CLARK FORKLIFT SM 566 HWP-25 PWD-30 PWD-25 HWD-30 HWD-25 HWD-36 PWD-36 SERVICE MANUAL - PDF DOWNLOAD

Service Manual

SM 566

P-25 HWP-25 PWD-25 HWD-25

P-30 HWP-30 PWD-30 HWD-30 HWD-36 PWD-36

FOREWORD

This service publication provides information covering normal service, maintenance and repair of the Clark industrial ltrucks noted on the cover. It has been specifically prepared to help owners and service personnel maintain these trucks in efficient and safe operating condition.

Regular, correct maintenance and care of industrial trucks is not only important for long and efficient truck life; it is essential for safe operation. The importance of proper maintenance through planned service, inspection and qualified repairs cannot be emphasized too strongly.

To assist in keeping industrial trucks in good operating condition, this manual includes preventive maintenance procedures to be performed at regular intervals.

These are essential to the service life and safe operation of all industrial trucks.

Instructions for safety inspections, operational checks, cleaning, and lubrication are provided for reference in setting-up and conducting a recommended periodic Planned Maintenance (PM) program.

Refer to the Operator’s Manual, located on the truck, for additional information on the operation, care and maintenance of your truck.

Genuine Clark replacement parts should be used for all service and repair requirements. Substitute parts from other sources may be different than original parts and may not meet OSHA or other safety requirements.

Any reference to brand names other than Clark in this manual is made simply as an example of the type of tools and materials recommended for use and, as such, should not be considered as an endorsement. Equivalents, if available, may be used.

For more information on maintenance and repair of these trucks, contact your authorized Clark dealer.

NOTICE

The descriptions andspec@ations inclua’ed in thismanual were in effect at the time of printing. Clark Equipment Company reserves the right to discontinue models at any time, or make improvements and changes in specifications or design without notice and without incurring obligation. Specl@cations, torques, pressures, measurements, adjustments, illustrations and other items may change at any time. Contact your authorized CLARK dealer for information on possible updates or revisions.

0 1989 Clark Equipment Company

SM568

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Dee 91

About This Manual

This manual is intended for use by persons who are trained and authorized to do lift truck maintenance. It is designed to provide essential information about the correct and safe service maintenance and repair of the truck by trained mechanics or service technicians.

The information is organized by use of the Bask Group Numbering System used in the Master Parts Book and the Customer Parts manuals. The manual includes: P.M. 01-40

Planned Maintenance Procedures including precautions and safe maintenance practices.

Service specifications, adjustments, maintenance and overhaul procedures including lubrication charts and recommended lubricants, etc.

General and detailed service and repair procedures areoutlined (as required) for each component or subsystem. Some procedures include explanations that are common to several components or subsystems.

In general, each Section is written to show and describe the general arrangement, adjustment, removal, disassembly, inspection, repair, and assembly steps that are normally required to service thecomponent. Component specifications (as applicable), information notes and safety messages are included within those procedures. In most cases, specificationsarealsolisted in GROUP40,TruckSpecifications,forconvenience of reference.

The Pictorial Index lists components or systems by Basic Group Number of Major Parts. Additional content listings are placed at the beginning of each Section in the manual, This manual has been made easier to use by providing only specific steps when necessary and general nstructions required to explain the activity, component, assembly, or process being worked on. The technician is expected to include obvious additional steps of standard procedure for removal, disassembly, cleaning, inspection, reassembly, installation, etc., as needed.

To be better prepared to do the necessary service work, take time to completely read the entire procedure, including any special instructions, before doing any work.

The technician is cautioned and expected to a hvays work in a safe manner by using the correct procedure. Do not take chances which may result in injuries.

Dee 91

ii

SM568

Safety Notice

IMPORTANT SAFETY NOTICE Read and understand all safety precautions and warnings before performing repairs on lift trucks.

Appropriate service methods and proper repair procedures are essential to the safe, reliable operation of industrial trucks as well as the personal safety of the individual doing the work. This Service Manual provides general directions for accomplishing service and repair work with tested, effective techniques. Following them will help assure successful repair and reliable truck operation.

There are numerous variations in procedures, techniques, tools, and parts for servicing industrial trucks, as well as in the skill of the individual doing the work. This manual cannot possibly anticipate all such variations and provide advice or precautions as to each. Accordingly, anyone departing from the instructions provided in this manual through procedures used or choice of tools, materials, and parts may jeopardize his or her personal safety and/or the safety of the vehicle user.

Improper or careless techniques cause accidents. Don’t take chances with incorrect or damaged equipment. Read and understand the proceduresforsafe 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.

General Precautions The following list contains general precautions that should be followed when working on a lift truck: l

l

l

Always wear safety glasses for eye protection.

Remove rings, watches, loose jewelry and open clothing before working on a vehicle, to avoid serious injury.

Do not smoke while working on a vehicle.

. Put ignition switch in the OFF position, unless otherwise required by the procedure.

Set the parking brake. Place wheel chocks orwood blocks of 4” x 4” size or larger to the front and rear surfaces of the tires to provide further restraint from inadvertent vehicle movement. l

9 Use safety stands or blocks whenever a procedure requires you to be under the vehicle. l

l

Service Electric Truck Batteries in a well-ventilated area to avoid the danger of igniting explosive gases.

Follow the Safety Instructions outlined in GROUP 12 “Handling Storage Batteries”.

Always Discharge the Capacitors prior to working on or around electrical components. Refer to the instructions outlined in GROUP 19 “Discharging Capacitors:.

l

Avoid contact with Battery Acid. The battery contains corrosive acid which can cause injury. Following the instructions outlined in GROUP 12 “Handling Storage Batteries”. l

SM568

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Dee 91

Handling CORKMaterial Company

PICTORIAL INDEX

Wal kie Models Rider Models

r39

\

01

12 16 17 19 20 23 25 28 34 35 39 40

SM568

28

Lubrication Charts Battery Motors Contactors EV-T5 Control Drive Unit Brakes Caster / Stabilizer Hydraulic Unit & Liness Lit Cylinder Load Wheel / Lift Linkage Body Partss Specifications

Index-l

act 91

Planned Maintenance Procedures P.M. CHECK SHEET A special coding system on the P.M. Check Sheet allows truck conditon to be reported with a minimum number of words. As the P.M. is performed, a check mark should be made in the appropriate box of the component being checked. l

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l

l

(4) indicates the particular truck component or system has been checked and is O.K. indicates the component or systemisinneed of a minor adjustment or service (not part of the normal P.M.) that should be taken care of in the near future. (x)

( r ) indicates there is a potential problem that couldresultindamage to acomponentorsystem and requires attention. ( s ) indicates the need for urgent repair or replacement of a component or system and the truck should be shut down as eminent damage or possible injury may result.

Code

$ =

The nature of problems found during a PM should be noted in the “comments” portion of the check sheet.

Whenever a svstem or comnonent is faultv or unsafe, it must be noted on the check sheet, and reported to the designated authority at the conclusion of the P.M.

O.K. Potential ~

O.K.

X = Adjust (Not P.M.) r

=

L. i... ..L......... ___ ____ ,,,,__ :~~.:.:.:.:.:.:.:.:.:.~I ........,.i,.................

Repair or Replace Requires Shop Repair

AWARNING Remove all jewelry before examining electrical components.

SM568

1

PM

Planned Maintenance Procedures Visual Inspection 1. Inswct Batterv Plug & Truck Rec@acle .

Disconnect battery from truck.

.

Inspectthespringloadedconnectors inthetruck battery receptacle and check the battery plug connectors. Severely burned connectors should be noted on the P.M. check sheet.

Battery and check the Spring Loaded Connectors Typical Illustration

2. InsDect Batterv Cover for darn= .

The cover should not be dented. A badly dented cover could short out across the battery cell connectors.

.

The cover should be free to swing open and closed without binding.

-Battery \

Cover

Check Cover for Damage

Typical Illustration

-

Typical Illustration

3. Inswct Pallet Forks for obvious damaye PWD& P

.

PM

Forks should not be bent or warped. If the forks are damaged, report condition to the designated authority.

H\ ND & HWP

2

SM568

Planned Maintenance Procedures Coast Control Decal /‘--(Optional Equipment)

4. Rider Models .

@SDeCt

Frame ComDonen&

.

Check truck console, access cover and doors for damage.

.

Inspect name plates and decals for damage and to be sure they are not missing.

Typical Illustration

4A. Walkie Models .

Insoect Frame ComDonents

.

Check truck console, access covers and doors for damage.

.

I

Access Doors

\

Control Handle

Inspect name plates and decals for damage and to be sure they are not missing.

Data Plates

1 Typical Illustration

A+\

5. Check for obvious oil leak% .

/O

Lift Cylinder 8 tines

Make a quick overall inspection for leakage. If anoil leakappears tobemajor,noteconditionon the check sheet for immediate attention. Minor leaks should be repaired during the P.M.

1 Typical Illustration

SM568

3

PM

Planned Maintenance Procedures 6. Insrxct Tires & Wheel% . Check for obvious damage to tires on the load, caster and drive wheels.

.

Look for excessive tire wear, cuts, breaks, chunking or bond failure between the tires and wheels. Note condition on the PM check sheet.

.

Remove embedded objects from the tires.

. .

Drive

I

1

Be sure wheel fasteners are secure and none are missing.

Make certain grease fittings are not damaged or missing.

\

\

\

Wheel Fastener Typical illustration

Grease Fittings

\

\

\

\

\

Caster Wheel

7. ExDose Internal ComDonent$ . Open the access doors exposing the drive unit, brake, lift cylinder, hydraulic unit, and SCR control. Each door hangs on a hinge pin. Lift the doors from their pins and set them to one side.

Hinge/

Typical Illustration

8. Connect Truck Batterv .

Connect truck battery and check truck operation.

Tvoical Illustration

PM

4

SM568

Planned Maintenance Procedures Operational Tests 9. Turn the key switch on.

10. All Models l

Check the horn to be sure it operates.

Walkie Models

Typical lllustratior

11. All Models l

Check the hour meter to be sure it operates.

SM568

5

PM

Planned Maintenance Procedures’ 12. Check Steer Control Handle .

Walkie Models

.

Be certain the control handle is mounted securely at the base of the drive unit.

.

Make sure fasteners are tight and none are none missing.

1Omm Allen Head Socket Scre

8mm Allen Head

.

Rider Models

.

Check the mounting bracket to be sure it is securely mounted to the base of the drive unit.

.

Make sure fasteners are tight and none are missing.

Steer Control

Mounting Bracket

-.-

Late Models

Early Models Typical Illustration

13. Check Steering . Operate truck in reverse at a slow rate of speed.

Make Full Right & Left Turns

Move control handle through a full right and full left turn. Steering should be smooth without binding or his&ion. .

If there is binding, hard spots or movement appears to be stiff this indicates either lack of lubrication, misadjusted or damaged steering ring.

.

Report condition on the P.M. check sheet.

PM

0

cl

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6

SM566

Planned Maintenance Procedures 1 _ Forward I Reverse . L Direction 1 Direction

14. Check Brake heration l

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Move the steer control handle downward 10 degrees from vertical (brake on) position. ataslowrateofspeed.

Operatetruckinreverse

Brake On

Slowly move control handle upward from the 10” travel (brake off) position..

Brake

Off (0

q

0

.. ‘L i

Check Braking in Reverse DIrection Forward Direction at a slow rate of speed high rate of speed

As Control Handle annroaches “Brake On” postion: (1st) the brake switch should operate shutting off the drive motor.

(2nd) the brake should operate bringing the truck to a stop. l

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l

Operate the truck in forward at a slow rate of speed.

Slowly move control handle upward from the 10” (brake off) position. The brake should apply when handle reaches the full up (brake on) position.

Walkie Models

Now, check the brake at a high rate of speed in both forward and reverse directions.

14A. Next, check for proper brake operation by moving the handle downward from the lo” (brake off) position. The brake check should be done at Low and High Speeds, and in Forward & Reverse directions. l

Rider Models

Check Braking in Reverse Direction Forward Direction at a slow rate of speed high rate of speed

If operation is not satisfactory, note condition on the P.M. check sheet. Report condition to designated authority for immediate attention.

Brake Off (O?Y

NOTE

Plugging Controlis normally used for gradual brake applications.

Braking with the steer control handle is normally used in emergency situations and parking the truck.

SM568

Tvoical Illustration

7

PM

Planned Maintenance Procedures AWARNING

Typical lllustratior

Brake On

After checking the coast control, be certain to return the coast control lever to the (brake on) position before resuming normal truck travel.

15. 1 h k

‘n

.

Move steer control handle past the full vertical position to partially compress a spring loaded rubber stop, see illustration.

.

Now move the coast control lever out of the “brake on” position and into the “brake off’ position.

.

Release the steer control handle. The truck is now set up for a “coast mode” of operation allowing the operator to “jog” the truck with the F & R speed control.

.

Slowlly operate truck in a reverse direction of travel.

.

Move steer control handle into vertical (brake on) position stopping truck.

.

If brake operation is not satisfactory, note condition on P.M. check sheet. Report condition to designated authority for immediate attention.

.

Return the coast control lever to the (brake on) position.

Brake Of1

Coast Control Lever

Coast Control Lever

16. Check Travel Speeds

Check Acceleration Check High SDeed Drive truck in a straight line, looking in the direction of travel.

1) w Always face in the direction of travel

Listen for any unusual drive train noise.

Accelerate

e r)

fromlow to high speed. Acceleration

shouldbeasmoothtransitionfromcreepthrough top speed to 1A (battery volts). If transition is irratic, the accelerator potentiometer circuit should be checked (Group 19). Note condition on the P.M. check sheet. -continued next pageOperating Truck in REVERSE

PM

8

Direction

SM568

Planned Maintenance Procedures 17. .

Drive truck forward, in a straight line of travel.

.

Fully rotate Directional Speed Control (1) until maximum(solidstatecontro1) speedisobtaiined

.

Depress Hi-SpeedButton (2) for approximately two seconds. The 1A contactor should close providing direct battery volts across the drive motor for maximum travel speed. This transition should be smooth. Ifit is not, if it is erratic, jerky etc., the accelerator potentiometer circuit should be checked (Group 19). Note condition on the P.M. check sheet.

Trwel

Tvniul

18. Override Control .

Illustration

he Override Control Circuit nly functions in slow speeds

The override control is used to by-pass the emergency reversal (belly) switch circuit. This is desireable when the truck is operating in areas whereplastic strip curtain doors (etc) are used.

COnaol

\

Depress Button to override ReversalControlCircuit

Typical Illustration

Example: When moving a truck through this type door, pressure from the door strips can cause the emergency reversal (belly) switch tooperate changing the direction of truck travel. By overriding the reversal switch, the truck can pass through the curtain door without miss hap.

.

To simulate the above, operate truck in slow speed reverse. “Depress button to override” and then depress the reversal (belly) switch. Truck travel shouldremainin slow speedreverse. Note condition on the P.M. check sheet.

19. Elevate and Lower Pallet Forks .

Elevate pallet forks to maximum lift. As the forks elevate, check to be sure they elevate smoothly and evenly without binding.

.

Lower forks. Look for erratic motion as they lower. They should lower smoothly without hesitation.

.

Typical Illustration

If there is erratic, jerking motion or binding of linkage as the forks elevate or lower, the lift linkage should be checked and adjusted (Group 35). Note condition on the P.M. check sheet.

SM568

9

PM

Planned Maintenance Procedures

20. Dischawe the CaDacitors l

l

Be sure the battery is unplugged.

Discharge capacitors using a 100 ohm, 2 watt resistor connected between the Positive and Negative power terminalson the SCR Control. Hold the restitor in place for2 seconds before removing.

I IIICover Should Be In Place

ACAUTION Usingashorting device without a “resistor load” could cause damage to the control.

AWARNING Discharging

the capacitors without using specified resistor could cause serious injury to yourself and bystanders.

AWARNING Prior to discharging the capacitors, make certain the Cover is installed on the Control Panel Power Base.

DischargeCapacitors

Typical Illustration

21. Rider Models l

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PM

Inmect Moderator Hand Rail Check hand rail for security of mounting. Try moving hand rail fore & aft checking for loose connections and damage. The mounting bolts shouldbe torqued to 177-221 Ibin (20-25 Nom).

Make certain the switch housing is mounted securely and the switches are not damaged.

Check wire harness condition. Check for loose connections and harness damage. Report condition on P.M. check sheet.

10

SM568

Handling ELqRRMaterial Company

GROUP 01

GROUP 01 LUBRICATION & Planned Maintenance Contents Grease Chart & Specifications (Rider Trucks) ....................................

Grease Chart & Specifications (Walkie Trucks) .................................

Fluids -Illustrated Instructions & Specifications ................................

01-l-4 Ol- l-5 01-l-3

Optional Equipment Lubrication Illussttations & Specifications ....... ..Ol- l-6 h4iscellaneous Linkage Illusstrations & Specifications ..................... ..Ol-l- 7

Test truck ground Clean drive motor air vents

1 Check brake shoe linings

SM568

I I.1

01-1-I

I I I

Section 1

Lubrication

GROUP 01 LUBRICATION SPECIFICATIONS

The listing of lubrication specifications compiled in this manual isfor the reference of Clark Engineering and Service personnel, Dealers and Customers. The listof products is intended as a guid in the selection of a lubricant to meet the requirements of Clark Industrial Truck Operation.

CLARK makes no representation as to the relative merits of any commercial oil product. With the exceDtion of MS-68 Hvdraulic Fluid, CLARK has no formal system for approving oil products, but has published herein general specifications which it believes will provide adequate or superior component lubrication of life.

It is the PREROGATIVE of each user to choose suppliers and products as they feel necessary for proper operation of the equipment under the conditions of the individual application. RESPONSIEHIJTY for the quality of the product and its performance in service must remain with the oil supplier, in agreement with the user.

Hvdraulic Fluids and &wine Oils CLARKdoesnotfollow aformal testandapprovalprocedureforspecificbmndedproducts.

RatheritisCLARK policy to establish basic specifications for oils (and fluids) which demonstrated suitable performance for the application. Ingeneral these specificationsfollowtherecommendationsofthemajorcomponentmanufacturer, such as engines and hydraulic pumps. Any oil or fluid which meets the respective specification is considered acceptable for use in CLARK products. Component operation should not be affected as long as the oil or fluid meets the stated specification and the recommended oil and filter change intervals are followed.

ForExtendedOilor FluidDrainIntervals,periodicanalysisbyareputabletestinglaboratory shouldbemade.

It is the responsibilityof the manufactureror supplierof the oil or fluids to insure that thisproduct meets the specificationsand gives the expectedpeq5ormance.

Technical Societies referenced on these Daaes

Section 1

AGMA

--

American Gear Manufacturers Association

API

_-

American Petroleum Institute

ASTM

-

American Society for Testing Materials

EMA

--

Engine Manufacturers Association

_-

Military Specification

MGPA

--

Natural Gas Processors Association

NLGI

--

National Lubricating Grease Institute

SAE

--

Society of Automotive Engineers

01-l-2

SM568

GROUP 01

Lubrication HYDRAULIC SYSTEM l

Wipe outside of reservoir clean before removing the fill/level plug. Fluid level should be to the plug opening Add fluid as required.. Checkfluid level withtheforksfilly lowered andtruckon a level surjSace.

MS 68Recommendation NormaZ overation use Hydraulic Fluid per Clark Specification MS68.

Hydraulic Unit

Reservoir Capacity 1.5 Quarts (nominal)

Specification Hydraulic Fluid must be high quality with Zinc or equivalent Anti-Wear additive which meets the requirements of ASTMD-2882pump wear test with 50 mg total weight loss maximum per Clark Specifications MS-68.

Hydraulic System Fluid available under Clark Part Numbers; 885385 @ 885382

One (1) Quart Can (MS-68).

u

One (1) Case of Six (6)

Reservoir

one gallon cans (MS-68).

Recommendation Cold Storage Operation Use Hydraulic Fluid which meets ML-H-5606A per Clark Specification MS-226.

Specification A petroleum base hydraulic fluid with additives to improve viscosity index, oxidation resistance and anti-wear characteristics blended to form a stable product under storage and operational conditions between -65 and +160” F., meeting MIL-H5606A* per Clark Specifications MS-226.

,,

ji ‘x. .,ji :: -:i ::

2 h=

MS 68

(*)The restrictive cleanliness specifications of later revisions is not required.

Typical lllusstration

Drive Unit l

Wipe area around flluid level plug before removing plug. Fluid level should be to the plug opening. Add fluid as required.

Recommendation Use Dexron II Automatic Transmission Fluid.

Transmission Fluid available under Clark Part Numbers;

@

897804

One (1) Quart Can.

941615

One (1) Case of Six (6) one gallon cans.

SM568

01-l-3

Section 1

Lubrication

GROUP 01 LUBRICATION CHART RIDER MODELS

Cold Storage

Two Fittings each link.

Three fittings each bracket.

99

$9

Two Fittings.

