PU and FW 00, stiffness of Regen reversal).

-4o-

PTT-7 PTT-7

EV-100 EV-100

SCR SCR

2-SPEED 3-SPEED

-41-

CONTROL CONTROL

PANEL PANEL

I

I.

L

.

FUNCTION

(Voltage

OF EVlOO CARD (Rl) TERMINALS CLARK PART NUMBER 912079 measurements with respect to NEGATIVE, SCR [ Rl CARD ONLY ]

FOR Power

Terminal)

I NOMINAL DESCRIPTION CONDITION 1 VOLTAGE I ______~__f-----~-~~~~~~~--~~~~~~~~~ I-w------I~~~~~~----~~~~-----~-~~~TER"1NAL JACCELERATOR POT INPUT TBl . iWITH KEY SW. OFF ov WITH KEY SW. ON AND ACC Q I I-CREEP SPEED 3-4.ov I I-TOP SPEED 0.5.ov I I i lSR0, ACC START, AND BRAKEIKEY, SEAT, START, OR TB2 I ov, ISW. INPUT. MUST BE HIGH I BRAKE SW. OPEN I IAFTER TB3,4 ARE AT BV AN01KEY. SEAT. START. BRAKE I BV ITB5,6 ARE LOW. f SW; CLOSED I 1"'" SWITCH INPUT TB3 1W;;FNKEY CLOSED, AND SEAT ov I

I I TB4

TB5

1

IKEY SWITCHINPUT ItMUSTGO LOW TO RESET I Pm) I lFWD DIRECTIONAL SWITCH IINPUT I

TB6

I I I REV DIRECT1ONAL SNITCH

PA1

I'"'"' I I IRB DRIVER OUTPUT

PA2 PA3 PA4 PA5

PA6

I

l(NOT PRESENTLY USED) I IREGENERATIVE BRAKING IINPUT SIG%U. I lRB SENSOR #2 INEGATIVE SIGNAL I IRB SENSOR 612 IPOSITIVE SIGNAL

IWITH KEY CLOSED, AN0 SEAT I CLOSED I' IWITH KEY SW. OPEN. 1WITHKEY SW. CLOSED

ov BY

I IWITH KEY,'SEAT, START, IAND BRAKE CLOSED, AND I-FWD IN NEUTRAL(OR REV) (-FWD SELECTED(F CLOSED)

ov BV

IWITH KEY, SEAT, START, IAND BRAKE CLOSED, AND I-REV IN NEUTRAL(OR FWD) I-REV SELECTED(R CLOSED) I IWITH KEY SW. OPEN IWITH KEY SW. CLOSED(RB I CLOSED) ----w

f

BV

ov BY IO IS-10 M/A

I

ISCR RUN MODE(RB CLOSED) IREGEN MODE(RB OPEN) I

I

1””

I

MoDES

I 1

_____ OV BV

Bv

I I BV I lALL MoDES lNOTE:VOLTAGEDROP PAS-PA41 VARIES IDURING REGEN ONLY I By Irn I _____ I _____ I I

1 I I(NOT PRESENTLY USED)

-43-

OF EVlOO CARD (Rl) TERMINALS FOR CLARK PART NUMBER 912079 (Voltage measurements with respect to NEGATIVE, SCR Power Terminal) [ Rl CARD ONLY ] I NOMINAL I ” DESCRIPTIOti CONOITIOtJ ‘I “’ FUNCTION

--------TERM1NAL t~-~~-~~~~~~--~~~-~~~~~~~~ I~~~----~--~~~-~~~~~-~~~~~ I_________ VoLTAGE i% O~bTItlE'OUTPUT CREEP SPEED I 2.5Y PBl TOP SPEED I I 6*5y I IMOTOR CURRENT SENSOR I l.BOY 0 MOTOR CURRENT PBZ 500A AVG MOTOR CURRENT IOUTPUT I t 3*30v ;FW DRIVER OUTPUT PB3 NO FW DEMANO(FW DROPPED OUT) I O FW DEMAND(lA PICKED UP, IS-10 M/A I HOTOR CURRENT AT FWPU I I SETTING(M PICKED UP) I

PB4

1

iPMT DRIVER OUTPUT

KEY, SEAT, START, BRAKE SW. CLOSED-FWD OR REV OPEN -FUD OR REY CLOSED (F-OR R CLOSED)

I

PBS

I I II A DRXYER OUTPUT

NO IA DEMAND(\A DROPPED OUT) jlA DbAND(TB1 Q .SY) 1 (1A CLOSED)

I PB6

I

1 [PLUGGING OUTPUT

INOT IN PLUGGING MODE IIN PLUGGING MODE

-44-

I i

0

I”-‘” M’A i O I

15-10 M/A I

I I 1

ov

12Y

ALL TESTING SHOULD BE DONE WITH TRUCK JACKED UP AND BLOCKED. Troubleshooting is based on the use a voltmeter to determine if “adequate” voltages are available for proper control operation.

TABLE I SxMPTon

PROBABLE

CiUSE

18. Contactors do not pfck.up. Bo controlVoItagefmm postiw to he&fw.

l

Checkpowerand control fames.

l

Checkbatteryfor low specific gravityand couuectioas for loosenessor brokenfittings.

?B. Contactors do uot pick up.

Controlvolts present frorp positiveto negativewith properpolarity.

4 Plug in the batterywith the Key switch OFF. Volts on TB4 shouldbe less than4 volts.

I)CloseKey switchand checkvolts at T2, Volt3shouldbe about50% battery volts. If above855 of battery volts, deck for shorted IA tips .or shorted 1EEC. ?

Closebrake,key switches(all svitchesneededto closeF or R contactor except the direction switch). Voltsou TB4, TB3, aud TB2 shouldbe at battery volts.