T- General Recommendation

Pumose Chassis arease

Use a Grade NLGI #2 per Clark Specification MS-107C.

Specification MS-107C A multi-purpose grease of refined mineral oil blended with lithium soap thickner or equal containing anti-wear, anti-rust and anti-oxidants with EP additives. Per Clark Specification MS-107C

T Low Temperature MIL-G-23827A,

Cold Storaae ODeration

Grease An extreme low temperature aircraft quality grease meeting Specification or

equivalent

product.

Temperature

range

-100

to

+250

F.

Wipe grease fittings clean before applying a grease gun.

Section1

01-l-4

SM568

GROUP 01

Lubrication Normal Operation

LUBRICATION CHART WALKIE MODELS

2

Two fittinas each link.

T-

Three fittings each bracket.

Two fittings.

Four fittings each bracket.

7Recommendation

General Purpose Chassis arease

Use a Grade NLGI #2 per Clark Specification MS-107C.

Specification MS-107C A multi-purpose grease of refined mineral oil blended with lithium soap thickner or equal containing anti-wear, anti-rust and anti-oxidants with EP additives. Per Clark Specification MS-107C

T-- Cold Low Temperature MIL-G-23827A,

Storaae ODeration

Grease An extreme low temperature aircraft quality grease meeting Specification or

equivalent

product.

Temperature

range

-100

to

+250

F.

Wipe grease fittings clean before applying a grease gun.

SM568

01-l-5

Section 1

Lubrication

GROUP 01 Optional Equipment

Typical Illustration

Battery Rollers Rollers are captive in trays. They should be pressure cleaned and lubricated at their pivot shafts.

Enaine Crankcase Oil Recommendation Use any good grade of motor oil.

Specification Use SAE lo,20 or 30 weight oil as the temperature and conditions dictate.

Section1

01-I-6

SM566

GROUP 01

Lubrication Miscellaneous Linkage

b -

Enaine Crankcase Oil

Recommendation Use any good grade of motor oil.

Specification Use SAE lo,20 or 30 weight oil as the temperature and conditions dictate.

SM568

01-l-7

Section 1

Lubrication

GROUP 01 Miscellaneous Linkage

b

Enaine Crankcase Oil

Recommendation Use any good grade of motor oil.

Specification Use SAE lo,20 or 30 weight oil as the temperature and conditions dictate.

Section1

01-l-8

SM568

Material Handling

El!!lRH

Company

GROUP 12 SECTION 1 Battery

Section

Contents 1 Battery Service Area ..................................... ............ .......... 12-1-2 Handling Storage Batteries ...................................... ...... 12-1-2 Battery Removal & Installation ..................................... 12-1-4 Battery Maintenance .................... ......... ........................ 12-1-5 Battery Installations........... ..........................*.......... ........ 12-1-6 Battery Service Life & Record Keeping ..... ................... 12-1-6

rvbal

Illustration

SM568 OCT 91

Section 1

GROUP 12

BATTERY

BATTERYHANDLING “..._._f Wash Stand

Changeor service batteries only in an areadesignated for this purpose. Refer to Page 8 for additional information. l

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Fine Extinguishe w

Be sure this area has provisions to flush and neutralize acid spillage.

Be certain the area has proper ventilation to ventilate fumes from gassing batteries.

Check to see that there is fire protection. Fire extinguishers should be properly maintained and located in designated areas.

A

DANGER

Explosive gas is always present around batteries, especially when they are being charged The following should be adhered to. l

l

l

No smoking shall be allowed in the charging area.

Battery electrolyte shall never be checked with an open flame.

Open flame, sparks, or electric arcs shall never be allowed in the battery charging area.

Persons maintaining storage batteries must wearprotective clothing such as: l

Face and head shields

l

Long shirt sleeves.

l

Gaunlet gloves.

AWARNING -SULFURICACID THE BATTERY CONTAINS

CORROSIVE ACID WHICH CAN CAUSE INJURY. IF ACID CONTACTS YOUR EYES OR SKIN, FLUSH IMMEDIATELY WITH WATER AND GET MEDICAL ASSISTANCE.

Section 1

12-l -2

act 91 SM568

GROUP 12

BATTERY Be sure the battery service area is equipped with material handling equipment designed for the purpose of removing and replacing batteries, such as a conveyer or overhead hoist equipped with safety hooks l

When using an overhead hoist, be sure to use an insulated spreader bar or similar lifting device.

To prevent side forces fi-om damaging the battery, the distance between the lij?irtghook (of the spreader bar) must be adjusted to the same dimension as .measured between the battery lifting eyes. Make sure the lifting hooks are the correct size to fir the l@itingeyes of the battery. l

l

Be sure the hoist is equipped with a chain container to accumulate excess lifting chain.

When this is not possible, be sure the battery is covered as shown below.

Typical lllustratior

I

Plyw~ -

If the battery does not have a cover ot its own, cover it with a non-conductive material such as plywood.

(Non-Conductive Cover)

Tvoical Illustration

l

Never lay tools or other metal objects on a battery. Metal objects contacting battery terminals will cause short circuits.The shorted circuits could ignite battery fumes and cause the battery to explode.

SM568 OCT 91

Typical Illustration

.

Section 1

GROUP 12

BAll-ERY

Battery Removal l

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Brake Applied

Key Switch Off

Move truck to the designated battery service area.

Typical Illustration

Turn key switch off and disconnect battery.

Be sure control handle is in the full vertical (brake on) position. Models huving “coastcon-

trol”:Be sure the coast control lever is moved to the “brakeon" position.

l

Remove battery retainer plate on those models having battery compartment rollers. Note: Bat-

tery Rollers are not serviced individually.

NOTE

Do not wash battery in truck.

If the battery to be handled is uncovered: Cover the battery with a non-conducting material (plywood, heavy cardboard, etc.) prior to attaching a lifting device.

l

l

Using an overhead hoist and a insulated spreader bar (see page 3), attach safety hooks to the lifting eyes of the battery.

Remove Battery

Remove the battery.

Insulated Spreader

Section 1

12-1-4

Bar

act 91 SM568

GROUP 12

BAnERY Battery Vents l

l

When Charging Batteries: Theventcapsmust be kept in place to avoid electrolyte spray. Care must be taken to assure that vent caps are functioning. The cap vents must be open to allow the battery to breath. The battery cover must be removed/opened to dissipate heat and explosive gas.

When Cleaning Batteries: The vents must be tightly in place.

Battery Cleaning The easiest and most satisfactory method of cleaning a battery is to wash it with a low pressure cold water spray. The battery top can also be washed with a baking soda solution and rinsed with clear water. l

l

Check to be sure all vent caps are tight before washing the battery.

Fill a bucket with cold water while adding a box of baking soda to the pail. Stir the solution until dessolved. It is advisable to have this solution

IMPORTANT Vent Caps must be free of obstruction

around the battery service area at all times. l

and in good conditior

Battery top should be clean and free of cracks or breaks.

Battery terminals must be clean and solidly mounted.

After washing battery, thoroughly rinse with clear cold water.

Damaged batteries should be repair or replaced.

Consoult

your battery vendor.

Battery Maintenance To obtain maximum performance and battery life, the instructions supplied by your Battery Vendor should be adhered to.

Battery Charging

REFER TO “SPECIFIC GRAVlTY OF ELECTROLYTE AND BATTERY LOAD TESTING”

Follow the instructions supplied by the Battery Charger Vendor.

OUTLINED IN GROUP 19, SECTION 4

Battery Electrolyte l

l

Always use a carboy tilter or siphon handling battery electrolyte.

when

OF THIS MANUAL.

When mixing electrolyte, always pour acid into water - never pour water into acid. Pouring

water into acid will cause a dangerous chemical action.

SM568

OCT 91

12-l -5

Section 1

BAnERY

GROUP 12 Clean Battery Compartment .

Using baking soda and water solution, clean the walls and floor of the compartment. Rinse with clear water.

.

Blow off the compartment walls and floor with an air hose. Allow to air dry.

Clean Battery Compartment REPLACEMENT BAllERlES Caution should be exercised to use a battery properly sized to the dimensions of the battery compartment.

Batteries too small can shift and cause damage to the truckor injury to the operator or bystanders.

Only use batteries that comply with factory recommendations as to size and capacity. t

Baking Soda 1

Water Solutiol

Typical Illustration Uncovered

Install -Battery If the battery is uncovered, cover the battery with a non-conducting material (ie.,plywood, heavy cardboard, etc.) prior to attaching lifting device. l

Using an overhead hoist andaninsulated spreader bar (see page 3), attach the safety hooks to the lifting eyes of the battery.

l

Lower battery into compartment.

l

Disconnect lifting device.

l

l

Models so equipped: plate.

Typical Illustration

Batteries:

Cover With Qwocd or Heavy Cardboard

Install battery retainer

ChainContainer

1 I

Insulated Spreader Bar -,

I ,

Connect truck battery.

Section 1

12-l -6

act 91 SM568

GROUP 12

BNTERY KEEPING BATTERY RECORDS

BAlTERlES

Records should be maintained to get the best service out of your battery and truck.

Industrial Batteries are used to supply the electrical power to operate an Electric Industrial Truck. Their voltage depends on the number of individual cells they contain. There areapproximately 2 volts for each cell in the commonly used lead-acid type battery.

Batteries normally range from 6 volts to 72 volts.

Their capacity varies depending on the application.

Onlyuse batteriesthatcomplywithfactoryspecijications as to size and capacity.

These records should contain: l

l

l

Test Date. Each test should be dated for future reference and comparison.

Specific Gravity andTemperature readings.

Each battery cell should be checked and recorded before and after charging. The specific gravity reading of the electrolyte should not be less than 1.260. If below 1.250, the battery should be recharged and tested.

HOW TO GET MAXIMUM LIFE OUT OF YOUR BAlTERY

Variation between eachcell tested.Thevariation in specific gravity reading between cells should not be greater than 15 points (.015). If readings are greater, this indicates there are defective cells. pilot cell shouldbe changedoccasionallyCO distributeany electrolyte loss over the battery when takingreadings.

The

l

l

l

l

Load Voltage Tests should be performed and recorded indicating the condition of a battery while it is performing work.

ActualOperatinghoursofthebattery.Record the actual time the battery is in use before putting it on charge..

Charging Time. Keep an accurate recordof the actual time the battery is on charge. After each charge, check to see if the battery is fully charged. Test the battery before placing it back into service. Record these results.

Visually Inspect for loose terminal connections or posts, a cracked case, or damaged cell covers (vent caps) and excessive corrosion.

This data should be noted to help ascertain work enviroment and possible trouble areas.

For further information, refer to Group 19, Section 4 in this manual.

Check with your local battery supplier for complete battery maintenance procedures and their expertise.

SM568

OCT 91

12-l -7

.

Do not add acid to a battery. Only qualified BatteryRepresentativesshoulddetermineifthis is necessary.

.

When lifting a battery, use a lifting device designed for this purpose

.

Check the electrolyte level before placing a battery on charge. Add water, ifrequired, before charging the battery. The electrollyte level in a battery should be slightly below the lower lip of thefilling holevent. Donotoverfill. Overflushing causes loss of electrolyte.

.

Keep the battery clean, dry andin goodconditon.

.

Keep metal objects and tools away from the top of the battery. Short circuits will cause battery damage and could ignite battery fumes exploding the battery.

.

Maintain good battery cable connections.

.

Check power cables and wiring for damage that can cause premature drainage of the battery.

.

Do not over charge a battery.

.

Do not under charge a battery.

.

Follow the instructions provided by your supplier(s) of the battery and battery charging equipment.

.

Maintain accurate battery records. If battery troubles occur, these records will help you and your battery representative determine the nature of the problem.

Section 1

GROUP 12

BAmERY

AWARNING SULFURIC

ACID

THE BAlTERY CONTAINS CORROSIVE ACID WHICH CAN CAUSE INJURY. IF ACID CONTACTS YOUR EYES OR SKIN, FLUSH IMMEDIATELY WITH WATER AND GET MEDICAL ASSISTANCE.

Disconnect battery before handling electrical components.

Polarity must be correct to prevent damage.

AWARNING Electric truck batteries are heavy and awkward to handle. On charge, they give off hydrogen and oxygen which, in certain concentrations, are explosive. Electric truck batteries are also costly, so before you remove, service, or install a truck battery, consult BAlTERY MANUFACTURER, for more recommendations and instructions on handling and charging batteries. Carefully read and follow recommendations and instructions.

Section 1

12-l-8

act 91 SM568

Handling EMRKMaterial Company

GROUP 16 Section 1 Electric Motors Contents

Inspection Procedures ........................................................................

Motor Insulation ................................................................................

Testing Procedures using a 500 Volt Megger .....................................

Testing Procedures using a Volt-Ohmeter ..........................................

Brush and Commutator Inspection .....................................................

CLEANING, INSPECTION

16-1-2 16-1-2 16-1-3 16-1-3 16-1-3

81TESTING PROCEDURES

Drive (Traction)

Drive (Traction)

Wal kie Trucks

Rider Trucks

Typical Illustrations

SM568 Ott 91

16-l-l

Section 1

GROUP 16

Motors

Electric Motor Maintenance A planned maintenance program of regular, routine inspections is important for long life and trouble-flee operation of electric motors. Make and keep records of your inspections. Use these records to help establish correct P M. intervals and to indicate maintenance required to prevent major problemsfrom occuring during operation.

Inspection Procedures To perform these service procedures, it is recommended that you first:

The presence of any oil on or near motor could indicate either bad bearings or leaking hydraulic system.

Determine cause and repair problem before extensive motor damage occurs.

Motor Insulation Park truck safely.

Fully lower upright.

If a reduction in motor performance has been noted, it may be due to breakdown in motor insulation causing internal grounding or a short circuit.

Apply parking brake.

Turn key switch OFF.

Failures of motor insulation are due to:

Disconnect battery from truck recepatacle.

l

(1) contamnation

l

(2) mechanical factors

l

(3) high temperatures

Discharge capacitor on control panel.

Motor Cleanliness Electric motors should be kept clean at all times to prevent shorting, minimize wear, and for best cooling.

l

l

l

Wipe off all dust, dirt, oil, water, etc., from outer surface of motor.

Remove any debris from cooling air vents and around motor frame to prevent overheating.

Air clean (blow out) open motors using cIea.n, dry (moisture-free) compressed air at [207 kPa] 30psi.maximumairpressure.

Aircleanallinner areas around commutator and brushes, including cooling air vents and fan.

Section1

Contamination includes dirt, moisture, oily vapors, metal chips, carbon dust from brushes, etc.

Mechanical factors overspeed, etc.

include

shock,

vibration,

Operation at prolonged or excessively high temperature will cause insulation to become brittle and crack leading to premature failure. The insulation condition can be judged both visually and by test measurement. Regular, periodic measurements of insulation resistance can give a useful indication of the rate of insulation deterioration.

A sudden drop or consistent trend toward low values of insulation resistance give evidence that insulation is deteriorating and that failure may be imminent.

16-1-2

Ott 91 SM568

GROUP 16

Motors TEST FOR MOTOR INSULATION “RESISTANCE TO GROUND”

TEST FOR MOTOR INSULATION “RESISTANCE TO GROUND”

(Using a 500 Volt Megger)

(Using a Simpson 260-6~ Volt-Ohmmeter or equivalent calibrated on the RxlO,OOOscale.)

1. Disconnect battery from truck receptacle.

1. Disconnect battery from truck receptacle.

2. Disconnect terminals..

2. Disconnect power cables from motor terminals.

3

power

cables

from all motor

3. Connect the positive lead of the VOM to all terminal studs of test motor. Use jumper wires to connect between motor terminals. Connect VOM negative lead to motor frame.

.Connect one lead of a Xl@volt megger to any motor terminal. NOTE: Test ALL terminals individually or by interconnecting with jumper wires. Connect other lead to motor frame.

Apply voltage.

4. Resistance should measure at least 1,000,000 ohms (1 megohm). If less than this, motor should be air-cleaned or dried to attempt to increase insulation resistance.

NOTE

Test all terminals individually, or joined together, as noted. ohms (1 megohm) 4. VOM must show 1,CKKl,OOO resistance or higher for a good motor insulation.

5. If less than 1 megohm is measured, air clean motorand repeat test. If air cleaning does not make an improvement, the motor will have to be removed from the truck and dissabled for a closer inspection.

Pump Motor

Drive d (Traction) Motor

NEG.

ii 1

1;

::: .y ‘ii

.;

j;

,x._ ______..

-:i Y,,

gj

--.._

ii

:: 2; ;; ::

,

::

:: I:

0

/‘-

’

Disconnect Truck Battery, Discharge the Capacitors - Refer to Group 19 Disconnect All Power Cables from the Motor Terminals Typical lllustation

SM568

Ott91

16-1-3

Section 1

Motors

GROUP 16 7.

BRUSH AND COMMUTATOR INSPECTION 1. Remove brush cover(s) and remove brushes from brush holders, Clean brushes and holders.

Check brush holders for damage.

8. If brushes do not need to be replaced, and commutator is in good condition, install brushes and brush springs into brush holders.

2. Inspect condition of brushes. Remove each brush from brush holder andinspect brushes and commutator for worn condition and uneven wear.

IMPORTANT

3. Clean commutator surface. Wipe commutator with a dry, lint-free cloth.

ALWAYS REPLACE BOTH BRUSHES AND SPRINGS DO NOT REUSE OLD SPRINGS.

DO NOT USE LUBRICANT OR SOLVENT ON COMMUTATOR. 4.

Check appearance of commutator surface where brushesrideInspectcommutatorba.rsforbumed, damaged or raised areas. The best signs of good commutation are a dark brown highly-polished commutator and uniform glossy brush-wearing surfaces.

5. Measure and make a record of brush length at each inspection. The record will verify amount of brush wear and indicate if there is enough brush length remaining until next scheduled inspection.

6

Brushes must be replaced when worn to approximately half of original length.

Check brush shunt for good contact with brush holder. Be sure shunt is not damaged or burned since this may cause brush spring to carry current and lose tensio

Be sure brush spring is correctly placed on brush holder and that brush isfree to slide in brush box.

9.

Cleanandcheckbmshboxandconnectorscrews.

Tighten if loose. Be sure brush box shunt connection is tight. Install brush cover on motor case.

10. Check and tighten all motor bolts. Check lower nut on each terminal post. It should be installed finger-tight, then tightened another l/4 turn with a wrench.

IMPORTANT Cross Connector

NEW BRUSHES MUST BE OF SAME SIZE AND GRADE (MATERIALSPECIFICATION) AS REPLACED BRUSHES.

Observe how brushes are assembled in brush holders, and position of brush lead (pigtail). New brushes must be installed in same manner.

Typical lllustation

Section1

16-1-4

Ott 91 SM568

GROUP 16

Motors

Brush Inspection Chart

REPLACE

I

BRUSH

CHIPPED

t CHECK TENSION OF EACH SPRING

IF SPRING TENSION

IS NOT THE SAME

REPLACE

FOR EACH BRUSH, REPLACE SPRINGS.

+-I-REPLACE PIGTAIL

BRUSH IF

IS LOOSE

IN THE BRUSH.

BRUSH IF OIL SOAKED

IF BRUSH PIGTAIL IS LOOSE AT THE BRUSH HOLDER TIGHTEN

SCREW.

REPLACE

BRUSHES

WHEN WORN TO d_

N_

HERE.

NEW BRUSHES

ypical Illustration

SM568 Ott 91

Section 1

Motors

GROUP 16

GENERAL Routine Maintenance Schedule with Recorded Findings is the best way to reduce shut-downs and repair of equipment during operating hours

costly

The goal of any maintenance program lung-life and trouble-free operations is related to the time spent making inspections and correcting minor problems as they occur.

Operating Conditions Operating enviroment of lift truck motors varies should be applied as actual conditions dictate.

Normal Service:

Basically an eighthour day of mostly indoororoutdoormaterial handling.

Extreme Service

widley

: The following recommendations

Severe Service:

Extended operating hours, or constant usage.

Dusty or Sandy Locations Cement Plants Lumber Mills Flour Mills Coal Dust Areas Stone-Crushing Areas

Section1

16-1-6

Ott 91 SM568

Material

EDIRH

Handling

GROUP 16

Company

Section 2 Electric Motors Contents Drive Motor ......................................................................................

Pump Motor ......................................................................................

Electrical motor mainmance General Procedures ...............................

Adjustment.. ......................................................................................

Drive Motor Installation ....................................................................

Pump Motor Installation ....................................................................