Voltson TBS and TB6 shouldbe near zero

volts.

Wait one second,

then

closethe forwarddirectional switch. Voltsat TB6 shouldremaili at zero. .Volts at TB5 and t&e TB5 side of the F contactor coil should be batteryvolts. If not, check the wiringand swftches. l

Connecta milllameter(10 mascale) from PMTDlto PMTDZ,you should read 5-10milliaups.If not, opeu the Key switch, open the lead from PHTDlto the PMT driver,nclose all the switches exceptthe directioualswitch,wait one secondand closethe forwarddirectional switch. If t&e readingis not S-10 milliamps,replacethe control card. If the readingis 5-10 milllamps,replace the control card.

If the reading Is 5-10

milliamp3,the coilor the wiring to the PMT driver is open or the Peltdriver is defective.Check the PMT driver.(4E) -45-

STMPTOM close.

NO power and NG SCR hum with accelerator ia SCR

1C Contactors

ma

PROBABLECAUSE -___ ~_--W~4 Checkpowerfuseat BCR positive Shouldbe batteryvolts,If not, checkpower fuse. .

Checkvoltsat T2. Shouldbe zero, not, checkvoltsat Sl,S2,Al and A2 to locateopen circuit. if

4

Checkvoltsat TBI, shouldbe 3-4 voltswith accelerator at creep speedand reducingto 0.2 voltsor less as the accelerator is pressed down towardstop speed. If TBl remainsat about4 volts,check accelerator output.

Checkfor au open thermal protector.(4J) Check 1C voltsit the or&go wire, if more than0.125timesthe battery volts,checkif 2RECwill gate ON. (4G) If less than 0.125 times the batteryvolts;checkif 1REC will gateON. (4G)Check the green lead on the currentsensorfor a good connectionto card inputpin 4.

t .*

1D

-I Check3REC for open circuit. (4HI

l

Check4REC for short circuit.(4HI

---

--

1E

Con&actorsclose. Littleor no power.AbnormalSCR hum.

--

~-----III---~~~~~ l

Check2REC for short circuit. (4G)

+

CheckSREC for shortcircuit.(4G)

4

Check22.9EC and 25REC. (4MI Note: A 2SRECwhichchecksgood with au ohmmetercan causea c&-operation of SREC underload.

l

Check 1C for low resistance.

(4B)

~-----------__-__________-_______

-_----II-----

1F

Replace the control card.

l

-----c--I-

Ccntactorsclose. Littleor n0 payer. NormalSCR hum.

Check23FILfor short.(4K)

Co&actors close. LiZ No BCR hum.

power.

-46-

--1G

lH

SmPTon

PROBARLR CAUSE

--

One contactor closes with normal operation but opposite contactor will not close.

l

PMTtrips after operat* in IA and with accelerator is returned

--Close key, brake aad start switches (all switches needed to close F or R contactor except the direction Volts on TBS and TB6 switch). should be near zero volts. Wait one second, then close the directional switch of the contactor that Volts at the other till not close. direction input (TB5 or T86) should Volts at the rnmain at zero volts. non-closing direction (TBS or TB6) Volts should remain at zero volts. at the non-closing direction (TBS or -TB6) and top of ‘the contactor coil should be battery volts.

If not, check ulriq and ‘sultchcs.

l

tOSCRRU.lga.

-47-

Check for cause of long 18 dropout time, i.e., defective 18 driver, low resistance in 1A filter, shorted turnsinlAooll, or low voltage coil.

ALL TESTING Failures

SHOULD, BE DONE WITH TRUCK JACKED UP AND BLOCKED. that cuase FULL or NO motor torque with SCR control.

TABLE

2

SYMPTOM

28

PROBABLECAUSE

Contactam close.Full SCB speed immediately with audible hm. Ho PMT trip.

4 Key switch on.

Check volts at TBl, (PA3 for L card) should be 3-4 volts with accelerator at creep speed postion.

Sf near zero volts, check accelerator output (5000 ohms or 4 volts depending on type of accelerator switch) + Replace

28

Contactor close

once or twice

and thenremainopen.

PMT

controlcard.

4

CheckSREC for open circuitor open gate. (4G)

l

Check 1C for open and loose conneotiozm(4B)

4

Check

l

Check2REC for short.(4GI

trips

1C for short.(4B)

4 CheckSREC for short.(4G) l

Check 1X chokeand reactor

.IICheckPA3 uire for open Utegen circultonly) # Replace control 2c

Co&actors close.Stallcurrent, SCR operation, higher than normal and uncontrollabe with under

C/L trimpot.

once or twice

Input pin 3.

l

and then remain

-48-

(4A)

I)Checkcurrentsensoryellowlead from negativeend of sensorto card

Contactors may open .

open.

card.

Replacecontrolcard.(4AI

ALL TESTING

SHOULD

BE DONE WITH TRUCK JACKED UP AND

BLOCKED.

Misoperation of other features.

TABLE 3 sYMPMn 3a

PROBABLECAUSE

1A or FU contactors

key switch.

close

with

l

Check drivers for short from terminals 2 to 3 by dfsconecting wires to terminal 1 on the driver.

(4R) Check pin 2 (brown wire)

tinuity

to negative.

for con-

Replace control 3B

.F or B contactor will close without returning t&e diractioual suit& to OFF.

l

l

card. (4A) --Check location of TR2. Any open switch betueen TR2 and the directional switch will satisfy the RR0 function.

Open the lead driver; Close used to. close If the F or R

fromPMIDlto

tbt

witches normally the F or R contactor. close,replace the

driver.

3C

PHT does not open F or R contactor.