Rider

16-1-1 16-1-2 16-1-3 16-1-4 16-1-5 16-1-6

Walkie Trucks

Trucks

Pump Moto Pump Motor

Drive (Traction)

For Drive Motor Removal refer to Group 20, Section 1

SM568

Ott91

Drive (Traction)

For Pump Motor Removal refer to Group 28, Section 1

Section2

Motors

GROUP 16 Insulatorb~\

Field Coils

_

Wave Washer

I I?J-

Spring

I I I

8

Screw, Pole Shoe

__.I’\_

Housing

-

End Frame

Drive (Traction) Motor

/dr ‘Ipflf spnng

End Cap

’

/

/

-6

llnsulator

Field Coils Housing

/-

h Hold

L

-

m

I-

Section2

-

Bearing

Wave Washer

_

Spacer J

Screw /

’

1

cre

%

L

Armature

Brush

/

Bearing-/

Thru Bolt i

Pump Motor 16-2-2

Ott 91 SM568

GROUP 16

Motors ELECTRIC MOTORS Disassembly l

l

l

Remove the cover band fmm the commutator end of the motor (if so equipped). Use a brush hook to reach into the motor and lift the brush springs. Pullthebrushesoutofthebrushholders.

Either position the brushes outside the motor or remove the brush retaining screws and remove the brushes from the motor.

Scribeor centerpunchlocatingmarksintheend heads 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.

Remove the commutator end head retaining screws or bolts. Almost all motors have a slip fit bearing at the commutator end, and theend head can be removed with very little trouble. 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.

Coupler

l l

l

Remove the drive end head retaining bolts or screws,ifnecessary. Someofthe smallerpump 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.

Separate the armature from the drive end head.

This operation is usually accomplised by pressingthearmatureoutofthedriveendbearing.

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

When a puller is used, protect the end of the armature shaft with a nut or a thick flat washer.

Ifthe shaft, coupling, or sphne is damaged when removingtheendhead, thearmatureorthedrive spline usually has to be replaced. Use caution and do not damge the armature.

SM568 Ott 91

l

Separate the bearing from the end head. On larger motors the bearing is Mainedwith a snap ring. Remove the snap ring, then press the bearing out of the end head.

There will be occasions when it will be necessary to remove ventilating fans and/or drive splines from armature shafts. The ventilating fans am, for the most part, cast iron or cast aluminum. Once these fans have been pressed onto the armature, they must be heated to be removed without damage.

Remove Fan 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 shaft. When the fan becomes loose on the shaft, as evidenced by thepuller becoming loose, it should be removed as quickly as possible.

16-2-3

Section 2

Motors

GROUP 16 Bearings

Remove Retainer Pin Pressor drive the spline retaining pin out of the shaft and spline.

l

Remove Spline Use a hammer and shisel or drift punch to drive the spline out of the shaft.

CLEANING & INSPECTION

l

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

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

Bearingsshouldbewipedclean withaclothandnever submerged in a solvent. Submerging bearings in a solvent will deteriorate internal lubrication which cannot be replaced.

l

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

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Armature

Drive End Head Check bearing recess for any signs of wear.

Checkmounting holes for any strippedorcmssed threads or broken studs.

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Commutator End Head

l

If upon disassembly of the motor, the field coils or commutator 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.

16-2-4

Where the spline was removed from the annature shaft, relmove all the old grease and any metal chips or filings that may be present.

Install & Drill Spline The new spline is pressed into the shaft and the retaining pin hole is drilled through the new spline. New splines have installation instructions calling out a dimension for spline installation. After the hole has been drilled through the spline, the armature and spline shouldbe blown out with dry compressed air to remove all metal chips and filings.

Oil Seal (where applicable)

Section2

Check the condition of all insulation. If the insulation on the field coils appears blackened or charred, the servicability of the coils is questionable. Burned or charred insulation is a result of coil overheating due to overloading conditions, grounded or shorted coil windings. Check condition of all other insulation such as brush rigging,undercoilconnectionsandaroundterminal StUdS.

Check bearing recess for any signs of wear.

Check brush holder insulation for cracks or any signs of burning. Check brush holders and springs for wear l

Ballbearingsthathavebeenpulledoffofshafts, pressed out of end heads, or side loaded in such a way as to apply pressure on the balls and races must be replaced. Although the bearing may appear or feel good, the bearing races have been brinelled and will fail within a relatively short period of service.

Frame and Field Assembly

Visual Insoection

l

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

l

Check Security of Fan When the fan is reassembled on the shaft, make sure it is a tight fit. Use “Loctite Retaining Compound 40” or equilvalent on the inside of

Ott 91 SM568

GROUP 16

Motors the fan hub when reassembling fan. After the motor has been separated into all its major subassemblies, the components should be cleaned and inspected for wear or damage. l

l

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

Loose commutator bars will usuahy 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 handled screwdriver. A contrasting dull thud or vibration will indicate a loose bar in which case, the armature must be replaced.

l

Place the armature in a lathe and clean the commutator with 00 or finer sandpaper to determine whether or not the commutator needs resurfacing. Light pitting and wear can be removed with the sandpaper. Excessive pitting and wearwill have tobemmoved by resurfacing the commutator.

NOTE

The individual service pages contain a minimum commutator diameter dimension.

The commutator must not be tumed below this diameter. To do so will impede the operation of the motor and possibly result in motor component damage.

Commutator Undercutting Most armatures have the mica undercut. However, if the armature does not have the mica undercut, this operation should not be done. The decision to undercut or not is determined by the type and grade of brush used in that particular motor. The mica should be undercut to a depth equal to the width of the mica.

Thisisusually 1/32inchbutmayvaryinsomemotors. l

After the commutator has been undercut, the armature should be placed in a lathe and the commutator lightly sanded with No. 00 sandpaper to remove any burns left from undercutting, The commutator should then be blown clean with dry compressed air.

SM568Ott 91

16-2-5

L COMMUTATOR

LCOMMUTATOR MICA

RIGHT WAY

WRONG WAY

Section 2

Motors

GROUP 16 TESTING Frame and Field Assembly thorough inspection, the Frame and Field Assembly should be checked for grounded, open or shorted circuits. Grounded and open circuits can be checkedusing a test light, Most commercial growlers incorporate a test light as shown in opposite illustration.

After

Armature

Grounded Circuit l

I-

Touch one test lead to aclean bare metal spot on the frame and check all terminals with the other lead. Ifagroundedconditionexists, the test light will light.

Open Circuit l

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Check between all connecting terminals with testleads. Ifthebulbfailstolight,anopencircu.it is indicated.

Shortedwindingsinseriescoilsarevery difficult to detect. Generally, if the coil insulation is sound and these are no signs of ovaheating, the coil can be presumed good. The individual service pages list the series winding resistance.

The resistance of the series coils is usually so lowaspecialohmmeterorohmmeterattachment is needed to check it.

Shunt coils can be tested with an ohmmeter for properresistanceorwithabattery,ofthespecified voltage, for proper cumznt draw.

Check the armature for grounded circuits by placing one test lead of the test lamp on the commutator and the other test lead on the armature shaft. If the test light lights, the armature is grounded

Section2

Growler

There are two

different electrically connected types of armatures used in motors. Each type requires adifferent method of testing for shorted circuits.

The individual service pages specify the type of armature used in that particular motor series.

NOTE

Ifthearmaturehasbeenturnedand undercut prior to testing, check for and remove any copper buildup or fillings between commutator bars and at the commutatorriser. This condition will cause an armature tocheckshortedandusuallyresults from adull undercutting tool.

Equalizer Winding Connections l

Armature l

/

Typical lllustrati~n

Shorted Circuit l

Switch

l

16-2-6

Thisqpeofarmatuxecannotbetestedona growler like the standard winding connection axmatures. Theequalizerconnectionsaremade between commutator bars and will cause the anna~e to test shorted.

The only practical method of testing these armatures is toperfo~alightloadtestafterthe motor has been completely assembled. If the motor does not meet or exceed all parts of the light load specification, replace the armature.

Oci 91 SM568

GROUP 16

Motors

r

Standard Winding Connections These amxmres are tested on a growler using a steel

strip or hacksaw blade to locate any shorted l

Ha&saw

Blade

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, the strip or blade will vibrate.

Lights

FRAME AND FIELD SERVICE NOTES If theinside of the motor is exceptionally dirty and there is evidence of a grounding condition caused by the dirt, the inside of the motor can be given an additional coat of insulating varnish. Red glyptol can be used 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 aerosol type dispensers.

I L

NOTE 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.

Before spraying field coils, make sure they are absolutely clean anddry. Protect brush rigging, pole shoe faces and end head seats to keep varnish off.

FIELD COIL INSTALLATION

l

Good solder connections are important due to the vibration characteristics encountered by these motors which can cause cold or poorly soldered connections to break. l

Prior toinstallingthejield coils,the connections

which require soldering should be buffed or wire brushed clean to remove any oxidation.

The connections should then be tinned with a soldering iron.

Switch

After tinning and installing the field coils in the frame, align the coil straps and drill an 1l/64” hole (#18 drill) through both straps. Insert a #8/ 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 theendheadtopreventgmundingtheconnection when the end head is installed

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. l

After Field coil instahation, connect the solder joint making sum the solder is flowing properly to avoid a cold soldered joint.

SM568 Ott 91

16-2-7

Pole Shoe Screw Removal& Installation (Field Coil Removal& Installation)

Section 2

Motors

GROUP16 ASSEMBLY AND TESTING After the motor components have been thoroughly cleaned, tested andrepaired or replaced, assemble the unit.

Bearing Installation l

l

Whenever ball bearings are pressed into an end head or onto a shaft, always press against the race that is absorbing the pressure. Press on the outer race when installing into end heads and against the inner race when installing onto a shaft After assembly, the motor should be connected as specified intest connections, and tested to the specificationscontainedon theindividualmotor page-

* Some motors are tested at a voltage different from the specified or rated voltage of the motor.

This is done to avoid excessive current draw and/or excessive free running RP.hI

Section2

16-2-8

Ott 91 SM568

GROUP 16

Motors

Brush Inspection Chart

REPLACE BRUSH IF

IF SPRING TENSION IS NOT THE SAME FOR EACH BRUSH, REPLACE SPRINGS.

I

REPLACE BRUSH IF PIGTAIL IS LOOSE IN THE BRUSH.

I

IF BRUSH PIGTAIL IS LOOSE AT THE BRUSH HOLDER TIGHTEN SCREW.

a_

N_

SM568 Ott 91

REPLACE BRUSH IF OIL SOAKED

REPLACE BRUSHES WHEN WORN TO HERE.

NEW BRUSHES

16-2-9

Section 2

Motors

GROUP 16

GENERAL Routine Maintenance Schedule with Recorded Findings is the best way to reduce costly shut-downs and repair of equipment during operating hours The goal of any maintenance program long-lifeand trouble-jfeeoperations is relatedto the

time spent making inspections and correcting minor problems as they occur.

Operating Conditions Operating enviroment of lift truck motors varies widley: Thefollowing recommendations should be applied as actual conditions dictate.

Normal Service:

Basically an eighthour day of mostly indoororoutdoormaterial handling.

Severe Service:

Extended operating hours, or constant usage.

Dusty or Sandy Locations

Extreme Service

Cement Plants Lumber Mills Flour Mills coal DLlstAreas Stone-Crushing Areas

Section2

16-2-l

0

Ckt91

SM568

Material Handling Company

CLSRK

GROUP 17

GROUP 17 Contactors Contents 16-1-2 Tlip Replacement ................ ..............................................................

OperationalCheck ............................................................................. 16-1-2

Typical Illustration

SM568 DEC 91

17-1-l

Section 1

GROUP 17

Contactors

Replacement of Contact lips

LINE & IA

Inspect contact tips. Replace contacts before contact tip wears through to the base copper material. l

Loosen four long screws in each comer of the contactor.

l

Remove Insulators.

l

Remove stationary contacts.

l

l

CONTACTOR ASSEMBLIES

Loosen and remove the retaining nut from the armature shaft and the movable contact assembly.

Remove the contact assembly.

Install New Tips l

l

Install new tips to reverse order of removal.

Torque the four long screws to 14 to 18 lb. in (1.6 to 2.0 Nom). using a diagonal tightening sequence.

l

Torque the armature shaft nut to 14 to 18 lb. in.

(1.6 to 2.0 Nom).

Armature Shaft Nut

Check Operation l

Retainer Screws

_ Movable Contact Tip

Use an insulated tool (wood/plastic) and push in on thearmatumshaft (movablecontact arm)nut.

Look for binding of the spring or contact assembly.

Section 1

1

17-l -2

(pica1 Illustration

DEC 91 SM568

GROUP 17

Contactors FORWARD & REVERSE CONTACTOR ASSEMBLIES

Movable Tips -

Screws

0 7% Covers

Tips

0 \

Typical Illustration

Replacement of Contact Tips

Install New Tips

Inspect contact tips. Replace contacts before contact tip wears through to the base copper material.

l

l

Loosen four long screws in each comer of the contactor.

Install new tips to reverse order of removal.

Torque the four long screws to 14 to 18 lb. in (1.6 to 2.0 Nom). using a diagonal tightening sequence.

Remove the movable contact covers. l

Remove contact bolts, lo&washers and washers.

Torque the armature shaft nut to 14 to 18 lb. in.

(1.6 to 2.0 Nom).

Check Operation

Remove insulators.

Remove movable contacts.

l

Loosen and remove the retaining nut from the armature shaft and the stationary contact sup-

Use an insulated tool (wood/plastic) and push in on the armature shaft (movable contact arm) nut.

Look for binding of the spring or contact assembly.

port Remove the stationary contact assemblies.

SM568 DEC 91

17-l -3

Section 1

Material Handling CLRRK Company

GROUP 19

Section 1 Contactor and EWT5 Control Panels Contents Control Panel(s) Removal . .. .. .. .... .. .. .. .... ... ... .. .. .... .. ... . ... ... .. .. .. ... . .... .. .. . 19-1-2 Separating EV-TS & Contactor Panels ... .. .... . ... .. .... .. .. .... .. .. .. .. .. .. .. .... . . 19-1-6 Control Card Removal . .. .. .... .. .... .. .. .. .. .. .. .. .. .. .. .... .. .. .. .. .. .. .. .. ... . .. .. .. .. .. .. 19-1-8 Control Card & Capacitor Data . .. .. .. .... .. ... ... .. .. .... .. .. .. ... ... .. .. .. .. ... ... .. .. . 19-1-9 EV-TS Control Exploded View(s) . .. .. .. .. .. .. .. ... ... .. .. .. .. .. .. .. ... .. . .. .. .. .. .. 19-l-10

A,,’

Truck (Battery) Connector

EV-T5 Transistor Control

r

Wire Harness

Contactor Panel

arness -

“‘-

Hydraulic

Unite

6.

2, s.

3. ,

Remove all Jewelry before handling electrical components

DIdve (Traction) UnitTypical lllustra .lion

SM568

Section1

Control Panels

GROUP 19 ,:,. ;?I:_._ ,;’ : “1.. ..

SERVICING THE EV-T5 Control

STEP 1 Disconnect

bat-

Control Fuse

FU2 (15 Amp)

Discharge capacitors .

Refer to 19-2-7.

Disconnect wire #K from TB#l on th< EV-TS control.

TC-Sl

/-

/ i

\ \

/

Al

Sl

Wiring and Cable Identification Diagram

Typical Illustration

Section 1

19-l -2

SM568

GROUP19

Control Panels

I

Harness d

‘._

/---

L__

/’

From Control d+y Panel

.i .,_*;i :: :: , : jj , ,.‘. ’

! Hydraulic :j i Unit $ r:I :<i:

PM-S (+)

,

/

r

iu- _--_-NEGl-1 cr

I

1

Lower Solenoid (Top view)

Wiring and Cable Identification Diagram #47B #47c

HYDRAULIC

UNIT

I-

SM568

19-l -3

Section 1

Control Panels

GROUP 19

Dsconnect Wiring

3

2

i

4

5

6

7

8

9

10

l

Loosen terminal screws.

l

Pull wire spades free of screws.

l

Tag wires as to their location.

11 1: -

Terminal

Board

NOTE ‘Wire #7A Connects to Wire #7E

Wire Harness

‘1

r’

I

1 --_

I L

J

_r T-iFiGiZllsdirZctly 1

3tZcK to 1 Contactor Conductor Bars i-

I

pS&HWD Models On4 Grab Control Handle Wire Harness _-I --A --7

L

L,,,_-_---_--_--_A

To rep&e Early Model Control Cards, refer to: 3erviceIPartsBulletins: SI-19-634-91 &TI-24351203.

Section 1

NOTE

PLPWD

All Models

:ontactor Harness

./: 5,’

L-

.

I-

Grab Handle Harness

19-1-4

To service theEV-TS Control used on earlv model trucks, the control must be removed from the truck. It is not necessary to remove the contactor panel.

.;~

*I_

SM568

Control Panels

GROUP 19 Disconnect Wiring l

l

Unplug Contactor Panel fron 1 control. h-on1

Unplugtruckwirehamess control.

7

Truck Wire Harness

-

@&Qw I

l- --I L _r iktiias Contactor

i

I l---

-I dir<c~y&c~ to 1 Conductor Bars

I l I 1

r

L

j: ,. r..;.:._ ;,/:

‘. .. .

‘._I. jj

,.:

.?

NOTE

It is not necessary to remove the EV-T5 Control for service on late model trucks.

A:,,,..‘: y ,; ,: .

._.

,;.

:, ;.

I ..

. ._.

._

i *.

.

I

,’ j,,

SM568

19-1-5

r

’

Section 1

GROUP 19

Control Panels

Transistor Box Removal (Control Card Replacement) :./\ Early Models Only

STEP 4 lisconnect l

l

Panels

Remove fasteners securing the EV-TS terminals to the contactor panel conductor bars.

It is not necessary to remove the conductorbarsfmmthecontactor panel.

n

Do Not Remove

Contach

Panel

ypical Illustration

Section 1

19-l-6

SM568

GROUP 19

Control Panels

STEP 6

STEP 5

‘I

&Bracket

:

.;‘.. ::

‘% __,

/’ ,

. .

.’

\:

‘.... i

.- . ..

,. ’

- ._. .. . ‘. . ’ -.

Remove EV-TS Control

Remove Panel Fasteners l

Loosen and remove all four retainer nuts.

l

Remove mounting bolts and brackets

l

Lift control upward away from contactor panel conductor bars.

securing control to truck frame.

l

Remove screws securing top and bottom panels to the control housing.

SM568

19-1-7

Section 1

Control Panels

GROUP 19

Control Card Removal & Installation W-T5 ControU hue ModeliTmsks STEP 7 Screw.

Lockwasher 8 Washer Screw, Lo&washer,

Washer

Yellow(Upper) wire /

I

_ower) Wire

Screw, Lockwasher 8 Washer -3

Remove Card

Remove Card l

Remove upper and lower covers from box.

l

Remove upper cover from box.

l

Slide front cover out top of box.

*

Slide front cover out top of box.

Remove three screws securing the yellow, green and black wires to the control card.

0

Remove three screws securing theyellow, green and black wires to the control card.

Slide card out the bottom of box.

*

Slide card out the top of the box.

l

l

Section 1

19-l-8

SM568

GROUP 19

Control Panels Replacement Control Card Data Black Ground Wire Yellow Sensor Wire

Card Harness Plug Green Sensor Wire

EV-TS Card

Face Plate

rypical illustration

TO Replace Early Model Control Cards, refer to: ~ervice/Parts Bulletins: S&19-634-91 & TT-24351203 HWP & HWD

Panel Harness Contactor

Grab Handle Harness

Typical Illustration

SM568

Panel Harness

19-1-9

Section 1

GROUP 19

Control Panels

Capacitors The capacitors are not sold separately. They are serviced in a bank of three. l

l

l

l

l

Remove capscrew, lo&washer, and washer (items 1) securing the Capacitor (+) Terminal to the Heat Sink.

Remove the screw, lockwasher and washer (items 2) securing Capacitor (-) Terminal to the Transistor Conductor NEG Tie Bar.

Wire Co&+xtions’ C&d.

1 /

Cover,_

Remove both capscrews (3) (with washers) securing capacitor mounting bracket (4) and capacitors (5) to the control box (6).

Lift capacitors upward as required to remove screw and TP2 from tcapacitor (see below).

Remove capacitor, bracket and conductors bars from control box (6). r

k.6.

TP2 Therm0 Protector

Yellow Bottow View Capacitor

Bank

TO car&dcld

voical Illustration

plr

(6)

I.I\

I

Current Sensor l

l

The current sensor is connected between T2 and NEG conductor bars with screws (7).

Remove screws and lift sensor from beneath A2 conductor bar.

Green a Sensor

TPl The Thermal Protector (TPl) Mosfet’s is attached to rectifier with one capscrew and lo&washer. The opposite end of TPl wiring is connected to the control card plug. (See oppositie illustration and wiring illustration on next page).

Refer to Section 3 for checking individual components.

Section 1

19-l-10

L

‘POS. #I Filter

(Located beneath A2)

Further Breakdown shown on Page 12.

Tmical Illustratior

SM568

GROUP 19

Control Panels

to Conrtol Card

Plug

Contro IB IOX internal WI rmcl 1

TP2

1

Therm0 Protector (Capacitors)

White & Green Wire to White & Plum Wire to

TPI

T2

A2

Conductor Bar Conductor Bar

Thermal Protector (Mosfet’s)

Connector

to Resistor

Connector

to Resistor

Black Wire to NEG Conductor Bar Q=

Typical lllustratior

SM568

19-1-11

Section1

GROUP19

Control Panels

i-lncl

datnr

Sensor Wires Connect To Control Card 8,

#3 &

#4 Diode Block Connects

To (+) POS Terminal of 1 C Canaritnr

Heat 1 -Sink

w

..A

PI

ransistors /

-.&d in pa&.. only

W”

To

1C Capacitor (-) Conductor Bar

A2

Typical Illustration

Section 1

19-l-12

SM568

Material Handling El!l!RK Company

GROUP 19 Section 2 EV-TS Control Contents

Description ........................................................................................

19-2-2

Control Features ................................................................................

Maintmance ......................................................................................

Trouble Shooting Notes .....................................................................

Waminrrs. Cautions and Notes ...........................................................

19-2-3 19-2-5 19-2-6 19-2-7

Typical Illustration

SM568

Section 1

EV-TS Control

GROUP 19

3. Check for closed emergency reverse switch. If TB9 is at 0 volts when brake switch is closed, the vehicle will not operate.

Description The EV-TS CONTROL is an electronic device that controls electrical power supplied to the vehicle drive motor to provide smooth power to move the truck and to minimize power drain from battery.

Thecontrolconsistsofatransistorunitandacontactor assembly unit, The transistor unit monitors power demand of the truck and then responds by controlling thepowerapplied todrivecomponents. Thecontactor panel contains switching devices to direct heavy power loads to the drive motor and its components.

The control is energized by plugging the battery. A capacitor charging circuit charges the 1C capacitor to battery volts in approximately 2 seconds. The control checksforOvoltsatTB3(withkeyandbrakeswitches open). When the key and brake switches are closed, the control then makes several safety checks: 1. T2 voltage is between 6 and 20 volts. This checks for shorted forward, reverse, and 1A contactors of shorted #3 REC. 2. Check for open High Speed switch. Should be 0 volts at TEB (ignored if TBlO is at battery volts--P truck only).

Section 1

4. Check for open F and R switch inputs, TB6 and TB7 at 0 volts.

5. Checkthattheacceleratorinputvoltageisgreater than 2.5 volts.

If all the above safety checks are satisfied and if the 1C capacitor is fully charged, the line contactor will close and notmal vehicle operation can begin.

Selecting either forward or reverse direction will close the proper direction contactor completing the power circuit to the drive motor. The card then supplies gate voltage to the power MOSFETs turning them ‘ON’. Current flows from the battery and from the 1C capacitor, through the motor armature, motor field, and power MOSFETs back to battery negative.

When the gate voltage at the MOSFETs is removed, they turn ‘OFF’. During the ‘OFF-TIME’, the energy stored in the motor, by virtue of the motors inductance, will cause current to circulate through the motor around the loop formed by the #3 REC. This current is called FLYBACK CURRENT. The battery current continues to flow from battery positive to the 1C capacitor to battery negative during the entire ‘OFF-TIME’. This action will charge the 1C capacitor to slightly higher than battery volts. The control converts battery current at battery voltage into a highermotorcurrentatlowermotorvolts.

Thisis why measured motor current will be greater than battery current.

The time for the next ON and OFF cycle to start is determined by the time the control card takes to oscillate. This frequency of oscillation is controlled by the accelerator input and automatic circuitry in the card. Slow speed is obtained by having maximum input voltage from the accelerator. As the input voltage decreases, the speed of the motor increases.

The MOSFET circuit is capable of delivering approximately 95% speed. For full speed operation, the 1A contactor is closed to apply full battery voltage across the motor.

19-2-2

SM568

GROUP 19

EWT5 Control

Figure 1 and 2 show battery and motor current paths during the ‘On’and ‘OFF TIMES for a typicalrunning condition of 100 amps motor at 50% ‘ON’TIME (half speed).

FET 50 AMPS

+

ON TIME -

Control Features Oscillator: The oscillator set tion of the card has two

adjustable features and one fixed feature. When the accelerator input voltage is at maximum, the creep speedcan be adjusted by the CREEP SPEED trimpot.

Top speed is fxed by the card design and is obtained with the accelerator input voltage at minimum. The % ‘ON-TIME’ has a range of approximately 5 to 95 percent. The center operating condition of the oscillator is at 50percent ‘ON-TIME’ and 33 microsecond ‘OFF-TIME’. This corresponds to a maximum operating frequency of about 15KH.z. At creep the ‘ONTIME’ will decrease to approximately 20 microseconds while ‘OFF-TIME’ will become in the order of 300 microseconds. At full MOSFET operation, this condition will be reversed (short OFF-TIME, long ON-TIME). This variation of ON and OFF-TIME of the oscillator produces the optimum frequencies through the MOSFETrange. The frequency curve of the oscillator is shown in Figure 3.

Figure 1 15KHZ FREQUENCY 1OKHZ

SKHZ

- 5

50

cs

FET RANGE

TS

% ON TIME

3 REC

Figure 3

100 AMPS 4

Figure 2

SM568

The rate at which the oscillator may increase its percent ON-TIME is limited by “CONTROLLED ACCELERATION”. The minimum timerequired to go from creep speed to 95% ON-TIME point may be varied by the CONTROLLED ACCELERATION trimpot. Adjustable from approximately 0.5 seconds to 2.5 seconds.

19-2-3

Section 1

EV-T5 Control

GROUP 19 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 so current may be limited to a pre-set value.

If heavy load currents are detected, this circuit overrides the oscillator and limits the average current to a value set by CURRENT LIMJT trimpot. The C/L setting is based on the maximum thermal ratingof the MOSFETs and the 1C capacitor. Because of the flyback current through the #3 REC, the motor current usually runs 2 to 3 times baattery current. The CURRENT LIMIT can be set by the c/L lrimpot on the card. m Slow down is accomplished when reversing by providing a small amount of retarding torque for deceleration. If the vehicle is moving in one direction and a change of direction is initiated, the motor field is reversed. The plug signal is initated by the fact that the directional switch has switched Tom one direction selection to the opposite direction. The motor armature, driven by the inertia of the vehicle, acts as generator. The generated current passes through 4REC and the sensor. The oscillator circuit regulates at a plug current limit level as set by the PLUG current trimpot. This controls the pulse rate of the MOSFETs to regulate the generated motor current and bring the truck to a smooth stop and reversal.

Accelerator Position PI= This feature will allow for plugging distance based on accelerator position.

Accelerator position will reduce the plugging current as the accelerator is returned to the creep position.

Maximum plug current is obtained when the accelerator is returned to the top speed position.

Ramtl Start; This feature provides full MOSFET torque to restart a vehicle on an incline.

Full Power Transition; This built-in feature provides smooth transition from MOSFETto 1A bypass.

This is accomplished by the MOSFET continuing to pulse until 1A contactor power tips close.

Control Acceleration and 1A Time; This feature

erator input is less than 0.5 volts. C/A is adjusted by the c/A trimpot from 0.5 to 2.5 seconds.

Accelerator Volts Hold-Off; This featurechecks the voltage level at the accelerator input whenever the brake switch is activated. Ifthe voltage is less than 2.5 volts, the control is turned ‘OFF’. This is tQassure that the control is calling for low speed operation at start UP*

Coil Drivers; These drivers are internal to the logic card. They are the power devices that operate F, R, 1A, and Line contactor coils. These drivers energize or de-energize these coils on command from the logic card.

1A Thermal Hold Off; This feature prevents the 1A contactor from closing when the truck is in severe thermal cutback to avoid torque jumps. If thecontrol goes into severe thermal cutback, below 20% ‘OnTime’, the MUST PULSE TO TIME feature will inhibit the IA timer.

Must Pulse To Time; This feature prevents the 1A timer from timing if the oscillation pulse rate has not reached a preset level of operation.

Pulse Monitor Triu (PMT); This feature shuts down or locks out control operation if fault conditions exist that would allow uncontrolled (run away) speed of the vehicle.

The PMT circuit will not allow the control to start under the following conditions: l

If the MOSFETs are shorted or if the 1A contactor tips are welded, the control will not allow theF and R contactor to close.

The PMT circuit will shut down operation of the control (opening of the F and R contactor) under the following conditions: l

If the MOSF’ETs fail to turn ‘Off or if 1A power tips remain closed when they should be open.

The PMT circuit can be reset only by returning to true neutral.

allows for adjustment of the time it takes on hard acceleration for the control to accelerate to 95% ‘ONTIME’of applied battery voltage tothemotor. The IA contactor will automatically close 200 milliseconds after the controlled acceleration stops and the accelSection 1

19-2-4

SM568

GROUP 19

El/-T5 Control Thermal Protectors CTP); These are temperature sensitive devices that are mounted on the MOSFET’s heat sink and the 1C capacitor. If the MOSFETs or capacitors temperature begins to exceed the design limits, the thermal protector will lower maximum current limit and not allow the devices to exceed its temperature limits. Even at a reduced current limit, the vehicle will normally be able to reach sufficient speed for full 1A operation, thereby allowing the panel to cool. As the panel cools, the thermal protector will automatically return the control to full power.

Cow Voltage Batteries under load, particularly if undersized or more than 80 percent discharged, will produce low voltages at the MOSFET control terminal. The EV-TS control is designed for use down to 16 volts. Lower battery volts may cause the control to mis-opemte; however the PMT will open the F and R contactor when battery volts drop below 16 volts.

HiPh Freauencv Oueration; This feature provides a bell shaped oscillation curve that ranges from KHz at creep speed to 15KHz at mid-speed to 5KHz at top speed. The high oscillation rate of the EV-T.5 allows quieter operation, higher average motor current with lower peak motor currents, less ripple current at the motor, and less motor heating.

Emewencv Reversal Circuit; The control logic protects against accidental opening of the emergency reversal switch. By monitoring several operating conditions, the control is able to determine if an invalid emergency reversal condition exist. If it does, the control automatically drops out the forward contactor, picks up the reverse and 1A contactors and reverses the vehicle at full battery power until the emergency reversal switch releases. At this time, the control is inoperable. If the emergency reversal switch is again actuated, the control will allow a full power reversal again, but normal control operation will not berestored until the brake switch is recycled.

Reduced 1A Arcing; Increased tip life can be expected due to arcless 1A operation when currents are below 250 amps.

SM568

Tiu Bounce Timer and Arcless 1A; The Tip Bounce Timer synchronizes the contactors and the power base so that under normal running conditions, the forward and reverse contactors do not make or break current.

Under normal operation conditions, the 1A contactor makescurmntbutdoesnothavebreakcurrent.

Arcless interruption greatly increases 1A tip life.

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

ACAUTIONS Capacitor polarity must be observed, do not connect them or test them with reverse polarity.

The capacitor bank must be torqued to 6-8 inch pounds.

Thermalgreasemustbeusedunderthe#3RECand #4 REC, FETl and FET2, between the #3 and #4 cotherm and the base.

Measurements of the Thermistors and other wires should be taken at the plug. Do not remove the wires from the plug without the proper tool to reconnect them.

MOSFETs must be replaced in pairs.

Capacitors must be replaced in banks of 3.

The following DO’S and DON’TS should be observed: .

19-2-5

The control should not be steam cleaned. In dusty areas, use low-pressure air to blow off control. In oily or greasy areas, a mild solution of detergent or denatured alcohol can be used to wash off control.

Then use low pressure air to blow unit completly dry. The control can also be cleaned with a Freon TF degreaser.

Section1

EWT5 Control

GROUP 19

Use symptoms indicated by the trouble to locate the proper diagnosis chart in troubleshooting section. You may also want to use the sequence of operation manual as a diagnostic tool.

Terminal boards and other exposed MOSFET control parts should be kep free from dirt and paint that might change effective resistance between points.

Proceed to find the problem by using the flow chart in the trouble shooting guide which defines symptoms and their possible cause(s) and solutions.

Locate the trouble by a process of elimination. The cause is usually simple, rather than mysterious and complicated.

&AuTION The truck should not be plugged when the truck is jacked up and the drive wheel is in a free-wheeling position.

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

IMPORTANT Use the electrical schematic diagram for the truck you are working on. You must be able to trace the following:

Do not HIPOT (or megger) control. Unless terminals of each semiconductor and card are connected together, the control may be damaged.

Power Circui@ which consist of heavy cables

Use a lead-acid battery with voltage and ampere hour rating as specified for the vehicle. Follow normal battery maintenance procedures, recharging before 80 percent discharged and with periodic equalizing charges.

and main power components of truck.

Control Circuit3 which control speed, time delay, and controlled plugging.

Directional Circuit8 which control forward and reverse contactors.

TROUBLESHOOTING

bccessorvCircui@ which control components,

When diagnosing and correcting the cause of trouble with an electrical control, do not begin by disassembling components.

includinghom,batteryindicatorandhourmeter.

ACAUTION

Start by analyzing the complaint and symptoms.

Make a preliminary investigation of trouble. Then systematically determine the probable cause.

The following points are fundamental shooting an electrical system. l

l

l

to trouble-

Never start your troubleshooting until you get facts. Talk with truck operator and review work order.

Operate the truck to observe fault and then determinewhat corrective action should be. Determine where to start.

All testingshould bedonewith drivewheel raisedoff thefloor.

Trouble Shooting Notes Trouble-shooting is based on using adigitalvoltmeter to determine if correct voltages are available to permit the control to operate correctly.

The pulsing of the MOSFETs are too fast for conventional instruments to measure. When the control is functioning properly, a high pitch hum can be heard.

Perform the basic checks. Check battery and test for grounds and shorts. Do not take short cuts by assuming these checks do not have to be made.

Section 1

19-2-6

SM568

GROUP 19

EWT5 Control Before proceeding with any testing, visually check for loose wiring, signs of overheating of components, condition of battery and battery receptacle, etc.

Tools and test equipment required are: Clip leads Volt-ohm meter (VOM)

AWARNING

(20,000 ohms)

Before troubleshooting or testing, the drive wheel must be raised off the floor, the battery disconnected and the capacitor discharged.

General hand tools NOTE A digital VOM (such as Simpson Digital multimeter Model 461, or equilalent) is recommended for all electrical and control testing.

To discharge the capacitors: 1. Unplug the battery.

2. Using a lOOohm, 2 watt resistor, short between the POS and NEG power terminals of the control. Hold the resistor in place for 2 seconds before removing.

ACAUTION

BREAKING THIS RULE CAN CAUSE SERIOUS INJURY TO YOURSELF. Make sure the truck has been parked in a safe position with forks fully lowered. Return all controls to neutral and turn key switch OFF.

Using a shorting device without a resistor load could cause damage to the control.

Check resistance(s) from frame to power and control terminals. A resistance of less than 20,000 ohms can cause misleading symptoms. If less than 20,000 ohms resistance is measured, conduct further tests to eliminate short circuit/ground fault conditions.

Refer to Systems Dignostic area for detailed information on sequence of operation and troubleshooting of control.

SM568

19-2-7

Section 1

Material Handling El!!3RK Company

GROUP 19

Section 3 Checking Components and Control Card Adjustments Contents EV-T5 Card Adjustments and Input / Output Connections ... .. .. .. .. .. .. .. 19-3-2 Component Identification . .... .. .. .. .. .. .. .. .. .. .... .. .. .. ...*............................. 19-3-4 Control Internal Wiring . .. .. .. .... .. .. .... ... . .. .. .. .. .. .... .. .. .... .. .. .. .. ... . .. .. .. .. .. .. 19-3-5 Checking Components (Battery Specific Gravity Test) . .. .. .. .. .. .. .. .... .. . 19-3-6

SM5f38 NOV 91

Section 1

EWT5 Control

GROUP 19 EV-T5 CARD ADJUSTMENTS AND INPUT /OUTPUT CONNECTIONS

1

EV-T5 0

T2n

= :O%ROL

2

POI~EP

4

8

3

5

6

7

9

'PEE

10

11

12

Card Adjustments

Input/Output Connections TBl

Battery Positive

TB2

Line Contactor Coil Negative

TB3

Key Switch/Brake Switch Input

TB4

Reverse Contactor Coil Negative

TB5

Forward ContactorCoil Negative

TB6

Forward Directional Switch Input

TB7

Reverse Directional Switch Input

TB8

High Speed Switch Input (Rider TrucksOnly)

TB9

Emergency Reverse Switch Input

TBlO

Key Switch/Brake Switch Input (Walkie Trucks Only)

TBll

1A Contactor Coil Negative

TB12

Accelerator Input

Section 1

CONTROLLED ACCELERATI

NEGn

A2 n CONNEi?Ik'J

Plug Current

8

on HWP/HWD Truck (Customer Preference)

Plug Current

3

on P/PWD Truck (Customer Pref)

Current Limit

7

(Do not Adjust)

Controlled Acceleration

5

(Customer

Creep Speed

3

(Customer Pref)

19-3-2

Pref)

NOV 91 SM568

GROUP 19

EV-TS Control EVT5 COMPONENT IDENTIFICATION rc_-__--

0 1

I

SM568 NOV 91

c-----_

0 n

II

Section 1

EV-T5 Control

GROUP 19 EV-T5 INTERNAL WIRING

I SEN+ , 1

GND

i

SECTION OF CONTROL CARD

I I ______--_--_-

b+

.-

!I Al

Section 1

--

I

BLK

FET 1

T2

A2

19-3-4

NOV 91 SM568

GROUP 19

EWT5 Control

COMPONENT CHECKING WITH COMPONENTS REMOVED FROM PANEL

CHECKING COMPONENTS Specific Gravity Test $mxific Gravity

State of Chars

1.260-1.300

100% Charged

1.230-1.250

75% Charged

AWARNING

1.200-1.220

50% Charged

1.170-1.190

25% Charged

Do not use Handyman to check MOSFETs

1.140-1.160

Very Weak

Test

1.110-1.130

Discharged

FETl and FET2 are MOSFET power modules and should measure infinity ohms on any scale in the conducting direction. Place a jumper wire between the GATE and SOURCE push-on terminals, measure resistance between DRAIN and SOURCE, the red lead on the DRAIN and the black lead on the SOURCE, ReadingshouldbeinfiiityontheRx10,000 scale.

MOSFETS

By using a Hydrometer, the specific gravity of the electrolyte solution in a battery can be determined.

The battery specific gravity is an indication of the battery’s state of charge. If the state of charge is low, the Hydrometer will read low. If the state of charge is high, the Hydrometer will read high.

As an example. A reading from: 1.260 to 1.300 indicates a fully charged battery.

1.200 to 1.220 indicates a battery is in a discharged condition and cannot give satisfactory service.

Tester

In the non-conducting direction the red lead on the SOURCE and the black lead on the DRAIN, they should measure from 5K to 20K on the RxlO,OOO scale.

Test

Battery Tests

Remove the jumper, measure from the GATE to the DRAIN on the RxlO,OOOscale, it should read infinity both directions.

USE BOTH TESTS DESCRIBED HERE Hvdrometer Test: Test at least six cells across battery with a temperature corrected hydrometer, see chart above. Battery should be recharged if specific gravity is below 1.120 to 1.140range. Battery is fully charged if the reading falls in the 1.280 to 1.3OOrange.

If the difference between cells is more than .015, battery needs maintenance.

Test Measure from the GATE to the SOURCE on the RxlO,OOOscale, should readinfinity both directions.

DRAIN

GATE

SOURCE

Load Test: Put the main hydraulic system into bypass while reading battery volts with a voltmeter.

24 Volt Battery

19.2 Volts

36 Volt Battery

28.8 Volts

48 Volt Battery

38.4 Volts

72 Volt Battery

57.6 Volts

CONDUCTING

DIRECTION

D

Battery needs recharge or repair if voltage drops below 80% of the rated voltage of the battery.

SM568 NOV 91

19-3-5

Section 1

EWT5 Control

GROUP 19 #3 and #I4 REC

Module

The #3 and #I4 RECs am diodes and will measure about 5 to 15 ohms when measured from ANODE to CATHODE on the Rx100 scale and should measure 10,000 ohms or higher from CATHODE to ANODE on the RxlO,OOOscale CATHODES CONNECTED TO B,ASE

ANODE 1 .

I

\

Measure the ohms through the capacitor using the Rx100 scale. The meter should swing toward zero then reverse and slowly swing to above 200 ohms.

Meter polarity is not critical.

ACAUTION Disconnect thecapacitorsand check individually. If checked as a bank, one shorted capacitorwill look bad but one open of three capacitors will look OK.

AYoDE * I

SW &OMMON

CATHODE CONNECT ION J

1C Capacitors The 1C capacitors are electrolytic capacitors which can store a significant amount of charge and must be discharged before handling.

AWARNING

Thermal Protector

Before troubling shooting or testing, disconnectthe battery and discharge the capacitors.

Measure the resistance between the gray and black wires at the card plug (inside female connector) for each thermal protector. Readings should be less than 200 ohms at room temperature.

To discharge the capacitors: 1. Unplug the battery.