3D

1A contActor will

l

Reconnect the lead to the driver.

Close the key suitch only.

Volts at IB4 should be battery Volts, volts at TR2, TB3, IB5 and TB6 should be near zero.

Close the seat, brake and start suitches.

Volts at TB3 and TB2 should be battery volts.

l

Replace control

l

not cl&e.

l

-49-

card. (4A 1

Operate the traction drive.

Jumper PHTDl to PMTD2.If contactor does not dropout replace Pl!T driver.

Connect a milliammeter f&i lAD1 to lAD2. Should read 5-10 mllliamps when the 1A contactor should be closed.

If near zero, see next step for improper input or control card. Check volts at lAD3, should be battery volts decreasing to about 2 Volts when the 1A contactor should be closed.

If near zero, check coil and wiring to lA3. If remains at battery volts, check uiring from PBS to lA1 and wiring from lAL2to negative, then replace 18 driver.

SYMPTOM

PROBABLE CAUSE

--_

3D

18 coatactor

(continued 1

-_w--

--_-___-___________WI-__

will

a If milliamps

lAD1 to lAU2 are near zero uhea the 1A contactor should be closed, open the lead from lAD1 to the &iver and recheck. If good, there is a wiring short to negative in the lead from

not close.

from

lAD1 or the driver

defective.

(4E)

is

Check the volts at TBl. reduce to less than 0.2 top speed. If over 0.2 check accelerator twitch 4

3E

18 contactor SC8 stall.

till

not close

Replace the control

-----m-

B-s---

at

card.(4A)

-I-II-uu---

s Check volts. at the GiUP lead to the thimal protector WI. If volts are above 3.4 volts t&e control is in themal cutback. Allou control to cool and recheck 18 function.

Turn 18 trimpot fully recheck.

Replace control

--a--

3F

18 will not open uutil switch is opened.

(4A) _wI-_____ Check volts at TBl. (PA3 for L card) Should be near 3 volts when accelerator is released.

If not check accelerator output.

start

l

-w-m

Fw contactor lA pickup.

uil.1 not close

C34 and

card.

---_-----

--

3G

Should volts at volts, output.

after

l

l

-5o-

----------~~~~-~~

Open lead to PVDl and counect zllliaumeter from Fnl to FVD2.

WheEcontrol signals PU to pick up, should read S-19 milllamps. If near zero, turn FW PU trimpot fully CY and recheck. If rellains zero, replace control card.

(4A) If reads 5-10 ma, reset m PU trimpot.

Reconnect lead to FWD 1 and check volts at PVDl uhen the PWcontactor should pick up. If near 8 volts, check lead EVD2 to negative for an open, then replace driver. If about 2 volts, check volts at FUD3.

Should be battery volts dropping to 2 volts or iess when PU contactor should pick up. If volts are near zero, check wiring from positive to FJ coil, PU coil and tiring to PUD3. If volts remain greater than 4 volts, replace. driver.

PROBABLE

SXMPTOM

3f;

Ew contactor will sot drop out with increasing load.

l

l l

35

Stiff

plug.

(Severe reversal)

l

l

CAUSE

Check drop out setting card.

on control

Check for shorted FWDdriver.

Replace control card.(4A) -Check plug adjustment setting control card.

Check yellow wire on current for open.

on sensor

Check 4RRCfor open circuit.(4H) Replace control

3K

Hourmeter feed faults:

(11

Pump contactor closes when dfrec tion is selected.

(2)

Ohe direction okay; opposite direction picks up both dlrcctfohal co&actors.

(3)

Either direction pioks up both direc tlonal contac tors .

3L

Very soft reversal

l

Diode shorted EKD3to EKD4. (4H) Replace hourmeter block.

Diode shorted ml to HMD4or RMD2to ElMD4.(4HI Replace hourmeter block a

l

l

l

3M

card, (4A)

Blown power -fuse.

Very hot power cables

l

-51-

Diode shorted HMO1to HMD4of m2 to mD4.(4H) Replace hourmeter block.

Check plug adjustznent setting control card.

on

Replace control card. (4A) -Check 3RRCfor shorL(4H) (Possible d&sage also _to 1RRC.I

CHECKING

COMPONENTS TABLE

48

4

Main SCR Control Card

All trouble-shooting is written to check all ou%fde devices and eliminate them as the source cf the symptoms. .ibe conclusion being then that the card if faulty.

1.

Instructfons

for Removal of Control Card.

.a. Remove control b.

c.

wires on the screw terminals 1 though 6 as required.

Unplug A, B, and z plugs by pressing dam on tab ulth wide blade screwdriver and rotating 90 degrees.

Remove the tuo mounting screws and lift card box free.

NOTE: d.

Mounting

Screw

Jo not attempt

to renove

Reverse procedures to install

circuit

new control

Terminals 1 - 6

A and B Plugs

-52-

board from card box. card.

2 Plug

Mounting Screw

4B

Capacitor

1C

Disconnect the battezy and discharge the capacitor. Measure ohms through the capacitor using the R x 10,000 scale. Meter should read zero and then swing slowly to above 100,000 ohms. Replace the capacitor if above reading Is not obtained.

4c

Co&actors

F, R, 18 and P

150 ampere coatactors 300 ampere contactors

4D

(see G&EL44691 .(see GEH-4469)

(1)

Control is arranged so that the F and R contactors do not break current.

Check to see that the 1A contactor drops out before the F or R contactor.

(2)

Most contactor coils are polarity sensitive. minal must be connected to positive.

Potentiomenter

The left-hand

ter-

in Accelerator

To check operation of the potentiometer, disconnect the battery and disconnect the wire at control card TRl. Connect a VGMto the wire that was removed from TB1 to negative. Place the VGMon teh R x .lOO scale. With the accelerator in the creep speed position, the ohms redfng should be 4800. to 6000 ohms. WLth the accelerator in the top speed position, the ohm reading should be 50 ohns or less.

With the wire disconnected as above, check fcr resistance of 1 .megohmor higher from pot uire to the truck frame.

4E

Coil Driver Module (1) Connect circuit as shown.

(2) Voltmeter .should read battery volts with switch open.

(3) Close switch and meter reading should be 3 volts or less.

(4) Move load to teFminal 4 and repeat steps (2) and (31.

4F

Hourmeter Module Check individual diode circuits trouble Ught or van. (4E)

yith

fm J

4

-53-

tam

4G

SCR’S (WC,

2REc, 5 REC)

controlled rectifiers. the battery and discharge capacitor 1C. SCR*s at the SCR terminal.

Before checking, disconnect Disconnect gate leads of

To check an S-CR,it diodes.

a 6 volt battery and 2 A-14

These are silicon

is

necessary

to

have

Connect the positive lead to the anode, connect the cathode as -shown below.

(1) The lamp should not light. and must be replaced.

the negative

If the lamp &es light,

lead to

the SCR ls shorted

test the SCR for its ability to be (21 If check (1) uas satisfactory, +nect positive through two diodes to the turned on by ‘the gate.

If the gate is operative, the lamp will come on and gate terminal. remain on when the gate is removed. Some SCR’s will operate correctly even if the lamp does not remain on, particularly with a weak battery.

(3) If the lamp does not light replaced.

under step (2) the SCR is open and must be

NOTE: -If you do not have a test light to check the SCRls as described above, they may be checked for shorts and opens by use of the KIM. ( 1) Measure resistance from anode to cathode (R x 100 scale 1.

If SCR is shorted (zero ohms), it must be replaced.

(2) Measure resistance from the gate terminal to the cathode and then from the cathode to the gate terminal (R x 100 If resistance reads either zero ohms (short) or scale). infinity ohms (open), replace the SCR. When reassembling SCR*s, refer to TAELE5.

-!54-

4H

Rectifiers(3RRC,4RRC,DiodeBlocks1 diodes, disconnect battery and discharge capacitor1C. When rectifiers, referto TAELR5. For 3RECand 4RKC,disconnectone lead or flexibleconnection.

When checking

replacing

48

Rectifiers(3RKC,4RKC,DiodeBlocks) (Continued) 3RKC and 4RKC are diodewith about7 to 12 ohms in the conducting dirsction (anodeto cathode)measureon the R x 100 scale,and 10,000 ohms or higher, in the non-conducting dire&Ion (cathodeto anode)measuredon the R x 10,000scale.

4J

ThermalProtectorWP) Removeboth thg GRAYand BLACKuiresfrom the "2" plug thatconnectsto the controlcard. Read the resistance between thesetwo uireswith the VCM set on the R x 100 scale. YOM shouldread 100 to 200 ohms if the 1RRC heatslnkIs at room temperature (23Cor EF). Set the VCH to the highest ohm scaleand read from eachwiresend to the lRKCheatsink, reading shouldbe infinity;

4K

FilterBlock (23FIL,etc.)

To check,disconnect all wiresfrom the filterblockand remove from panel.

With Vow on the R x 10,000,touchthe.leadsto the filterterminalstc chargethe filter. Aftera few seconds,reversethe meterleadsand the filterterminal.The VOM needlewill deflectand return to infiz;ty.

If this capacitoractionis not observed,replacethe filterblock.

4H

Filter

Block (23FIL,etc.)

Filter_ blocktest 4K is_@y to detectan open or shortedfilter. If the controlhas symptomsas in lE,interchaage 22RRCand 25 RKC and try again.

If the problem1s corrected, the old 2SRKCis marginalshouldbe replaced.

If the problem ls not corrected, ‘replace both filters.

4N

1X Chokeand ReactorT3-T4 Refer to panelwiringdiagramto locatewindings. With VCH on R x 1 scale,measure chokeor reactorwinding,readingshouldbe less than 1 ohm.

-55-

REPLACEMENT

OF

EVlOO

TABLE

COMPONENTS

5

When replacing stud semiconductors such as 3REC and 4REC it is uot necessary to torque these devices to a specific value.

The use of a heat-transfer lent) is recommended.

5a.

When replacing

grease (such as GE Versilube G-350-H or equiva-

module semiconductors such as lRRC, 2RRCor !5REC

Remove all module connectious.

(As required) Remove module by hacking out the tuo screws at the device sides.

Clean the insulator surface with a clean rag and isopropyl alcohol.

Inspect the insulator surface for tears or cracks.

If defective, replace.

Wipe a light layer of machine oil on t&e base and smooth the insulator into position.

NCTR: Insulator not required for 2RRC’and 5RRC. (5) Coat insulator with a light coat of heat-transfer grease similar to GE-350.

Be sure (6) Set new module on insulator and start screws back into base.

Ruu screus into base “finger to use the orginial screws and uashers. tight”.

Check that the bottom of the module is flat ag&.nst the insulator or base.

Alternately tighten the two screus by l/4 turu until firm.

(71 Replace alI connections removed iu Step 1.

(1) (2) (3) (41

5B

Capacitor ( 1.) Remove nuts from capacitor counections and remove wires.

(2) Remove hold down brackets aud lift out.

(3) ‘Reverse procedure to replace capacitor.

5C

22RRc, 23mc, and 25REC ( 1) Remove mounting screws and lift out.

NOTE : When replacing these devises,

same holes,

5D

as the inserts

use the or&ml hardware in the are used for electrical connections.