Current Sensor Shunt

2. Using a 100 ohm, 2 watt resistor, short between POS and NEG power terminals on the control.

Hold the resistor in place for 2 seconds before removing.

Measure the resistance between green and yellow wires. Should read zero ohms on the Rx1 scale, if not replace.

ACAUTION Using a shorting device without a resistor load could cause damage to the control.

BREAKING THIS RULE CAN CAUSE SERIOUS INJURY TO YOURSELF. TWiSTCD PAIR

Section 1

19-3-6

NOV 91 SM568

GROUP19

EV-T5 Control Snubber (1 FIL) 1 FIL is a resistor/capacitor filter assembly. With meter set on the Rx 100 scale, measure across the two terminals. The meter will briefly swing toward zero and quickly back to infinity. reverse the meter leads to repeat test.

SM568 NOV 91

19-3-7

Section 1

Material Handling Company

Cl!!NRIC

GROUP 19 Section 4 EV-T5

Sequence of Operation (Electrical Sequence Drawings)

I

SM568

“IIII

KEY

1941

Ill1

I

Section 4

Control Panels

GROUP 19 OPERATIONAL SEQUENCE #I Drive Control This standard schematic is shown with all switches and contactors in their normal ‘OFF’ position. No circuits are operating. The four basic areas of circuitry are identified. l

POWER

l

SPEED

l

DIRECI’IONAL

l

ACCESSORY

Section 4

19-4-2

SM568

GROUP 19

Control Panels

NEG ~ CTP 3 REC ‘“,_I

t

13

t

l-l

x---

I-rzl

a

1

FET#l

II

1s

.

IA

FF ”

12

-lo--+

/ 10

1

-12

i

12

*

TBl

i 12

SWfTCHE_

I II\

12

I

T t 12

ACCELERATOR

U-72

.‘HM

\_. /--

:

13

13

\ __BATTERY

I

lo-

ACCESSORY

-43

_L I

NOTE

SM568

,2-

HORN .SW’TC”

25

NOTE 2: Solid lines - Standard P Truck Dash lines - Add on for HWP Truck Phsmom lines- Options

1: Wire X7A should be connected to terminal TBlO of the EV-T5 control only on a P truck

194-3

Section 4

Control Panels

GROUP 19 OPERATIONAL SEQUENCE ##2 Drive Control Connect the Battery A. Battery positive will be applied to terminal TB 1 of the card through wire #2, the control fuse and wire #12.

B. The negative circuit will be completed from the ground (GND) terminal of the card, through the black wire, to the control panel negative cable terminal.

C. The card, through an internal circuit, supplies a charging current through the yellow sensor wire to the positive side of the 1C capacitors. This charging current will charge the 1C capacitors to battery volts in approximately 2 seconds time.

When the 1C capacitors are charged to battery volts, the flow of the charging current will stop D. The Battery Discharge Indicator (BDI) will now operate with battery positive being supplied through wire #12, and to negative through wire #13.

E. The horn is operated by pushing the horn button which will supply battery voltage to the horn through wire #25, and to negative through wire #13.

Voltages Present: A. Battery positive B. Battery negative C. Battery voltage across 1C capacitors D.

Battery voltage across the BDI

E. Battery positive on wire #25

Section 4

19-4-4

SM568

GROUP 19

Control Panels

3 REC I1

l-l

FTP -12

?r-FETXl

tS

.

R DRIVE MOTOR li

13 1: ‘-12

TBI

PL9

-I-

-II

I

PL6 “r”“-

10 TBS TSII

L

FWD

13

I 7--%-

TB6

-d-

13

HtGH SPEED

SEE NOTE 1: 7-32

SWITCHES

D1 _

1: Wire X7A should be connected to terminal of the EV-TS control only on a P truck

D2

13

ACCELERATOR

i9

!C-

72

SM568

I

•l

10

NOTE

RI K

GND

-31

I

. _, 23 HOUR METER ..-

\

.

._:

13

131 I

NOTE 2: Solid lines - Standard P Truck Dash liner-Add on for HWP Truck Phantom lines -Options

TBlO

19-4-5

Section 4

Control Panels

GROUP 19 OPERATIONAL SEQUENCE #3 DRIVE CONTROL Close the Key Switch A.

Closing the Key Switch will supply battery positive to the lift and lower switches through the #lO wires.

B.

Closing the lift or auxiliary lift switch (on grab bar) will apply battery positive to the pump contactor solenoid coil through the #43 wire, the lift limit switch and wire #MS.

C. The pump solenoid coil will be energized, closing the pump contact tips.

D.

Current will now flow from the battery through the 1FU fuse, the pump motor, the closed contact tips, to battery negative. This causes he pump motor to operate resulting in the raising of the forks.

E. If the forks are raised to a predetermined height, the lift limit switch is activated (opened). This will deactivate the pump solenoid, which will in turn shut off the pump motor.

F. Closing of the lower or auxiliary lower switch will apply battery positive to the lower solenoid coil through the #47 wires. This energizes the lower solenoid, opening a hydraulic valve to release the hydraulic pressure, thus, lowering the forks.

Voltages Present: A. Battery positive on all #lO wires.

B. Battery positive on all #43 wires.

C. Battery voltage across the pump solenoid.

D.

Battery positive at ‘S’terminal, battery negative at ‘A’terminal.

E.

Battery positive on all #47 wires.

Section 4

19-4-6

SM568

GROUP 19

Control Panels 24 VOLTS

PUMP MOTOR P

NEG CTP

1A

,.............. ~1 FIL : q--c’ :

2

FETI2 , *

FU FTP

4 REC

e FETll

12

L

12

+,+,+ 10

TB4

PL6

7

l t”“-

J J

I

13

10 .

1

I

ACCELERATOR

7

j-.1oe.7 -It-7

NOTE

I7

~?%ER

1: Wire X7A should be connected lo terminal of the EV-T5 control only on a P truck

SM568

:7

t

n FILTER vLdwF

-IT

131

NOTE 2: Solid lines - Standard P Truck Dash lines-Add on for HWP Truck Phantom lines - Options

TBlO

19-4-7

Section 4

Control Panels

GROUP 19 D.

OPERATIONAL SEQUENCE #f4 Drive Control Energizing the Line Contactor A. Before the brake switch is closed, the control checks for 0 volts at terminal ‘ITS3 on thecard. If voltage is present, the system is shut ‘OFF’. TO restart, the brake switch must be cycled.

B. Pulling the steer control handle down to the operating position will close the brake switch.

This will apply battery positive to the card at terminal TFS3,all contactor coils, the directional switches, the emergency reverse switches, terminal TB9, and the high speed switch on the rider trucks or to terminal TBlO on the walkie trucks.

If all of the above safety checks are satisfied and if the 1Ccapacitors are fully charged, thecontrol will complete the circuit from wire #24 to battery negative. This will energize the line contactor coil in turn closing the line contactor power tips.

Voltages Present: A. TB# must be 0 Volts before the brake switch is closed.

B. Battery positive on all #7 wires and at terminal TB3.

C. See explanations 1 through 5 above.

D.

Battery voltage across Line Contactor coil.

C. The control will now make the following safety checks: 1) T2 voltage is between 6-20 volts. This checks for shorted forward, reverse or 1A contactor drivers, shorted #3 REC orpower MOSFETs, or welded forward, reverse or 1A contact tips.

2) Check for open high speed switch. Should be 0 volts at card terminalTB8 (Control will ignore TB8 if TB 10 is at battery volts).

3) Checksforclosedemergencyreverseswitches.

Card terminal TB9 must be battery positive when the brake switch is closed or the vehicle will not start.

4)ChecksforopenF&Rswitchinputs,TB6and TB7 at 0 volts.

5) Checks the accelerator input volts at terminal TB 12. Must be greater than 2.5 volts.

Section 4

19-4-8

SM568

GROUP 19

Control Panels

NEG

CTP

L

tFlL

i....~;

F!....

i i s

12 KEY SWITCH

1

IG

f

r

SEE NOTE 1: 7-32-31 EM;;gpcy SWITCHES 10

I

ACCELERATOR 29 HOUR METER 13------------

I

12

tb

-L loJlo-

BAf?&Y F

LIFT -43 AUX LIFT -43

~9

-9

,3

LIMIT

J_

LOWER

-L

-47--t-47 A, 1Y _ LOWER

loIfI-

NOTE

1: Wire #7A should be connected to terminal of the EV-TS control only on a P truck

SM568

NOTE 2: Solid lines - Standard P Truck Dash lines-Add on for HWP Truck Phantom lines -Options

TBlO

19-4-g

wnmc,

Section 4

Control Panels

GROUP 19 OPERATIONAL SEQUENCE #5 Drive Control Energizing the Directional Contactom A. Rotating the directional/speed control handle forward will close the forward switch. With the forward switch closed, battery positive is applied to termina1 TB6 at the card.

B. When the control senses battery positive at TB6, and 0 volts at terminal TB7, it will complete the circuit from the forward contactor coil to battery negative through wire #27.

C. This will energize the forward contactor coil and in turn, open the normally closed contactor tips and close the normally open tips.

D.

Current also flows to the hour meter (HM) from wire #6 (or #8 in Rev), through the Dl or D2 Diodes, #72 wire and to battery negative through wire #13.

NOTE If battery voltage is applied to both

terminalsTB6andTB7atthesame time, the control will be shut OFF.

Voltages Present: A. Battery positive at terminal TB6.

B.

Battery negative at terminal TB5,battery voltage across the forward coil.

C. Battery positive at T2.

D. Battery voltage across the hour meter.

Section 4

19-4-l 0

SM568

GROUP 19

Control Panels

i ; CTP

2 :. . . . . . . . . . . . .,1 FIL .,.* : : . ....... .

I FET#2

2s

T 13

FTP

k--FETXl

I I

1’2

DRIVE MOTOR

1s

1 +

1

I

KEY SWITCH

13 13 12 7 PLIO

PL6 +_1.

7-

7

TBlO

SEE NOTE 1:

,”

_

I

RED

pL2,

I

WHTlRED

PL4t

l

l?

_I

1 BLU I

13

J

J

J

WHTlBLU

I TB9

7_e?F32-31 EMERGENCY REVERSE SWITCHES

GND*

’

BLK

TB12 I

.”

ACCELERATOR

I

8

12

’

pm

-30 HIGH SPEED

7

PLl *

13 13

12 10

I=

L

-L loJ_

LIFT

DISCHARGE

LIFT -43

INDICATOR

l3

rwl

LIMIT

LOWER

lo-

-

AUX I -47-T-47 . . . ..e_ L”WC”

HORN

NOTE

1: Wire #7A should be connected to terminal of the EV-TS contml only on B P lruck

SM568

NOTE 2: Solid liner - Standard P Truck Dash lines-Add on ior HWP Truck Phantom lines - Options

TBlO

19-4-l 1

w-cl

Section 4

Control Panels

GROUP 19 OPERATIONAL SEQUENCE ##6 Drive Control Turning ‘ON’ the MOSF’ETs A. The control senses that the forward contactor has closed when it senses that T2 voltage is at battery positive through the white and green wire at PLlO. B. A signal from the accelerator at terminal TB 12 starts the time delay which controls the oscillator in the card.

C. The control applies a gate voltage at terminals PLl and PL3, through the red and blue wires, to the gates of the MOSFETs, turning the MOSFETs ‘ON’. This will complete the drive motor circuit to battery negative.

D.

Current now flows from the battery, through the 1FU fuse, the Line contactor, sensor, drive motor armature and field windings, the closed directional contactor tips and through the MOSFETs to battery negative.

E.

Current will also flow from the Capacitors through the same drive motor circuit to battery negative. The amount of current flowing out of the capacitors will depend on the percent ONTIME of the control.

F.

The interaction of magnetic energy between the motor fields and the armature causes the armature to rotate.

Voltages Present: A. Battery positive at terminal PLlO (T2).

B. Less than 3.5 volts at terminal TB12.

C. Not measurable.

D. Battery positive.

E.

N/A

F. N/A

Section 4

194-l

2

SM568

Control Panels

GROUP 19

NEG

1

CTP

2 FU

FET#l

li

1;

KEY SWITCH

t

13

:-7-+23-t-

l

PLY &

T&r

12

l-7--&

SEE NOTE 1:

P7-32

12

FWD TS6

7

7

OTB10 .

-31 EMERGENCY REVERSE SWITCHES

TB9

a

pL4.

WHTl

BLU

I

GND*-fl

TB12

10 ACCELERATOR

Dl

_.

HOUR METER HM 0

“-‘==-I

13

12 : 12

I IO

L lo-

LIFT -43 AUX

,o_--LLIFT -43 L lo-

LOWER -47 FILTER I

-7 _L ,2-

HORN .SWrCH

26 HORN

NOTE

1: Wire #7A should be connected to terminal of the EV-TS control only on a P truck.

SM568

NOTE 2: Solid lims - Standard P Truck Dash lines-Add on for HWP Truck Phantom lines - Options

TBlO

19-4-13

Section 4

Control Panels

GROUP 19 OPERATIONAL SEQUENCE #7 Drive Control Turning ‘OFF’ the MOSFETs, Capacitor Charging and Flyhack A. The control now removes the gate voltage and the MOSFETs turn ‘OFF’ (unlike an SCR, a MOSFET will turn ‘OFF’ when the gate voltage is removed). The filter, WIL, suppresses the voltage spikes from the MOSFETs as they turn ‘OFF. B. Because the battery and capacitors no longer have a circuit through the drive motor, the current stops and the magnetic energy of the drive motor field is allowed to collapse. This collapsingmagneticfieldinducesavoltageacross the field that is opposite battery voltage.

C. This voltage forces current through the armature and sensor and the #3 REC. This current, called ‘FLYBACK CURRENT’, continues to drive the armature during the MOSFET OFF-TIME. D.

Because the Line contactor is closed and the 1C capacitors have been discharged, battery current will now flow to the capacitors, charging them to battery voltage.

Voltage Sequence: Too quick to measure.

NOTE

Average armature current, compared to battery current, will beabout twotothreetimesasgreat when operating in the MOSFET range.

Section 4

19414

SM568

Control Panels

GROUP 19

i I

2 I

FU

_..._

i A _ FTP

GRN

Al

KEY SWfTCH

SWITCH 12 r BRAKE 10 10

7 10 91

12

5

0 SEN

12

-

PL9 I

.

3 z

E

<

SEN

TBl

YEL

I

?z 0

3

_I

10 t-7-+27+

TB5

t-7-+-_41+-TBll

PL7.

;

GRY

PL8-

1

BLK

S h

ACCELERATOR 01

HOURMETER

12

12 -L

lo1o

B-13_

BDI

13

BA%Y DlSCHARGEl~~TOR

LIFT -43 AUX

1

45

131 _T

;t.

f

3

+LlFT -43 _L

olo-

-I. J_

,2----r

LOWER -47

7

%ZER -7

FILTER

.

HORN .SW’TCH

25

25_13I HORN

NOTE

1: Wire #7A should be connected 10 terminal of the EV-TS control only on a P truck.

SM568

NOTE 2: Solid liner - Standard P Truck Dash lines-Add on for HWP Truck Phantom lines - Ootionr

TBlO

19-4-l

5

wmnn c,

Section 4

Control Panels

GROUP 19 Voltages Present:

OPERATIONAL SEQUENCE #8

A. 3.5-4.0 volts at creep speed. 0.5 volts or less at top speed.

Drive Control Accelerator, thermal protectors and PMT

B. Others N/A

Turning the MOSFETs ON and OFF produces a switchingtechniquethatcontrolsthespeedandpower of the truck. More or longer pulses produce more power.

A. The number and length of pulses is governed by the accelerator module and the sensor. Rotating the directional/speed control handle changes the input into the control at terminal TB 12 and the control works faster. The sensor monitors the motor current and signals the control to shorten the pulses during high motor currents.

B. If the control is overworked, the MOSFETs and/ or the 1C capacitors and their corresponding TPs will get hot. Resistance in the TPs will increase and reduce the control power regardless of accelerator position.

C. When the MOSFETs are turned ON, the #3 REC stops conducting.

D. The white/green wire to the card pin PLlO allows the control to sense pulsing. If the MOSFETs fail to turn OFF, the card opens the circuit from terminals TB4 and TB5 to battery negative so the directional contactor coils deenergize, dropping out the contactor tips.

E. The control will quickly re-close the proper contactor in a ‘LOOK AGAIN’ mode and drop out the contactors if the problem still exists. To reset the PMT, you must return the truck to a full neutraI, that is, open the brake switch with the directional switches also open.

Section 4

19-4-l 6

SM568

GROUP 19

Control Panels &

24 VOLTS

01 s:

FU

PUMP MOTOR

NEG CTP

2

t

FU

v _ FfP

a

C”

FETYI

1s

DRIVE MOTOR 1‘2 KEY SWITCH t 12

L

12

I 7+*

TB3

(PLlOW

I I I I

I

I

I

I

10

7

7

* TBlO

PL4 .

.

GND.

I

WHT / BLU

<iEE I lOTE 1:

10

7-32-31

TB9

BLK

EMERGENCY REVERSE SWITCHES ACCELERATOR Dl HOUR METER

12

12 -L

29 e13----------1

BDI

13

13

13

13

LIFT _AUX

loL

LIFT -43

loJ_

LOWER

lo-

-7 -7

,

,2

HORN ,SWITCH

25 HORN

1: Wire #7A should be connected to terminal of the EV-T5 control only on a P truck

SM568

NOTE 2: Solid lines - Standard P Truck Dash lines -Add on for HWP Truck Phantom lines - Options

TBlO

194-l

7

Section4

Control Panels

GROUP 19 Voltages Present:

OPERATIONAL SEQUENCE #9

A. ‘II312 voltage less than 0.5 V. TB8 at battery

Drive Control

voltage on rider trucks.

1A Contactor Operation - (Walkie Trucks Only) Rotating the directional/speed control handle will gradually reduce the voltage input to the control at terminalTB12whichallowsmorefrequentpulsingof the control resulting in smooth speed and power control up to 95% of available battery voltage.

A. Rotating the directional/speed control handle fully signals the control to start the 1A time delay.

B. BatterynegativeatTB the 1A coil.

11. Batteryvoltageacross

NOTE

The control has a built in thermal lAhold-off.The 1Acontactorwill not close if the control is in severe thermal cut-back.

B. After a short time delay, the control completes the circuit from the 1A contactor coil, through wire #Ml to terminal TB 11 to battery negative.

This energizes the 1A coil.

C. The 1A power tips close completing the control bypass circuit.

1A Contactor Operation - (Rider Trucks Only) Rotating the directional/speed control handle will gradually reduce the voltage input to the control at terminalTE312whichallowsmorefrequentpulsingof the control resulting in smooth speed and power control up to 60% of available battery voltage.

A. With the directional/speed control handle fully rotated, depressing the high speed button on the grabbarappliesbatterypositivetoterminalTB8 signaling the control to continue through the controlled acceleration mode to 95% ON-TIME and than start the 1A time delay.

B. After a short time delay, the control completes the circuit from the 1A contactor coil, through wire #41 to terminal TB 11 to battery negative.

This energizes the IA coil.

C. The 1A contactor power tips close completing the control bypass circuit.

D.

Once the 1A Contactor has closed, the high speed switch can be opened and the control will stay in the 1A modeunless the directional/speed control handle is rotated back until the accelerator input voltage at TB 12 raises above 0.5 volts.

Section 4

19418

SM568

GROUP 19

Control Panels 2

i

bHII%e

I 24VOLTS

8’ m

FU

PUMP MOTOR

CTP

1A

3 REC

m

r,,a1 I-

2

\

NEG

1 FIL

-1

FETX;!

FU FTP

u + FETYl

1s

i2 KEY SWiTCH

r

10

12

BRAKE SWITCH

WHT/RED

SEE NOTE 1:

6

7

7

l

7-32-31---MRg;;CY

TBlO

pL4.

TB9

GND.

WHT/BLU

I

BLK

SWITCHES 10

ACCELERATOR DI HOURMETER

1

29e13-

HORN

NOTE

1: Wire #7A should be connected to terminal of the EV-T5 control onb on a P truck.

SM568

NOTE 2: Solid lims - Standard P Truck Dash lines-Add on for HWP Truck Phantom lines -Options

TBlO

19-4-l 9

Section 4

GROUP19

Control Panels

OPERATIONAL SEQUENCE #lO Drive Control Plugging Controlled plugging (using the reverse power of the drive motor as a brake) is attained when changing direction from forward to reverse (or reverse to forward).

A. The directional/speed control handle is rotated from forward, opening the forward switch.

B. While the handle is in it’s neutral position, both the directional switches are open.

C. The control stops functioning because the voltage has been removed from terminal TB6.

D. The forward and 1A contactor coils are deenergized and the contactor tips return to their normal position, opening the drive motor circuit.

NOTE

Thetruckwillbecoastingforward.