Reactor/Choke (1) Disconnect all lead&to the reactor.

(2) Remove the two mounting bolts and lift out.

Be sure (3) Set new reactor on SCR base and start screws back into base. to use the orignial screws and washers. Run screws into base “finger tight”.

Check t&t the bottom of the reactor is flat against the base.

Alternately tighten the two screws by % turn until firm.

(4) Replace all connections removed in step 1.

-56-

7.5

Coast Control Pm-5 7.51

No c!Q& 7.511

81 Pm-7

control,

forward/reverse

voltage

at:

1.

Positive side of coast control switch.

0 volts - repair open wire from key switch to coast control switch.

2.

Negative side of coast control switch.

0 volts - replace coast control switch.

3*

Positive side of jog switches (left and right).

0 volts - repair open wire from coast control switch to jog switch.

4.

Negative side of left and right jog switch.

0 volts on left or right switch - replace defective jog switch.

5.

Positive side of directional contactor coil for direction selected. . 0 volts - repair open wire or diode from jog switch to directional contactor coil.

No second speed in coast, forward/reverse when selected with directional switch.

7..521

ok.

Conditions for test: Battery plugged in, key switch closed, coast switch closed, direction selected with jog switch.

Test for battery

7.52

operates

coast ok, 2nd speed ok

Conditions for test: Battery plugged in, key switch closhd, coast switch closed, direction selected with jog switch, directional contactor closed.

Test for battery

voltage

at:

1.

Positive side of 2nd speed time delay.

0 volts - repair open wire or diode from jog switch to time delay.

2.

Negative side of time delay.

0 volts - replace time delay.

39

Positive side of 2nd speed contactor coil 0 volts - repair open wire froxti time delay to 2nd speed contactor coil.

-57-

7.6

Electrical 7.61

- Resistor

Dead truck, 7.611

Truck - Power circuits

no travel,

Conditions

no hydraulic

for test:

Test for battery

7.62

closed.

Battery plugged in.

volts

at:

1.

Positive side of power circuit breaker.

0 volts - repair open wire from battery power circuit breaker.

2.

Negative side of power circuit 0 volts - replace power cirmit

3.

Positive side of dire&ion contactor and hydraulic oontactor .

0 volts - repair open wire from power circuit beaker to respective contactors.

No forward travel-contactors 7.621

contactor

Conditions for test: actor closed.

Test for battery

positive

to

breaker. breaker.

closed.

Battery plugged in,

voltage

forward cont-

at:

1.

Normally open side of forward contactor tips.

0 volts - replace tips or repair contactor.

2.

Al on drive motor armature.

0 volts - repair open wire Prom forward contactor A2 on drive motor armature.

3.

Al on drive motor.

0 volts - repair drive motor.

4.

Reverse contactor tips normally closed side. thru 0 volts - repair open from Al to resistor resistor to contactor tips.

5.

52 Drive motor terminal.

0 volts - repair open wire from contactor, contactor tips ro repair contactor.

6.

Sl drive motor terminal.

0 volts - repair drive motor.

Battery volts - repair open wire from Sl drive motor terminal to battery negative.

-58-

to

replace

7.63

No reverse

7.631

Conditions for test: tor closed.

Test for battery

7.64

No

forward and reverse

ok. contactor

closed,

across:

Tips of second speed contactor (positive lead of voltmeter on one top and negative lead on other tip>.

0 volts - check for open wiring.

Battery volts - repair contactor or replace tips. speed - forward,

reverse

and second speed ok.

Conditon for test: directional contactor closed, second speed contactor closed, third speed contactor closed.

fourth

7.661

contac-

at:

Conditions for test: Directional second speed contactor closed.

No third

ok.

voltage

Normally close side of forward contactor tips.

0 volts - replace tips or repair contactor.

1.

7.66

battery plugged in reverse

2.

1.

7.651

ok.

Normally open side of reverse contactor tips.

0 volts - replace tips or repair contactor.

Check voltage

7.65

forward travel

1.

No second speed, 7.641

closed

travel-contactors

Test for voltage across contactor tip.

Use same procedure as for testing second speed contactor tips. speed - forward,

reverse,

second speed,

third speed

Directional contactor closed, second Condition for test: speed contactor closed, third speed contactor closed, fourth speed contactor closed.

1.

Use same Test for voltage across contactor tips. procedure as for testing second speed contactor tips.

-59-

8.0 DIRECTIONALCONTROLSWITCH To removethe control

switch from the control

housing,

follow

these steps:

Removal 1.

Removeaccess cover on the control

handle.

2.

Removethe four (4) screwsthat hold the switchin the handle.

3.

Pull controlswitchout and removeattachedwires. (Notingtheir position.)

4. Removegear and shim(s).

INSTALLATION 1. Place miter gear and shim(s)insidehandleprior to inserting master switchshaft.

NOTE: Numberof shims to be determinedby the free play betweenmiter gears.

2. Insertmasterswitchinto handlewith wires attaohedand tightenfour (4) mountingscrews.

3.

Check for free play betweenmiter gears. (0 free play withoutbinding.)

4. Add or removeshims to achievecorrectfree play.

5. Installaccesscover on the oontrolhandle.

MASTERCONTROLSWITCH DISASSEMBLY 1. Remove-potentiometer wires and potentiometer.

2. Removethe module retaining 3.' Gentlypry off potentiometer

screws. bracket.

4. Removethe switch housing and cam making sure that the snap switches go with the housing.

NOTE: The contactson the switchare silverand need only be replaced when worn thin. Do not file contacts; discoloration and slight pitting of the contacts is not harmful.

When contacts need replacing, the switch is replaced; there is up to four (4)

switchesin the switchhousing. There is also a blank spacer used to replaoethe switchif not all four (4) switchesare used.

5. Removecover from spring return housing.

-6O-

6.

Slideoff of the shaft,the shaftbearings,springdrive,springsupport, springand lock nut.

7.

Removethe mountingbracketfrom the springreturnhousing.

ASSEMBLY 1.

Thoroughly clean all parts.

2. Installthe shaft lock nut and shaftbearingon shaft.

3.

Slide the returnspringon the shaft so that both springends are above the springreturnhousingprotrusions(taps). Using a screwdriver, load the springbelow the springreturnhousingprotrusions(taps).

4.

Replacethe springsupportand the springdrive so its hub is adjacent to the springhousingprotrusions(taps).

5.

Installthe shaftbearing.

6.

Installthe cover for the springreturnhousing.

7.

Installthe cam.

NOTE: When lookingat the open end of switchhousing,installthe cam so that the large slot in the cam is to the left.

8.

Installthe snap switchesin the switchhousing(and any switchspacers if used.) terminalsin the same NOTE: All switchesmust have theircommon(corn) directions.

NOTE: All N.C., N.O. and cornterminalson switchmust be lined up with switchterminaldesignations on label.

9*

Installthe switchhousingwith the switchesinstalled.

bracket.

10. Installthe potentiometer 11. Installthe moduleretainingscrews.

12. Connectwires and test operationof switch.

-61-

MASTER CONTROL SWITCH TROUBLESHOOTING

SYMPTOM

POSSIBLE CAUSE

REMEDIES Replace return spring

1.

Handle is free and does not return to center

Broken return spring

2.

Switch binds

Mounting

3.

Snap switch contacti or poor switch lift

Contact material worn too thin

Replace switch

4.

Sivitch contacts

Contact worn or welded

Replace switch(s)

do not make, break, or carry load properly

Cam may be deformed

Replace can

screws too tight

-62-

Loosen mounting screws jtst enough to eliminate binding

RESISTOR

ITEM #

4

SPEED MASTER COFJTROL SWITCH

# FOR ASSY.

NAME

1 2 3

Lockmasher SC:rOU Cover

4

Retacner,

5

Pl n,

dstrnt

6 7 8 9 10 11 12 13

Cam,

dot

14

Shaft

I5 16 17 18 19 20

Beattng,

pin ent

Housing,

detent

Houstng,

soltth

Space Cam Srtteh,

snap

Cam Cover

Drtve, Support,

shaft spring tprtng

Spring Drrve, Housing,

sprtng sp

ring

-63-

return

2 2 1 2 2 1 1 2 3 1 5 1 1 1 2 1 1 1 1 1

TRANSMISSION 1 .O

Removal 1.1

Disconnect

battery;

machine should be fully .

lowered.

_

1.2

On trucks with a rider platform, remove two pivot mounting bolts that secure the rider platform to the uarrier frame. Remove the rider platform.

1.3

Remove shield

1.4

Remove control

from carrier

frame around transmission.

handle.

Note: The transmission can be removed with the control handle Disconnect the wiring harness from the oontrol attached. and go to stop 1.6.

1.4.1 Remove brake rod linkage

actuating

lever.

between control

panel

handle and brake

1.4.2 Pull

handle to full down position and secure handle return spring in collapsed position with two (2) spring holders, Prime-Mover part, 20393-00.

1.4.3 Remove retaining

the transmission

ring and pin that secures ease.

the return spring to

1.4.4 Disconnect

control wiring harness wires from control Label wires for reassembly.

1.4.5 Remove motor cover

from side of transmission harness clamp from cover.

1.4.6 Disconnect

wires from brake interlock

1.4.7 Drive out roll

pin that secures remove the handle pivot shaft. off the machine.

panel.

and remove wiring

switch.

the handle pivot shaft and The handle is now free to come

1.4.8 Guide the wiring

harness down through the transmission tube and remove handle and harness together.

pivot

1.5

Disconnect power cables from drive motor. Hark cables Pull cables up through transmission pivot tubes.

for reassembly.

1.6

Loosen the steering

1.7

Raise and block the truck carrier ground.

1.8

Support the transmission Prom overhead.

A chain or lifting eye through the pivot tube is a good place to lift the transmission.

1.9

Remove the three cap screws that secure the transmission uarrier frame.

guide rollers.

-64-

frame so the drive

tire

is off

the

mount to the

1.10 Lift 2.0

and remove the transmission

Dissassembly and Repair;

14:l Transmission of transmission

before disassembly.

2.1

Throughly clean the outside

2.2

Remove drive

2.3

Remove six (6) cap screws that hold on the steering Remove the guide ring.

2.4

Remove four (4) motor mounting hollow hex key cap screwsfrom the cover side of the transmission and remove the drive motor.

2.5

Lay transmission

2.6

Remove cover bolts,

2.7

Use four threaded holes in cover with cover bolts to push cover off dowels. Apply pressure equally with all four pusher bolts.

2.8

Remove baffle

2.9

Remove intermediate

tire

and wheel. gulda ring.

on work surface with cover side up. and 1” locknut from side cover.

from bottom of gear case.

2.10 Remove brake lever

gear from case. and adjusting

-65-

rod from over top of brake discs.

of

2.11 Remove brake discs , plates

and retaining

2.12 Remove axle locknut and hub from axle.

shafts.

Remove axle from case.

2.13 Remove bearing races and snap rings from case.

-66-

2.14

Removemotor pinionbearingand coverand intermediate gear bearingand coverfrom side cover.

2.15

Removeintermediate gear bearingand coverfrom case.

2.16

Removeall old gasketmaterialfrom cover,oase and drivemotor.