Section 4

19420

SM568

GROUP 19

Control Panels 2

01 g

FU

i NEG

4 2

FET#2

FU

-12

2G FET#l

DRIVE MOTOR

z

i2

’

1s

L

1G

KEY SW ITCH

SWITCH BRAKE

10

10

12

4 7

7--j-.

TB3

PLlO+-J

?J PL6 PL7

. .

7-

+--

WHTIRED

.

-30 HK;H SPEED

-

I

RED

BLU

tii-

ACCELERATOR

I

Dl

12

12

I

10

lo-

-L

-43LIFT

L

AUX LIFT -43

loJ_ lo-

_T_

,3

1

LOWER

-I_

47 ?&ER

‘7 J_

,2-

45

LIMIT

‘7

10’

13

BDI BA-%&Y DISCHARGEIND;CJ

HORN .SW’TCH

25 HORN

NOTE

1: Wire X7A should be connected to terminal ot the EV-TS control oniy on B P truck.

SM568

NOTE 2: Solid lines - Standard P Truck Dash lines - Add on for HWP Truck Phantom lines -Options

TBlO

19-4-2

1

,Lnm CI

Section 4

Control Panels

GROUP 19 OPERATIONAL SEQUENCE #I 0 Drive Control Plugging (continued) A. The operator rotates the directional/speed control handle through neutral to reverse, closing the reverse directional switch.

B. With the reverse switch closed, voltage is applied to the control at terminal TB7. The control senses that the truck has been moving and that the handle has been rotated through neutral. This causes the plugging logic in the control to take over.

C. The control now completes the circuit from the reverse contactor’s coil negative through wire #23 and terminal TB4 to battery negative. This energizes the reverse coil.

D.

With the reverse contactor coil energized, the reverse contactor tips close changing the drive motor circuits to the reverse direction.

E.

The control now gates ON the MOSFETs.

Section 4

19-4-22

SM568

GROUP 19

Control Panels

NEG

Cl-P

I

---2

3 REC

1 FIL I

2

2s

FET#2

rl 13

3

FU FTP

4 REC

d

u

x---

FET#l

1s

DRIVE MOTOR i2 I

GRN

KEY SWITCH

z

YEL

1G

5

5 SEN ( *

( SEN _

SWITCHES ACCELERATOR

l-l-

Dl

12

12

12

10

_L

LIFT

-!-

-AUX LIFT -43

loloJ_ lo-

-7 -L

lo-

i”

LOWER 47

47-qa-v3

?%ER

FILTER

-7

12-

25

*,-Q-13 HORN

NOTE

I: Wire X7A should be connected to terminal of the EV-TS control only on a P truck.

SM568

NOTE 2: Solid lines - Standard P Truck Dash lines - Add on for HWP Truck Phantom lines -Options

TBlO

19-4-23

Section 4

Control Panels

GROUP 19 OPERATIONAL SEQUENCE #I 0 Drive Control Plugging (continued) As the MOSFETs are turned ON, the truck is continuing to travel in the forward direction because of inertia. Because the drive motor fields have been reversed, the motor armature now becomes a generator because it is driven against the magnetic effect of the field.

A. The voltage polarity reverses across the arma? ture of the motor changing the voltage of terminal A2 to positive and that of Al to negative.

This voltage causes the #@IREC to conduct and thus provides a path for the generated current.

B. This generated current is sensed by the control at pin PL9 through the whitebiolet wire, which over-rides the main oscillator section of the control allowing only a predetermined slow pulsing, as adjusted by the ‘PLUG’ uimpot on the control and by the accelerator position. The control is locked into the plugging mode.

C. The control also over-rides the 1A timer section and will not allow the 1A coil to be energized during the controlled plugging operation.

D. This slow pulsing will bring the truck to a smooth, controlled stop. The voltage polarity at the armature will return to normal. When the control senses this through the white/violet wire at pin PL9, the truck will start to accelerate normally in the opposite direction.

Section 4

19-4-24

SM568

GROUP 19

Control Panels PiVciLTS 01 PUMP MOTOR

< i

NEG

I CTP

3 REC

tA

I

2 FU I

I I

DRIVE MOT0

i

I

II’

KEY SWITCH

FET#2

rl

1G

-1o'I 10

BRAKE SWITCH

4

7

10

7-

-30 HIGH SPEED pL4 ~

WHTlBLU

SEE NOTEl:

10

ACCELERATOR

HOUR METER

29e13A 13

n I 12

I 10

L

LIFT _AUX

lo-llo-

LIFT -43

L lolo-

LOWER -47

-l-

-7

%JER

12-

FILTER

25 HORN

NOTE

1: Wire X7A should be connected to terminal of the EV-TS control oniy on a P truck.

SM568

NOTE 2: Solid liner - Standard P Truck Dash liner - Add on for HWP Truck Phantom lines -Options

TBlO

19-4-25

rc-

c,

Section 4

Control Panels

GROUP 19

NOTES 1) The Emergency Reverse function is inoperable if the Emergency Reverse Switch is opened before the brake switch is closed.

OPERATIONAL SEQUENCE #ll Drive Control Emergency Reverse A. Actuating the Belly-Button will open the Emergency Reverse Switch(s).

B. With the opening of either Emergency Reverse Switch, the battery voltage at the control terminal TB9 is removed.

C. The control senses this and will de-energize the forward contactor coil, in turn dropping out the forward directional contactor tips.

D.

2) On the rider truck only, holding the high speed switch closed will disable the Emergency Reversefunctionunderanymodeifthedrivemotor current is less than 120 Amps.

3) On the rider truck only, if the accelerator is held at maximum speed, the 1A contactor is energizedandthedrivemotorcurrentislessthan 120 Amps, the Emergency Reverse function will be disabled.

The control now energizes the reverse and 1A contactorcoilsthrough terminalsTB4andTBll. This will close both thereverse and 1A contactor tips.

E. The closure of both the reverse and 1A contactor tips with the truck still moving in the forward direction, causes a maximum reverse current to flow through the drive motor field. This generates maximum reverse torque to stop and reverse the drive motor, resulting in moving the truck away from the operator.

F. As the truck moves away from the operator, the Belly Button will be released. This will re-close the Emergency Reverse Switches and apply battery positive to terminal TB9. The control senses this voltage and disables the normal operation of the truck.

G. Re-opening of one of the Emergency Reverse Switches will continue to operate the truck at maximum power in the reverse direction only.

H. To reset the control for normal operation after the initiation of an Emergency Reverse, the truck must be returned to a true neutral. True neutral is defined as: The brake switch must be opened and re-closed with both directional switches open.

Section 4

19-4-26

SM568

GROUP 19

Control Panels & 8’ m

24 VOLTS

FU

PUMP MOTOR

NEG

FTP

FETM

1s .

DRIVE MOTOR i2 KEY SWITCH

r

I

13

BRAKE SWITCH

1

1

f-7

7.+

TB3

PLlO.-y

.

GRY

.

BLK

.

GRY

]

10

7-y=y-S#

TB7

PU*

’

t

J

WHT’RED BLU

HIGH SPEED pL4.

SEE INOTE 1:

WHTlBLU BLK

10

ACCELERATOR 29-w-13-

-7-T-“’ lb

A

LIFT

_L

r

lo-l_ lo-

LIFT -43

_L 10’

LOWER -47

-L lo,7

(

HOUR METER

%&ER

FILTER

-7 _L _

HORN ,SWITCH

25 HORN

NOTE

1: Wire #7A should be connected to terminal of the EV-TS control only on a P truck.

SM568

NOTE 2: Solid lines - Standard P Truck Dash lines-Add on far HWP Truck Phantom lines -Options

TBlO

19-4-27

Section 4

ELqRH

Material Handling Company

GROUP 19

Section 5 EV-T5 Flow Chart Trouble Shooting Procedures

ALL TCSTINC, SIIOULD BC DONC WlTll DRIVE WIIKLS RAISCD orr TLOOR. BATTCRY SIIOULD BI: UNPLUCCCD rOR CONNCCTING OR DISCONNCCTING ANY WIRES AND/OR COtlPONCNTS

SM568

19-5-l

Section 5

Control Panels

GROUP 19 SYMPTOM

DEFECTIVE ZFU. REPLACE.

I

No

CHECK BAlTERY FOR LOW S.G. AND LOOSE/ BROKEN CONNECTIONS.

PLUG IN THE EAlTERY. TURN KEY AND BRAKE SWITCHES’OFF. MEASURE VOLTAGE ON TERM. TBl OF CONTROL CARD.

CHECK C0NTlYUll-Y OF WIRES 12 & 12.

TURN KEY AND BRAKE SWITCHES ‘ON. MEASURE VOLTAGE ON TERM TB3 OF CONTROL CARD. CHECK CONTlNUllY

BRAKE SWITCHES. REPAIR /REPLACE. MEASURE VOLTAGE ON POSITIVE TERMINAL OF UNE CONTACTOR COIL. CHECK CONTINUITY OF WIRE 17 TO UNE CONTACTOR COIL REPAIR I REPLACE.

MEASURE VOLTAGE ON TERM. TB2 OF

CHECK C0NTlNUi’t-f OF WIRE 124 FROM UNE CONTACTOR COILTO

CHECK LINE CONTACTOR MECHANICAL BINDING.

DEFECTIVE CONTROL CARD. REPLACE.

FOR I

ALL TESTING SHOULD BE DONE WITH DRIVE WHEELS RAISED OFF FLOOR. BATTERY SHOULD BE UNPLUGGED FOR CONNECTING OR DISCONNECTING ANY WIRES AND/OR COMPONENTS.

Section 5

Control Panels

GROUP 19 SYMPTOM

ALL TESTING SHOULD BE DONE WITH DRIVE WHEELS RAISED OFF FLOOR. BATTERY SHOULD BE UNPLUGGED FOR CONNECTING OR DISCONNECTING ANY WIRES AND/OR COMPONENTS.

LINE CONTACTOR CLOSES DIRECTIONAL CONlACTORS CLOSE.

2

BUl WILL NOT

-1

NEUTRAL, MEASURE VOLTAGE AT TERM.

CHECK FOR SHORTED I MISADJUSTED FORWARD OR REVERSE SWITCHES.

WITH TRUCK IN NEUTRAL, MEASURE VOLTAGE AT TERM. 188 OF CONTROL CARD.

CHECK FOR SHORT FROM WIRES 16 L #*TO BATTERY POSITIVE. REPAIR I REPLACE.

NO SPEED SWITCH.

WVH TRUCK IN NEUTRAL, MEASURE VOLTAGE AT TERM. TB9 OF CONTROL CARD.

CHECK FOR OPEN EMER. REVERSE SWITCHES OR STUCK BELLY BUTTON.

MEASURE VOLTAGE ON TERM. TBA A TB5 OF CONTROL CARD.

MEASURE VOLTAGE ON TERM. TBl2

OF

YES YES MEASURE

VOLTAGE ON T2 OF CONTROL.

CHECK FOR 1A CONTACTOR TIPS TO BE CLOSED.

YES

CHECK FOR JGFWDl

1A CONTACTOR TIPS ARE WELDED. REPAIR/ REPUCE. REPAIR I REPLACE.

SM568

CONTACTOR TIPS. CHECK FOR REVERSED A2 AND 12 POWER CONNECTIONS. REPAIRI REPLACE.

NO

19-5-3

Section 5

Control Panels

GROUP 19 SYMPTOM

3

DIRECTIONAL CONTACTORS CLOSE. NO POWER AND NO AUDIBLE SOUND. TRUCK INOPERATlVE WITH ACCELERATOR IN FET

1 CHECK POWER FUSE 1 FU.

1

CHECK AND REPAIR LOOSE CONNECTlONS AND /OR REPLACE DEFECTlVE FUSE 1 FU. PLUG IN THE SAlTERY. CLOSEALLSWITCHES REOUIRED TO CLOSE DIRECTION CONTACTOR. MEASUREVOLTAGEATPOWERTERMINAL72 OF CONTROL.

&Al

TO A2 ON DRIVE MOTOR. YES ROTATE (MOVE) CONTROL HANDLE TO CLOSE FWD, REV SWITCH. MEASURE VOLTAGE ON

REPAIR / REPLACE DRIVE MOTOR.

CHECX CONTlNUlTY AND A2 CABLES.

OF Sl, S2, Al

REPAIR I REPLACE CABLES.

ROTATE (MOVE) CONTROL HANDLE FORTOP SPEED. MEASURE VOLTAGE ON WIRE 129AT TERM.TS120FCONTROLCARD. CHECK CONTINUITY OF FWDl REV CONTACTOR TIPS TO LOCATE OPEN. REPAIR I REPLACE.

CHECKGREEN WIREONCURRENTSENSOR FOR CONTINUITY BROKEN INSULATION AND

DEFECTIVE SENSOR. REPLACE.

CHECK BOTH THERMAL PROTECTORS FOR HIGH RESISTANCE (OPEN) OR LOOSE I BAD

DEFECTIVE CONTROL CARD REPLACE

ALL TESTING SHOULD BE DONE WITH DRIVE WHEELS RAISED OFF FLOOR. BATTERY SHOULDBE UNPLUGGED FOR CONNECTING OR DISCONNECTING ANY WIRES AND/OR COMPONENTS.

Section 5

19-5-4

SM568

GROUP 19

Control Panels SYMPTOM

4

ONE DIRECTIONAL CONTACTOR CLOSES WITH NORMAL OPERATION Bm OTHER DIRECTIONS

PLUG THE BATTERY CLOSE KEY AND BRAKE SWITCHES MEASUREVOLTAGEONTERM TB6

CHECK FOR SHORT FROM WIRES -=2.‘12.=10&=7TOTERM’S TB6 AND TB7

NO

&YES WAIT ONE SECOND, THEN CLOSE DIRECTIONAL SWITCH OF CONTACTOR THAT WILL NOT CLOSE. MEASURE VOLTAGE ON OTHER DIRECTIONAL INPUT TERMINAL (TB6 OR TB7) OF CONTROL CARD

CHECK FOR MISAIJJUSTMENT AND /OR PROPEROPERATIONOF DIRECTIONAL SWITCHES REPAIR / REPLACE

NO l

CHECK FOR SHORT FROM SWITCH (FbvD / REV) OF CONTACTOR THAT WILL NOT CLOSE & CORRESPONDING WIRE (“6 OR ‘8) TO OTHER DIRECTION INPUT TERM (TB6 OR T671 ON CONTROL CARD REPAIR 1 REPLACE

MEASURE VOLTAGE ON NON CLOSING DIRECTIONAL INPUT TERM (TB6 OR TB7) OF 1 CONTROL CARD CHECK CONTINUITY 8, PROPER CONNECTIONS ON WIRES ‘7 AND c =6 OR =8 AND OPERATION OF DIRECTIONAL SWITCH REPAIR / REPLACE

1

MEASURE VOLTAGE ON POSITIVE OF NON CLOSING CONTACTOR COIL (WIRE =7)

MEASURE VOLTAGE ON NEGATIVE OF NON CLOSING CONTACTOR COIL (WIRE =23 / ‘27)

MEASURE VOLTAGEONTERM TB40RTB50F CONTROL CARD (NON - CLOSING COIL DRIVER

YES

CHECKFORCONTINUITYOF WIRES “23 OR ‘27 AND / OR BINDING - DIRECTIONAL CONTACTOR REPAIR / REPLACE

DEFECTIVE COIL DRIVER INSIDE CONTROL CARD REPLACE CONTROL CARD

ALL TESTING SHOULD BE DONE WITH DRIVE WHEELS RAISED OFF FLOOR. BATTERY SHOULD BE UNPLUGGED FOR CONNECTING OR DISCONNECTING ANY WIRES AND/OR COMPONENTS.

SM568

194-5

Section 5

GROUP 19

Control Panels SYMPTOM 6

SYMPTOM 5 1PMTTRIPSAFTER

OPERATING IN 1A 1 MODE AND RETURNINGTO FET MODE.

CONTACTORS

1 1

CLOSE. HIGHER THAN NORMAL

NOT ADJUST. CONTAGTORS

i

MAY OPEN ONCE

UNPLUG BATTERY. DISCHARGE 1C CAPACFTORS. CHECK PART NUMBER OF 1A CONTACTOR COIL. SCREW -ON POSTS MARKED’SEN

-‘a ‘SEN l

WRONG 1A COIL. REPLACE. REPAIR I REPLACE. MEASURE THE RESISTANCE CONTACTOR COIL.

OF 1A

DEFECTIVE IA COIL REPLACE.

1 CHECK IF 1A CONTACTOR MECHANICALLY BINDING.

IS

I

1CHFCK ddRFCK FOR

I

DEFECTIVE 14 REC. REPLACE.

REPAIR I REPLACE.

I

DEFECTIVECONTROLCARD.

[ DEFECTIVECONTROL’-“”

REPLACE

q C01

Apc

1

ALL TESTING SHOULD BE DONE WITH DRIVE WHEELS RAISED OFF FLOOR. BATTERY SHOULD BE UNPLUGGED FOR CONNECTING Ofi DISCONNECTING ANY WIRES AND/OR COMPONENTS.

Section 5

19-5-6

SM568

GROUP 19

Control Panels

SYMPTOM 7

IA CONTACTOR

WILL NOT CLOSE

ON RIDER.

“NPLVG BATTERY& DISCHARGECAPACITOR. CHECK ,A CONTACTOR FOR FREE M3VEMENT.

Fy?+i$k+ MEASURE

, RESISTANCE

OF 1A CONTACTOR

REPLACE.

PLUG THE BATTERY. OPERATE THE TRUCK FOR TOP SPEED AND MEASURE THE VOLTAGE FROM’POS POWER TERMINAL ON CONTROL

r WITHOUTACTU~TING CONTROL

ADJUST

VOLTAGE CONTROL

CARD.

THE HIGH

AT TERM CARD.

TBll

7

OF

CHECK CONTINUITY OF WIRES “7 AND Ml TO 8 FROM IA COIL AND BAD I LOOSE CONNECTIONS. REPAIRIREPLACE.

TO SPECIFICATION.

MEASVRE DRIVE MOTOR CURRENT LlMlTUSlNG PROPER PROCEDURES.

MEASURE VOLTAGE ON TERM. 7812 AS CONTROL HANDLE IS ROTATED FOR TOP SPEED.

CHECK FOR BAD DRIVE MOTOR AND /OR CABLES

OPERATE THE TRUCK IN STALL MODE. MASURE VOLTAGES ON GRAY WIRESOF BOTH THERMAL PROTECTORS AT THE PLUG (PIN f5 & “7) ON CONTROLCARD.

OF CONTROL

CARD

CHECK CONTINUITY OF WIRES “7 6 130 AND OPERATION OF HIGH SPEED SWITCH. REPAIR I REPLACE.

10 I YES

CONTROL MAY SE IN THERMAL CUTBACK. ALLOW TRUCK TO COOL. RECHECK IA CONTACTOR OPERATION. YES

DETERMINE CAUSE THERMALCUTBACK

OF

DfSCONNECT PLUG ON CONTROL CARD. CHECK FOR OPEN THERMALPROTECTORSBETWEEN PIN #S L #6 AND PIN 17 8 1(8.

YES

DEFECTIVE THERMAL PROTECTOR (S). REPLACE.

YES

YES REPLACE

TESTING SHOULD BE DONE WITH DRIVE WHEELS RAISED OFF FLOOR BATTERY SHOULD BE UNPLUGGED FOR CONNECTING OR DISCONNECTING ANY WIRES AND/OR COMPONENTS ALL

SM568

19-5-7

Section 5

Control Panels

GROUP 19 SYMPTOM 8 1A CONTACTOR

WILL NOT CLOSE ON WALKIE.

UNPLUG BATTERY (L DISCHARGE CAPACITOR. CHECK 1A CONTACTOR FOR FREE MOVEMENT.

MEASJRE COIL.

RESISTANCE

OF 1A CONTACTOR

PLUG THE BATTERY. OPERATE THE TRUCK FOR TOP SPEED AND MEASURETHE VOLTAGE

-

CONTROL CARD.

WITHOUT ROTATING THE CONTROL HANDLE FOR TOP SPEED, MEASUREVOLTAGE AT TERM. TBl 1 OF CONTROL CARD.

10 CHECK CONTINUITY OF WIRES 17 AND 141 TO 6 FROM 1A COIL AND BAD I LOOSE CONNECTIONS. REPAIR I REPLACE.

ADJUST TO SPECIFICATION.

MEASURE DRIVE MOTOR CURRENT LIMIT USING PROPER PROCEDURES.

MEASURE VOLTAGE ON TERM. TB10 OF CONTROL CARD.

WIRE87.REPAlRlREPlACE. 110

OPERATE THE TRUCK IN STALL MODE. MEASURE VOLTAGES ON GRAYWlRESOFBOTHTHERMAL PROTECTORS AT THE PLUG (PIN #S 8 17) ON CONTROL CARD.