2.17

Cleanall parts in safetysolventand dry with compressedair. !CAUTION!Use only a compressed air blowerthatmeets OSHA and other safetystandards.

2.18

Inspectall gear3

for damageand near.

2.19

Discardall o-ringsand bearings. New partsshouldbe used during reassembly.

2.20

Installtwo (2) internalsnapringsin the driveaxle bore of the gear case.

2.21

Pressthe drive axle bearingracesinto the gear case. Races should be installedwith the smallestinsidediametersback-to-back and tight againstthe snap rings.

2.22

Pressone bearingcone on the driveaxle with the large diameter againstthe gear.

2.23

Pl&ce the drive axle into the case.

2.24

Turn the gear case over with the gear aide down. Supportthe drive gear from underneath.

2.25

Installsecond'bearing coneover driveaxle.

2.26

case.

Installlip seal in transmission

2.27

Installwheel hub on driveaxle.

2.28

Put a solid bead of Loctite515 ngasketeliminator" aroundthe seam betweenthe axle and the hub.

2.29

Use Loctitethreadlock on axle locknutand installaxle locknuton axle. Torqueto 250 ft. lbs.while rotatingthe axle.

2.30

Pressthe intermediate gear bearinginto the gear case. Installthe bearingcone and one .OlO"shim.Use Loctite515 as sealant and use Loctitethreadlockon the cover screws. Do not installthe intermediategear at this time.

2.31

Installa new gasketon the drivemotor. Use a smallamountof Loctite515 as sealant.

-67-

TORQUE NUT TO

250

FTJLBS. WHILE TURNING HUB.

2.32 Install the bushings and o-ring gear case.

2.33 Install

for the brake actuating

rod into

the

the drive motor in the gear case.

2.34 Install the brake actuating rod through the drive motor into the Sear This is done to help keep the drive motor properly aligned in case. the Sear case during assembly.

2.35 ‘f&n the transmission case so that the gear case is facing up. The Support the drive axle end of the motor will be on the work surface. end of the case with a block.

2.36Install

the straight gear motor adaptor over the armature shaft without the pinion gear.

2.37Install shaft.

a brake separator pad in the gear case over the motor armature See illustration for proper orientation.

2.38Place a brake disc on top of the separator plate. must be towards the motor (down).

2.39Install

The hub of the disc

a second separator plate over the brake disc.

2.40Place the second brake disc over the second separator plate.

Position this brake disc with the hub away from the drive motor. Orient the disc so that the rivets are spaced between the rivets of the first disc at a 45O angle.

2.41 Place the third separator

plate over the second brake disc.

-68-

2.42 Place the pinion gear on the armature shaft and strike it with a non-

marking hammer to snap it into the motor adaptor.

2.43

Install new o-rings on the retaining shafts and install the retaining shafts through the separate plates acidinto the gear case, small end first. Make-sure the shafts are fully seated and do not pinch the lower separator plate.

2.44

Install the intermediategear into the bearing in the gear case.

2.45

Install the brake lever and adjusting rod into the gear case. The brake lever must be free to pivot on the adjusting rod and roll pin.

A locknut adjusting nut secures the adjusting rod into place on the motor side of the gear case.

-69-

2.46 Adjusting the brake lever: a)

The brake lever has a slight n-Vn shape on the side closest to the brakes. The section of the brake lever directly under the three countersunk spring anchor holes should contact the outer brake separator plate.

b)

Lift up on the adjusting rod to hold adjusting against motor side of gear case.

c)

Use a feeler gauge between brake lever determine contact area.

d)

Tightening the nut will move the adjusting rod towards the drive motor and will move the contact area towards the brake lever pivot.

Incorrect adjustment will cause the brakes to drag or loss of braking force.

locknut tight

and separator

2.47 Place three (3) springs with spring seats into the three sunk spring seat holes in the brake lever.

2.48 Install

the baffle

plate

to

(3) couuter-

in the bottom of the gear case.

2.49 Use a solid bead of Loctite 515 “gasket eliminatoP around the gear case oover flange.

Circle all bolt holes and dowel pin holes.

2.50 Upstall

dowel

pins

in

gear

case.

2.51 Carefully install gear case cover.

Take oare to line up the three (3) brake springs and the brake separator plate retaining shaft with the appropriate holes in the cover.

The motor pinion and intermediate gear bearings have not yet been installed.

2.52 Tighten down all

the cover screws equally.

Torque to 30 ft/ibs.

2.53 Put new o-rings on and install four (4) motor mounting bolts. bolts in an “XN pattern and torque to 35 ft./lbs.

2.54 Install the locknut on the brake adjusting the side cover.

2.55 Install screws

Install

2.56 Install cover.

Tighten

rod end that comes through

three (3 1 spring adjusting hollow hex key screws.

Tighten the they just touch the spring seats then f additional turn. locknuts on screws.

till

the bearing for the intermediate

-7o-

gear into the gear case

2.57 Place shimsaroundbearingsso that shimsare flushwith outer race.

2.58 Installbearingcover. Use Loctite515 as a sealantand put Loctite threadlockon the covermountingbolts.

2.59 Installthe drivemotor pinionbearingin the cover. a) Make sure the motor shaftand gear are concentricwith the bearing mountinghole in the gear case cover. !WARNINGI Do not force the bearinginto the mountinghole by bendingthe shaft. This will resultin armaturebreakage. gauge and a microb) To check for concentricity, use a telescoping meter to measurefour (4) opposinglocations. Measurefrom edge of bearingbore to the motor shaft.

Subtractthe smallestnumberfrom the largestnumber.

The specifications for the totalindicatedrunout (TIR)is .005"or less. c) If the drivemotor shaftand gear are not concentric,firstremove the drivemotor and check for burrs,piecesof old gasket materials,ects.,that might cause these-parts to be misaligned.

If okay, shim betweenthe drivemotormountingand gear case until properalighmentis achieved.

2.60

Installthe bearingcover over the bearingwith shimsand Loctite515.

The bearingcovermust be shimmedso that it is .OlO"above the outer bearingrace. Put shimsaroundbearingso they are .OlO"higherthan the bearing.

with about one (1) quartof ATF Dexron11.

2.61 Fill transmission 2.62 Installthe steeringguide ring with six (61 boltsand lockwashers.

Torquebolts to 50 ft./lbs.

2.63 Installthe drivewheel assemblyto the hub with five (5) bolts.

Torqueto 100 ft./lbs.

-71-

2.0 DISASSEMBLY AND REPAIR: 22:l TRANSMISSION

The procedurefor disassemblyrequiresno specialtoolsand no specialprooedure. Only basicmechanicalskillsare requiredto disassemble.

ASSEMBLY Transmission reassembly&es not requireany specialtoolingother than a torquewrenchcapableof at least 900 ft./lbs.of olejadurement.

The assemblyprooessis a straightforwardmechanicalprocedurebut care must be taken to assureproperaxle bearingsand brakemechanismassembly.

Beforereassembly,thoroughlycleangear case and all parts. Keep parts clean. All part numbersrefer to illustration. case.

2.1 Installspacerring into driveaxle bore in transmission This spaceris part of the driveaxle bearingassembly(20)which is a matchedset and shouldbe replacedonly as a set. The TimkenSS set consistsof two bearingcones,two bearingraces,one large spacer ring, and one small spacerring. case with the smaller 2.2 Installbearingraces (20) into transmission diametersagainstthe spacerring.

2.3

Installone bearingcone (20) in axle bore with large end of bearingout board.

2.4 Installoil seal spaoerring (19)againstbearingrace. case.

2.5 Installoil seal (18) into transmission 2.6

Test fit drivegear (29) onto driveaxle (17) outsideof transmisison case to removeburrsand assureproperfit. Removegear from axle and set aside.

2.7 Installsmall spacerring (20) betweenbearingcones.

2.8 Place remainingbearingcone (20) in bearingrace on insideof transmission.

2.9 Completelycoat insidesplinesof drivegear (29)with Loctite#609 retaining compound. case in order to installaxle 2.10 Place drivegear (29) into transmission (17). case throughbearingsand gear. The 2.11 Installaxle into transmission axle will have to be pressedinto the bearingand gear.

2.12 Put LoctiteThreadlockonto driveaxle threadsand installnut (30).

Torquenut to 250 ft./lbs.while rotatingaxle.

2.13 Stake the flangedskirtof the nut into the key way slot on the axle.

Do not stake too hard so the flangeskirt is torn.

-2.14 Installinner needlebearingrace (31) onto end of axle.

-72-

2.15

Installpad or bar (56) into gear case with two flatheadcap screws (11).

2.16

Install brake arm (48) and eyebolt pivot attaches to pivot bolt with a pin (47).

(49) in case.

Brake arm

2.17 Install

eccentric dowel pin (13) with ring (14) into case.

The high side of the cam offset on the bolt should be towards the center of the gear case.

2.18

Install drive motor into transmission with o-rings (9 and 10) between motor mounting plate and gear case.

Secure with three bolts and one nut but do not tighten mounting bolts.

2.19 Installbrakeplate locatingdowels (47 and 57) in transmission

case.

2.20 Installfirst separatorplate (54) with the side without pads against the inside

of the transmission.

2.21 Installone brake disc (53) over pinion gear. iustalled

with the hub first

and the rivet

The disc should be heads facing out.

2.22 Installthe plate spacerwashers (50 and 51) as shown in the inset diagram of illustration.

2.23 Install

Note the direction

a second separator

plate

that the washers (51) face.

(54) over guide pins.

.2.24 Install second brake disc with hub facing outwards and oriented that the rivet heads do not line up with the first disk.

so

2.25 Install

another set of spring washers (50 and 51) and the outer the locatingdowels. The outer plate (54) should be installed with bare side to the outside.

spacerplate (54)‘over

2.26

Installclinchrings (46) over locator

from rattling.

dowels to keep separator Do not compress expansion washers (50 and 51).

plates

2.27 Check and adJust contact point of brake lever.(48).

Contact point of lever on plates should be directly under the spring locating holes.

The.eyebolt that the lever mounts to can be screwed in or out to adjust contact area.

2.28

Install

idler gear bearing cups (31) and axle bearingcup (31) into transmission case and cover. Installso that inside of races are flush with inside

surfaces

of case and cover.

2.29 Place two shims (32) on idlergear shaft (33) and installgear into transmission case. Installa thirdshim (34) on outside shaft of gear.

2.30 Put brake springs

(43) and seats

(44) in place on brake lever

(48 1.

2.31 Coat mating surfaceof tranmission case with Loctite 515 and carefully install cover (35) onto transmission.

Line up dowel pins (28) and spring seats (44) as cover is put into place.

2.32 Bolt cover in place with cap screws. Be sure that four (4) round head hex screwsare used at four (4) holesclosestto steeringring.

-73-

2.33 Install brake adjusting bolts not tighten at this time.

2.34

(38) and locknuts

(39) into cover;

do

Install brake actuating rod (6) and adjusting cam (3 and 4) In transmission ease* The complete brake adjusting procedure must he followed after the transmission is_ installed In truck.

2.35 Install

steering

2.36 Install

new pivot

2.37 Fill

guide ring (26) and drive

tire

(21).

bearing and washer on top of transmission

transmission with ATF Dexron II transmission

-74-

fluid.

case.