YES

CONTROL MAY BE INTHERMAL CUTBACK. ALLOW TRUCK TO COOL. RECHECK 1A CONTACTOR OPERATION. YES

DISCONNECT PLUG ON CONTROL CARD CHECK FOR OPEN THERMAL PROTECTORS BETWEEN PIN t5 & 16 AND PIN 17 6 18.

YES

DEFECTIVE THERMAL PROTECTOR (S). REPLACE.

YES

ALL TESTING SHOULD BE DONE WITH DRIVE WHEELS RAISED OFF FLOOR. BATTERY SHOULD BE UNPLUGGED FOR CONNECTING OR DISCONNECTING ANY WIRES AND/OR COMPONENTS.

Section 5

19-5-8

SM568

GROUP 19

Control Panels SYMPTOM STIFF PLUG AND/OR WILL NOT ADJUST.

9

PLUGGING

DISTANCE

4 CHECK PLUG ADJUSTMENT CONTROL CARD.

DESIRED

SElTlNG

ON I

LEVEL.

CHECK IF GREEN AND YELLOW WIRES FROM CURRENT SENSOR ARE CONNECTED TO SCREW _ ON POSTS MARKED’SEN = 8 ‘SEN +RESPECTIVELY ON CONTROL CARD.

REPAIR / REPLACE.

CHECK GREEN AND YELLOW WIRES FROM CURRENT SENSOR FOR OPEN.

CHECK #4 REC FOR OPEN

DEFECTIVE

#4 REC. REPLACE.

DEFECTIVE

CONTROLCARD.

REPLACE.

ALL TESTING SHOULD BE DONE WITH DRIVE WHEELS RAISED OFF FLOOR. BATTERY SHOULD BE UNPLUGGED FOR CONNECTING OR DISCONNECTING ANY WIRES AND/OR COMPONENTS.

SM568

19-5-g

Section 5

GROUP 20

Drive Unit

Section 1 Drive Unit Assembly Description ............................................................................................................... 20-l-l Ring & Pinion End Play, Backlash Check & Adjustment ..................................... ..20-1-2 6 Removal .................................................................................................................. .20-l-2 Installation ............................................................................................................ .20-l-29 Disassembly ........................................................................................................... 20-l-12 Reassembly ........................................................................................................... .20-l-18 Specifications ........................................................................................................ .20-l-10

DESCRIPTION The drive unit has a sealed housing and is equipped with double reduction helical spur and spiral bevel gears that operate in a bath of oil. Power is supplied by a vertically mounted drive motor and transferred to

the floor via a 10 x 4.75 x 6.5” drive wheel & tire.

The drive motor is covered in Group 16 and the drive tire is covered in Group 22. Service procedures for both walkie and rider models are the same.

Typical Illustration Drive Motor Assembly

Drive Unit Assembly

Mounting Ring 8 Bea

SM568 Dee 91

Wheel & Tire

Section

1

Drive Unit

GROUP 20 REMOVAL 1. Move truck to a flat level surface.

2. Disconnect truck battery.

Tvoical Illustration

3. Remove battery from truck.

lnsulated -r%, Spreader Bar

m

TvDical Illustration

4. Elevate and block front of truck as shown. *

Loosen (do not remove) the drive wheel mounting nuts at this time.

Typical Illustration

Section 1

20-l-2

Blocking-e

Dee 91 SM568

GROUP20

Drive Unit 4. Remove the drive wheel. The wheel lug nuts require a 22mm socket.

Typical Illustration

Drive Wheel & Tire

6.

Walkie Models Open doors exposing truck components. l

l

Hinge

Hinge Tvne: Lift door until it is free of the hinge pins and set it to one side.

Steel Door Models

Bolt-on Tvne: These models are made of steel and are hinged to the truck frame with several bolts. Support the door prior to removing the hinge fasteners.

Door / Frame 1

6A. Rider Models Open and remove doors exposing truck components.

-or

SM568

Dee 91

20-l -3

,

j:

/

Section 1

Drive Unit

GROUP20 7: Disconnect motor cables from the drive motor.

Tag cable ends as to their proper location on the motor.

Typical Illustration

h

Figure 4

8. Walkie Models .

Remove the 8mm bolt fi-om the front face of the control handle mounting bracket.

Control Handle

8mm Bolt &

Washer

L

Figure 5

9. Walkie Models .

Move the control handle downward as far as it will go and place a block between the control handle and the mounting bracket. (

Figure 6

Section 1

20-l-4

Dee 91 SM566

GROUP 20

Drive Unit 10. Walkie Models l

dle Mounting Bracket

Remove rubber handle stops from the mounting bracket.

Figure 7

11. Walkie Models l

Remove cotter pin and washer securing the brake actuator rod to the brake arm.

Figure 8

11A. Rider Models l

Disconnect actuator rod from brake arm.

l

Remove cotter pin and washer.

l

Pull adjustor free of brake arm.

.. ..__._.....____ _/.-..-. ,_..-/,.,.”

‘-,,‘.. _x.;.__..____.__.___..

C..x.dr’ . _,’ .’ . ...:..__..________ _..-.-._.-_

Typical Illustration

Figure 9

SM568 Dee 91

20-l -5

Section 1

Drive Unit

GROUP 20 10. Walkie Models .

Remove the 1Omm Allen head socket mounting screws that secure handle and bracket to drive unit.

Control Handle & Bracket Rider Models

10A. Rider Models

.

I

Remove four capscrews that secure handle and bracket to drive unit.

11. All Models

.

l

Lift control handle and mounting bracket free of drive unit.

Control Handle & Bracket Walkie Models

Locate handle to one side so that upon removing drive unit the handle and wiring will not be damaged.

Typical Illustration

Section 1

20-l-6

Dee 91 SM568

GROUP 20

Drive Unit 12. Drive Unit & Motor Assemblv Removal

6mm Allen Head

NOTE

TheDriveUnitSwivelBase(Steer Bearing) is mounted on shims and need not be removed at this time

r

Drive Motor 6mm Allen Head

If thebearing is to beremoved, go to the next page for instructions. l

Remove twelve drive unit to bearing bolts using a 6mm allen socket.

,_‘. ‘. j :,_+2

I l

l

l

I

:

Typical Illustration

Now wrap a lifting strap around the neck of the drive motor beneath the brake backing plate.

Connect the eyelets of the lifting strap to a chain hoist equipped with a safety hook.

Lift the assembly straight upward being careful not to damage the steer bearing.

Drive Motor

Place the assembly on blocks in a clean work area. Keep the lifting strap in place for motor removal.

. ..

. . ..

-.

.. .: : , ,._ .“ZC . ..“L. _/ ‘. ._ ‘-...

I ;’ ,; .--..._.X ‘. ,/ ......

--“‘--.-~.._.._,,c”’ .’ ., “.. .’__ ,I ’ ...

Typical Illustration .’ \.:... .______, __ ’ _’ *’ ’ _

SM568

Dee 91

Section 1

Drive Unit

GROUP20 12A.Drive Unit. Motor and Swivel Base Removal l

l

l

Typical Illustration

Mark the truck frame as to the exact location of the swivel base. To do this, locate the roll pin in the top of the base. Below this pin there is a plug (refer to opposite illustration). Drift punch the frame directly opposite this plug. The swivel base must be installed and shimmed exactly as it came from the factory or possible damage to the base may result.

Swivel Base lSteer Rina) %_

,.*”

,*-

!..

Truck Frame +i

Roll

i: -.;;-..,

.

IMPORTANT Locate PLUG on Swivel Base.

Mark it’s location on the truck frame with a drift punch. This location may vary with different truck models. ‘.--.i..-‘..*..

Remove the 70mm capscrews and washers securing the drive unit mounting flange’ to the truck frame. Note these screws thread into dual nut retaining plate weldments located on the bottom side of the truck frame. These plates will drop free upon removal of the capscrews (two capscrews per plate).

_,p:

Plate Weldment

Now wrap a lifting strap around the neck of the drive motor beneath the brake backing plate.

Connect the eyelets of the lifting strap to a chain hoist equipped with a safety hook.

Brake Backing Plate Lifting Strap Tvpical Illustration

l

Lift the assembly straight upward paying particular attention to the location and number of washer/shims located between the drive unit swivel base (steer ring) and frame. The number of shims may vary per mounting bolt. There is

onespacerusedoneachbolt. Afterremovingthe drive unit, tag the shims as to their exact location so they may be properly installed at reassembly. l

Place the drive unit on blocks in a clean work area. Keep the lifting strap in place for motor removal.

Section 1

<As l

tration J

*oo**o~~~***~~*~om~o~*~~**o~

Note the number and location of each shim upon removing the drive unit. The same number of shims must be installed between drive unit and frameatexactly the same location as when removed, or damage to the swivel base (steer ring) may result.

20-l-8

Dee 91 SM568

GROUP 20

Drive Unit 13. Drive Unit removed with Swivel Base. .

Remove the twelve 6mm Allen head screws securing the drive unit to the swivel base.

.

Carefully lift the assembly out of the swivel base (steer bearing).

.

Set the swivel base to one side.

.

Reposition the drive unit on the blocks.

I

14,

6mm Alien Head

I

Swivel Base (Steer Bearing)d

Remove the drive motor to drive unit bolts using a 6mm socket.

6mm Allen Head Screws -,

Typical illustration

L

Drive Motor

Typical Illustration

15. Slowly lift the drive motor straight upward until themotorshaftisfreeofthedriveunit.

Carefully lay over the assembly and secure it from rocking or moving. l

Discard old gasket located between the drive motor and drive unit. Install a new one at reassembly.

Use Safety Hook Lifting Strap

Gasket\ I--Drive Unit

Swivel Bases$k,_. ,. .“,..:;’ ‘.:‘:: _.-.._ _,_,.... ‘. ..- , Steer Bearing) ..,,....1_ ........‘:_.r _.

SM568

Dee 91

20-l-9

Section1

Drive Unit

GROUP 20 -

-

Grease Fitting

r

Drive Unit Assembly

Swivel Base - (Steer Bearing)

Hub, C Stud, Wheel -

II

Shims

-Retainer Bolt (Axle Shaft)

I YIA

(Bearing Preload Adjustment) and (Rina Gear Adiustment)

I

,in Plug sservoir)

Shield Ring A

I \ ’ O-Ring

Bearing (Cup & Cone) / Spacer, Bearing Ii

-

Bearing (Cup & Cone)

Cut-A-Way Typical Illustration

Section 1

20-l-10

Dee 91 SM568

GROUP 20

Drive Unit

r

_-_-

__----_---

-I KZhG2 gyy I I When replacing the drive motor i with a new one, always use the I pinion gear off the old motor, assembly. ______----Whenreplacingthedriveunitwithl_ , 1a new one, remove the gear l-ram I 1the original motor and replace it 1 I with a new pinion gear supplied1 wth_____---_the drive unit.

NOTE

i

-Spur

(Reduction) Gear (12)

Wheel Stud (14) -m

Lower Searing (Cup & Cone)

ACAUTION Bearing preload and proper ring & pinion foofh contact is maintained by the use of shims in various quantifies and thickness at four locations.

(24)

When removing these shims fag them as to their proper location. Upon reassembly, fhe same quantify and thickness shims must be installed in the location from which they were removed or damage could result. (Ref: ifem32,33 and 34.)

SM568

Dee 91

:: w

Pinion Shaft (9)

J

Cover Screw (47)

H

r I I

L

_______----__ NOTE An exploded view of the drive unit is shown on page 13.

-____-------

1 I

I

J

Cut-A-Way Typical Illustration

20-l-11

Section 1

GROUP20

Drive Unit

DISASSEMBLY 1. Drainoilfmmdriveunitbyremovingdrainplug (44) and thoroughly clean the magnetic insert of the plug. Install plug. Discard old oil.

2. Remove cover screws (47) and cover (3) from the drive unit. Discard O-ring (30) . We recommend a new O-ring be installed at reassembly.

Drain Plug (44) 1

rypical Illustration

2. Place a bronze bar between the wheel studs of the axle shaft.

3. Loosen (do not remove) retainer nut (13). Note that the threads of original production pinion shafts have been upset against the shoulder of the retainer nut. .

Carefuly grind away the threads securing nut (13) to pinion shaft (9) using a hand grinder.

ACAUTION Guard againsf metal fi/ings falling into the gear case and bearings.

Typical Illustration

4. Removebolt(36)andretainer(l8)securingring gear (9) to axle shaft (5). [Note this bolt is torqued to 150 lb.ft. and further secured with Loctite 277.1 Using a bronze drift, gently tap axle shaft (5) free of ring gear (9) . Remove ring gear (9), bearing cone (26), shims (34) and retainer (18).

Bearing Cone (26)

NOTE Bronze Drift

Bearing Cone (26) is pressed onto the ring gear and may be removed with a suitable bearing puller. .

-Bronze

-----me

-I

i

I

Tag the bearing cone and shims as to theirproper location.

Section 1

Bar

lTypical Illustration

20-l -12

Dec91 SM568

GROUP 20

Drive Unit

1

r -12 -19

r

21 l--l3

9

38/

44 I

Torque Specifications 157 IbIt. (212 N-m) 080 - 100 Ib.ft. (108 - 135 N-m) 150 Ib.ft . (200 Nom) *Coat bolt threads with Loctite #277.

15 lb% (020 Nom) Item (41)(41A) 15 Ib.ft.

(020 N*m) Item (42) 120 - 140 Ib.in. (013 - 015 Nom) Item (43) 055 - 060 Ib.ft.

(074 - 081 N-m) (Item 47) Item (13) item (21) Item (36)

SM568 Dee 91

20-l-13

l

Section 1

Drive Unit

GROUP 20 Bearing Cone (25) [Press Fit]

r Spacer

Shims (33)----i

I

(17)

Axle Shaft (5)

Typical Illustration

the area from which they were removed. Bearing cups and cones are a set. They must not be intermixed with one another. If either the cone or cup show signs of wear, both should be replaced as a set

5. Now remove axle shaft (5),bearing cone (25), spacer (17) and shims (33). Cone (25) is pressed onto the pinion shaft and may be removed with a suitable bearing puller. Pay particular attention to the quantity and size of the shims noting their location. Tag the shims and bearing cone as to

NOTE Bearing preload and proper ring & pinion tooth contact is maintained by shims in various quantities andthickness at fourlocations. When removing shims tag them as to their proper location. Upon reassembly, the same quantity and thickness shims must be used in the location from which they were removed or gear damage could result.

6. Next remove nut (13) from pinion shaft (9). .

Nuts

Place a shop rag beneath the pinion shaft. Then, using a bronze drift, tap the pinion shaft out of gear (12). Remove gear .

?3 -9 8 Gear (12)

Bronze Drift

Typical Illustration

Section1

20-l-14

Dee 91 SM568

GROUP 20

Drive Unit 7. Lift out bearing cone (24).

NOTE The pinion shaft and parts may be

removed through the side cover opening.

Pinion Shaft (9) rypical Illustration

8. Remove pinion shaft (9) with bearing cone (24), and spacer (16) through the side cover opening of the drive unit

Spacer (16)-

Lower Searing Cone (24) Pinion Shaft (9) i

/

9. Remove bearing cone from pinion shaft using a suitable bearing puller.

Tv&al

SM568

Dee 91

20-l -15

Illustration

Section 1

Drive Unit

GROUP 20 9. Remove string (shield) ring (15) from the axle housing.

ypical Illustration

10. Remove Beariw CUDS& Shims l

l

l

Using a bronze drift gently tap against the lower bearing cup and shims from the top end of the housing. The wall of the housing is channeled between the cups for easy access.

Now remove the upper bearing cup and shims driving them out from the bottom of the drive unit.

Tag cups and shims as to their location so they may be properly installed at reassembly.

Section 1

Dec91 SM568

20-l-16 CUP (24)

GROUP 20

Drive Unit Cleaning & Inspection 1. Clean metal parts with cleaning solvent. Use a soft fiber brush for heavy deposits.

2.

Clean roller bearing cups and cones with cleaning solvent. Use a soft fiber brush ro remove all grease and dirt

3. Dry parts with a clean shop cloth or let air dry.

4.

5.

Carefully inspect all rollers, cages and cups for distortion, scratches, signs of heat damage or cracks. Replace any that have excessive wear, chipping, nicks or scratches. Do not replace a bearing cone or cup individually. The cup and cone are a matched set. Do not permit parts to become separated or mixed with other parts.

Thoroughly lubricate the bearing rollers and cups. Keep cup assembled to cone. Wrap the cup & cone in clean cloth or paper to protect them until installation.

An air gun may be used to clean gear teeth, splines, small threaded areas or passages in a P*-

6.

Inspect parts for corrosion, damage to threaded areas or defects in a part.

7.

Inspect machined surfaces for scratches ordamage that would prevent proper mating with an other part. Gear teeth that are cracked or show spots where case hardening is worn through should be replaced with new gears. The ring and pinion gears must be replaced as a matched set, they should not be replaced individually.

*

Small nicks may be removed with a suitable hone or file.

8.

Inspect mating surfaces of the drive unit housing, cover, axle and parts to be certain they are thoroughly clean and free of nicks or burrs.

9.

Oil seals and gaskets should be discarded and new onesinstalledin theirplace. Seals shouldbe handled carefully, particularly when being installed. Cutting, scratching seals or curling under of a seal lip impairs the seal’s efficiency.

Lubricate O-rings and seals with lubricant at time of installation.

SM568 Dee 91

20-l-17

A WARNING AIR PRESSURE

Wear eye protection and protective clothing when cleaning or drying with air pressure. Reduceair pressure to 30 PSI (207 kPa). Debris removed with air pressure can cause injury.

ACAUTION BEARING DAMAGE

Do not let bearing rollers spin when drying with air pressure.

Bearing damage muy result if they are allowed to spin without lubrication.

Section1

Drive Unit

GROUP 20 REASSEMBLY

Upper Bearing Cup (24)

1. Pini Qn Shaft Bearing l

Install upper and lower bearing cups (24) and shims (32) into theirrespective bores.Be certain to install the same number and thickness shims as removed.

Drive Unit Housing

New Bearing Sets When new bearings are instalkl, use the same thiclcness shims as removed to accurately position the bearing cups in the housing. Each new bearing is supplied with shims

Lower Searing Cup (24)

Typical Illustration

2. Axle Shaft Bearing CUDTnstallatiqll .

If removed, install bearing cups (25) and (26) into their respective housing bores.

3. Stritw Shield RinP Installation .

Install string shield (15) over axle housing lip and stake the ring in three places as shown.

Tvoical Illustration

4.

Assemble Pinion Shaft (9)

.

Using Loctite 620, sparingly coat the shaft area that makes contact with bearing cone (24).

ACAUTION Do not get Loctite on bearing

Spacer (16)-

rollers or damage will result. .

Pressbearing(24) onto pinion shaft (9).

Lower Bearing Cone(24) [Press Fit]

5. Install spacer (16).

Typical Illustration

Section 1

20-l-18

Dec91 SM568

GROUP 20

Drive Unit 6. Support the pinion shaft with a wooden block placed between the shaft and bottom of drive unit.

7. Locate bearing cone (24) over pinion shaft and push it downward as far as it will go by hand.

Drive Unit

Typical illustration

c

8. Position a sleeve or pipe over the pinion shaft.

The O.D. of the sleeve shouldbe slightly smaller than the O.D. of bearing cone (24). l

.

Mallet

Center the sleeve on the bearing.

Gently tap on the sleeve with a mallet until bearing cone (24) is correctly positioned on the shaft and in the bearing cup.

Drive Unit -

Typical Illustration

SM568

Dee 91

20-l-l

9

Section 1

Drive Unit

GROUP 20 9. Install spur reduction gear (12) onto the pinion shaft (9).

10. Install a new retainer nut (13) fmger tight. Do not reuse the old one. The collar of the nut was staked at original assembly and may cause an incorrect trorque reading when tightening the nut.

\

11. .

/

a

Typical Illustration

Assemble Ring Gear (91 Install shims (34) onto ring gear (9). Use the same quantity ana’ thickness shims that were

removed at disassembly. .

Install bearing cone (26). This is a press fit.

New Bearing Sets When new bearings are installed, use the same thickness shims as removed to accumtely position the ring gear.

Each new bearing is supplied with shims.

Ring Gear (9) Typical lllusl

12. Install bearing cone (25) into bearing cup (25).

Bearing Cone (25)

Section 1

20-l -20

I Ii-

Bearing Cup (25)

Dec91 SM568

GROUP 20

Drive Unit 13. Install a new oil seal (28) into housing. The spring side of the seal should face inward. Be certain seal is firmly and evely seated in housing groove.

NOTE Do not install oil seal at this time if

bearing preload checks are to be made. Installation of the oil seal will give a false reading of rolling torque.

Oil Seal --;4

1 Spring

_!

1

Typical llustration

14. Start axle shaft (5) into bearing cone (25) by hand.

15. Install Shims (33) and spacer (17) onto the axle.

Use same quantity and thickness shims that

DO NOT DAMAGE SEAL-

DO

were removed at disassembly.

IIII I IL-L

SM568 Dee 91

20-l-21

Section 1

GROUP 20

Drive Unit

16. Position ring gear (9) in housing (as shown) rotating the gear until it meshes with the pinion.

Be sure cone (26) fully seats in cup (26). Hold ring gear in this position. l

Now move axle shaft (5) inwardrotating axle as necaessary to align shaft splines with those of the ring gear. Push axle into gear as far as possible by hand.

Bearing Cone (26) J

17. Placeretainer(18)ontoathreeinchlongboltthe same size as bolt (36). Screw the bolt into the axle shaft. l

L

Bearing Cup (26)

Nut (13)-,

Tighten bolt pulling the shaft through the bearings and into the ring gear.

To keep the axlefrom rotating, place a bronze bar between the wheel stub and hold. l

l

Remove the three inch bolt.

Install and tighten bolt (36) to completely seat a.U parts.

L

Section 1

20-l -22

Bronze Bar

Dec91 SM568

GROUP20

Drive Unit 20. .

Check End Plav Next, install a dial indicator to the top side of the drive unit and check end play of the pinion shaft bearings. Move the pinion up and down to check bearing clearance. Add or remove shims (refer topage24)asnqiredtoobtain0.001”(0.03mm) end play.

Typical llustration

21. Loosen nut (13). Remove bolt (36), retainer (18) and ring gear (9).

22.

Using a bronze drift, gently tap axle shaft free of the ring gear and remove gear.

.

Remove nut (13).

.

Using a bronze drift, gently tap the pinion shaft free of the spur gear. Remove the spur gear.

.

Tap shaft free of the upper bearing cone and remove shaft.

Ring Gear (9)

Remove Spur Gear

SM568 Dee 91

20-l-23

Section 1

Drive Unit

GROUP 20 ADJUSTMENT SPECIFICATIONS

,

I~)‘4

EndPlay Adjust to obtain 0.001’ (0.003”mm) end play.

To adjust Pinion Shaft downward, move a 0.004’ shim from Point A to Point B

Bearing preload and proper ring & pinion tooth contact is maintained by shims in various quantities and thickness at four \ locations. Upon reassembly, the same quantity and thickness shims must be used in the location from which they were removed or damage could result.

\

r

If the ring gear needs to move inward, and a 0.004’ shim is removed from Point B, then a 0.004’ shim must be added to Point A to maintain bearing preload (axle shaft end play).

Each new bearing is supplied with the following shims: 0.004 lW0 I:; 0.012 one 0.020 one (1)

If the ring gear needs to move outward, then you remove a 0.004’ shim at Point A and install a 0.004” shim at Point B. This moves the gear outward and maintains bearing preload (pinion shaft end play).

End Play: 0.0 Bearing Preload: 11 lb. in. (1.25 +/- 0.05 N-m) Ring & Pinion BacklashAdjustment:O.lO too.15 mm (0.004 to 0.006.) end play. Install dial indicator as shown on page 26.

L

Section 1

20-l -24

Dec91 SM568

GROUP 20

Drive Unit 23.

Now install axle (5), ring gear (9), retainer (18) and bolt (36).

.

Position a bronze bar between the wheel studs to keep the axle from rotating and torque bolt (36) to 150 lb.ft (200 N*m).

24.

Install a dial indicator to the housing.

Make

certain the indicator is solidly mounted. Move the axle back and forth and check end play. Add or remove shims (refer to page 24) as required to obtain 0.0” end play. .

Using an inch pound torque wrench, check the bearing preload. If preload is not 11 lb.in. (1.25 +/- 0.05 N.m), add shims to decrease preload or remove shims to increase preload (refer to page 24).

25. Now check and adjust ring & pinion backlash. .

Remove the axle shaft and ring gear.

.

Install axle shaft oil seal.

.

Install the pinion shaft.

.

Install the axle shaft and ring gear.

.

Torque nut (13) and bolt (36) to proper specifications. AtJinul assembly, coat the threads of

Bolt (36)

both nut and bolt with Loctite 277. Stake nut (13) to the pinion shuj?.

Tvoical Illustration

SM568

Dee 91

20-l-25

Section1

Drive Unit

GROUP 20 26.

RinP & Pinion End Plav Install a dial indicator to the housing. Make

l

“\i

i .%._ ?p.__LI:.--..---._._._.~:;-’ . ..\_ * ..

certain the indicator is solidly mounted. with the stem perpendicular to the tooth surface at the extreme heel. Position the indicator on one tooth

. . . . . . ..--.--..._

i

i

,..A

. . .._

l, ‘.

‘2.- .._.. __.__

,_./

!

of the ring gear as shown. End clearance must be 0.004to0.006”(0.10to0.15mm).Ifitisnot,add or remove shims (34 & 32) as required. Refer to page 24.

Typical Illustration

27. l

Check RinP & Pinion Tooth Contact

Paintringgearteethwithmixtureofredleadand linseed oil. Rotate pinion shaft to cause one full revolution of ring gear. Check tooth pattern on ring gear and pinion to determine if proper pinion-to-ring gear tooth engagement exists.

Typical Illustration L

Typical Illustration

Move Pinion AWAY from Gear in this direction Move Pinion TOWARD Gear in this direction

Center I

Pinion in this direction.

Profile Dedendum Ring Gear

Pinion

Spiral Bevel and Hypoid Tooth Bearing Contact Patterns see following page for adjustments

Section 1

20-l -26

4/

0 ...”

....

Dsc 91 SM568

GROUP 20

Drive Unit l

Contact Pattern 1

Preferred Beariw Pattern on pinion and both sides of gear tooth while under a light load.

Preferred Pattern

l

T (

To

Contact Pattern 2

move bearing toward theheel, increase backlash within limits by moving the gear away from pinion.

l

Gear Set Noisv

Heel bearing on both sides of gear tooth. To

Contact Pattern 3

move bearing toward the toe, decrease backlash within limits by moving the gear toward pinion.

Gear Set Noisy Could result in early gear

Move Gear TOWARD

SM568

Dee 91

20-l -27

Section 1

GROUP20

Drive Unit

*Low bearine: on Gear and High Bearing: on Pinion

Contact Pattern 4

Correct by moving pinion away from gear.

(Increase mounting distance).

Move Pinion AWAY from Gear. +

lHiPh bearinp on Gear and Low bearing on Pinion.

Contact Pattern 5

Correct by moving pinion in toward gear.

(Decrease mounting distance.)

toward Gear.

BACKLASH Backlash should be measured with a DiaI Indicator rigidly mounted with the stem perpendicular to the tooth surface at the extreme heel. The amount should vary from .004 to .006” (0.10 to 0.15 mm) depending upon the pitch of the gear - fine pitches being near the low side and coaser pitches near the high side.

Bearing Preload: Make sure all parts are clean

Bearing Preload (Rolling Torque Only)

and free of foreign material and the bearings are serviceable, clean, free-running.

Rolling torque is the torque required to keep the axle shaft rotating (measured without axle seal). Breaking torque is the torque to get the axle rotating.

correct, shims must be added. See page 24.

There is no bearing preloaa’for the pinion

Insufficient Bearing Preload: If all conditions

Shaft.

are correct,

Section 1

ExcessiveBearing Preload: Ifallconditons are

20-l -28

shim must be removed. See page24.

Dsc 91 SM568

GROUP

Drive Unit

20

28. Lubricate cover o-ring and caarefully install it into cover groove. Take precaution not to cut or nick the o-ring upon installation or it will leak.

.

Locate cover into position on drive unit.

.

Install screws & lock washers (42).

\ -ring

Torque screws to: 15 Ib.ft. (20 N*m).

.

Check to be certain the drain plug is in place and tight.

Drain lug (44) Lubricate O-Ring and install into cover iroov’e.

Swivel Base 1Steer Rinp) Installation

29.

ACAUTION The swivel base must be installed and shimmed exactly as it came from the factory or possible damage to the base may result.

Locate PLUG by

0.060 Spacer Shim 0.010 Shim (AR) 0.003 Shim (AR)

Typical Illustration

30. Install Swivel Base: . Be certain the deck mounting area for the swivel

;i Swivel Base ii (Steer Ring) -

base is clean and free of debris.

.

Locate the punch mark made in the deck prior to removal of the drive unit.

.

Locate the side plug in the new swivel base.

.

Place the swivel base’ on the truck deck so the plug is directly opposite the punch mark.

.

Position one 0.60” spacer shim at each bolt hole.

0.060 Spacer Shims

.,:-

‘j‘.2_ A

-.>

.

mounting holes in base with those in truck deck and set the base on the spacer shims.

Align

J .-

.

. \_

* ..

Dee 91

20-l-29

j,.

”

c

*.: ..._. .

’

,_.

s:’

L:::-

, ..*

<:C-

.- .

‘.

, ..

__.*

-. .- ._

SM568

:.*

.. : : ’ ..: :

‘/_ .._

*:* _ _.*

Section1

Drive Unit

GROUP20 3 1. Insert mounting bolts thru base, shims and deck.

32. Check Swivel Base Mounting:

ACAUTION The swivel base (steer rjng) must be shimmed perfectly level with the floor deck. If not, damage to the base may result. l

Exert hand pressure at opposite bolt pairs - see arrows. If the base “rocks”, add shims(0.003 and/.or 0.010”) where they can be installed without force between the base and the 0.60” spacer shim.

..<.

.........................................

x.

‘C.,

. .

,,;:

.....................

........................... .O

.. .

..

:

c C’

T6ikalIll”strati0~

33. Now check the other opposing bolt pairs. Add shims as required to eliminatae any rocking motion of the swivel base. l

Check all eight bolts to make certain there is no gap existing between the base and the shim spacer. Ifthere is, fill these gaps with appropriate shim(s).

. ...:-: ,<:-

,.::-

:

i

Tvpical Illustration

34. Locate the dual nut plate weldments bemeath the floor deck and thread the 70mm mounting bolts into them. Late moadel trucks have the

r

70 mm Mounting Bolt

dual nutplate weldments as apermanent part of the truck. l

Torque the mounting bolts to: 55 - 60 lb. ft. (74 - 81 Nom)

Ty&l

Section 1

20-l -30

lllustratior

Dsc 91 SM568

GROUP 20

Drive Unit

Steer Ring Must Rotate Freely

35. Check Steer Rim for Freedom of Move-

ment; .

Rotate the steer ring by hand. The ring must rotate easly by hand without binding. If the ring spins freely, the shimming is correct.

.

If there is binding, hard spots or movement appears stiff, follow the steps below.

!Swivel Base -

Loosen one set (of two mounting bolts), see arrow.

Rotate the steer ring by hand. If the ring (inner race) now rotates freely, add a 0.003” shim to both mounting bolts.

Torque the bolts to specifications and recheck adjustment.

Steer Ring

Ifoperation is stillnot satisfactory, then go to the next pair of bolts. Loosen, check and adjust as required. Continue this procedure until the ring (inner race) operators satisfactory.

36. Install Drive Unit; .

Lifting Chain

Align the mounting holes and lower the drive unit onto the swivel base.

Use Safety Hooks Eye Hook

- Drive Unit

..I k.$ _+..,. ..f.-.!T--- Swivel Base .’

SM568

Dee 91

20-l -3 1

Section

1

Drive Unit

3OUP 20 37. .

Install 6 mm Allllen Head Screws

Install the 6 mm Allen Head drive unit to swiv el base mounting screws - finger tight.

Torque mounting screws to: 15 lb.ft. (20 N*m).

Drive Unit

38. Position gasket over drive unit alining mounting holes in gasket with those in drive unit.

39. Install drive motor.

- Gasket \

40. .

Install 6mm drive motor mounting bolts finger tight.

Motor Mounting Bolts

Torque motor mounting bolts to: 120 - 140 lb. in. (13 - 15 Nom)

Section1

20-l-32

Dsc 91

SM568

GROUP 20

Drive Unit 41. .

Rider Models

Control Handle & Bracket J3ider Models

thecontrol handle andmounting bracket onto the drive unit.

Lower

ACAUTION Becareful when lowering hand/e and bracket that you do not damage the wiring. .

Align bracket mounting holes with those in the drive unit.

.

Install mounting bolts with lockwashers finger tight.

.

Torque bolts to: 213 - 240 lbft. (258 - 325 N*m).

42. .

i

!

Walkie Models Set the control handle andmounting bracket on the machined surface at the base of the drive unit.

A CAUTION Becareful when lo wering handle and bracket that you do not damage the wiring.

;

Bracket

-k Control H

.

Align bracket mounting holes with those in the the drive unit. Install both 1Omm Allen head screws finger tight.

.

Torque bolts to: 100 lb.ft. (113 Nom).

SM568

Dee 91

Typical Illustration

20-l-33

Section1

Drive Unit

GROUP 20 43. Rider Models . Connect adjustor (or actuator rod used on early models) to brake arm. Secure with flat washer and cotter pin.

Typical illustration

43A. Walkie Models .

Connect adjustor (or actuator rod used on early models) to the brake arm. Secure with flat washer and cotter pin. ...::,. ..,:. ... :: .::.: :.;.I::.

.

i LBrake

“‘

.

-\..“:,

7

44. Walkie Models

Am

Handle Mounting Bracket

Install rubber handle stops to the mounting bracket.

Section1

20-l-34

Dsc 91 SM568

GROUP20

Drive Unit 45. Walkie Models .

Move the control handle downward as far as it will go and remove the block between control handle and mounting bracket.

.

Release control handle.

Control Handle

46. .

Walkie Models Install 8mm bolt and washer securing bracket to drive unit.

.

Torque bolt to: 60 lb.ft. (6.8 N*m).

Handle

8mm Bolt&Washer Typical Illustration

47. Install power cables to drive motor.

SM568

Dee 91

20-l-35

Section1

Drive Unit

GROUP 20 48. Remove fil plug and fill crankcase using the approved lubricant specified in Group 0 1 of this manual (Lubrication Instructions).

49. Walkie Models - install doors. l

l

Hinge TvDe Doors: Slip door hinge pins into hinges located on side of truck frame.

Bolt-on TvDe Doors: Line up hinge mounting holes with those in truck frame - support door in this position and install hinge fasteners.

,, Fastener

Door /

I

II

1

M/

n/ I/Frame

Frame 2 MI

1 / /f-fHiwe ,I,!-

v

49A. Rider Models - install doors. l

Slip door hinge pins into hinges located on side of truck frame.

:: _.’

Section 1

20-l -36

Dsc 91 SM568

GROUP 20

Drive Unit 50. Set drive wheel on mounting studs. Install lug

nuts finger tight.

Drive Wheel & Tire

.

r

Drive Tire

51. Alternately tighten the wheel lug nuts in a crisscross pattern. The wheel lug nuts require a 22mm socket.

\

Lug Nuts

Torque lug nuts to 81-92 lb.ft. (1 lo-125 N*m).

Drive Wheelv

Drive Tire & Wheel Assembly Typical Illustration

52. Elevate truck and remove blocking. l

Typical Illustration

Lower truck to floor.

Blocking Typical Illustration

SM568

Dee 91

20-l -37

Section 1

GROUP 20

Drive Unit

53. Install truck battery.

Chain

Insulated v Spreader Bar

Typical Illustration

54. Connect truck battery.

Section 1

20-l -38

Dsc 91 SM568

GROUP 23

Brakes

Section 1 Drive Motor Brakes Contents Motor Brake Description .......................................................................................... 23-l-3 Inspection .............................................................................................................. ...23-l- 5 Removal

...................................................................................................................

23-l-6

Installation ............................................................................................................... 23-l-7 Linkage - Late Model Installation ............................................................................ 23-l-8 Linkage -Early Model Installation .......................................................................... 23-l-9 Brake Switch .......................................................................................................... 23-l-10

MOTOR BRAKE ASSEMBLY The brake is double acting, spring applied, cam actuated shoe and drum type. The brake assembly is bolted to the end frame of the drive motor. The brake drum is keyed to the drive motor armature shaft.

Braking is accomplished through the gear reduction of the drive unit for increased braking torque. Movement of the control handle up or down from normal operating position applies the brake. The spring loaded control handle will automatically return to the upright “brake on” position when released, therefore serving as a parking brake when the truck is not in use.

The brake assembly is the same for all models but the brake linkage differs between “walkie” and “rider” type. And, there are “early” and “late” model versions.

These are easy to identify visually as shown here and on the following pages.

Typical Illustration

Typical Illustration

Rider Models

Walkie Models

SM568 Sep 91

23-l -1

Section 1

Brakes

GROUP 23 HWD / HWP

Steer Handle Mounting Bracket Steer Handle Mounting Bracket Brake Actuator Rod

Brake Actuator Rod

See Page 10

Section 1

23-l -2

Sep91

SM568

GROUP 23

Brakes i ;-..<_-; ,.;, ,’ * : ,.j:y ;‘.. ..~~ .:::;.. : .a_(

ontrol Handle Bracket ,.* ,>’ , ‘>,’ Early Model Rider ; : I. pi: : j ,;9 Trucks ; /:./I

MOTOR BRAKE INSPECTION . Remove the brake drum. Loosen and remove the drum retaining nut and washer securing the drum to the motor armature shaft. Work the drum upward a little at a time until it is free of the shaft (see Figure 1) exposing the brake assembly. On late model rider truck it may be

necessaryto remove the ControlHaruileBracket providing clearance for drum removal.

NOTE The brake shoes are equipped with

bonded linings.

1. Remove shoe return springs and both brake shoes. Wipe shoes clean and check for further serviceability.

2. Clean return springs and brake drum in a S toddard type cleaning solevent 3. Inspect return springs for breakage or distortion. Check brake drum for scoring, cracks or other abnormal wear. Install new parts as required and reassembly brake.

Nut

Brake Drum

If farther brake removal and dissassembly is required, continue with the following steps.

Control Handle Bracke

Brake Shoe 8 Lining

Brake Springs

NOTE

brake arm by removing cotter

,,

Walkle Trucks

-Tip the top of ., the bracket to onesideallowing removal of brake drum.

--.v-: . .._ ....C-C._ATypical Illustration

Typical lllustratio

Figure 2

Figure 1 SM568 Sep 91

23-l -3

Section 1

Brakes

GROUP 23

Figure 4

Figure 3

2.

If the brake assembly is to be removed, pull the cotter pin, remove the washer and disconnect the actuating rod from the brake arm of the brake assembly.

NOTE

Some models use a pivot adjuster (Figure 4) to secure the actuating rod to the brake arm. Others use a clevis pin (Figure 3).

3. Remove two mounting bolts and lift brake off motor, see Figure 5.

4. Wash all parts in a Stoddard type cleaning solvent and wipe dry. Inspect parts for excessive wear or damage. Replace parts as required.

Figure 5

Brake Spring-$

Brake Shoe with

, Typical Illustration

Figure 6 Section 1

23-1-4

Sep 91 SM566

GROUP 23

Brakes

BRAKE INSTALLATION 1. Locate brake onto drive motor alining mounting holes of brake backing plate with those in the top of the drive motor (Figure 7).

2. Install two capscrews finger tight and then torque them tospecifications (Figure 7).

3. Position retainer key into the slot of the motor armature shaft (Figure 8).

Typical Illustration Drive Motor Shaft

Key

Mounting

Bolt Torque Specifications 170- 191 Ib*ft

Figure 8

4. Locate the brake drum over the shaft alining key slot in drum with the key in the shaft. Tap drum into position with a plastic mallet.

5. Install washer and nut onto shaft finger tight and torque nut to specifications (Figure 9).

Washer

A_

Nut Torque Specifications 18 - 22 Ib.ft (24 - 30

“.

Walkie Trucks (Early & Late Models)

rypical illustration

/“-

-

I

Figure 9

Figure 7 SM568 Sep 91

j \...._..-.*.

23-l -5

Section 1

Brakes

GROUP 23 LateModels

Early Models

iAdjustor M

are nwcie~s

_j

$ii;F L Pivoi Arm

I

Figure 10

Brake Linkage Installation

Late Model Trucks

5. Secure the adjuster rod to the brake arm with washer and cotter pin.

2. Move adjuster until it lines up with the hole in

NOTE

the brake arm. and install the adjuster.

Late model trucks use a pivot adjuster (A) to secure the rod to the brake arm while early model trucks use a clevis pin (B).

3. Install washer and cotter pin.

4. Tighten both nuts to secure adjuster.

5. Check the brake torque spring for maximum

If you experience difficulty in connecting the rod end to the brake arm, adjust the linkage as follows:

Section

1

1. Loosen the nuts on both sides of the pivot adjuster (A), see above.

spring length of two inches as measured from inside to inside of the spring washers, see illustration above. If adjustment is not as specified, loosen spring jam nut and rotate the adjusting nut as required. Secure adjustment with jam nut after correct measurement is obtained.

23-l -6

Sep 91 SM566

GROUP 23

Brakes Earlv Model Truck$

Brake Cam

1. Remove the retainer ring from the brake cam shaft.

2. Remove the brake arm from the cam.

3. Remount the arm to the cam, moving enough serrations to allow the hole in the brake arm to align with the hole in the actuator rod.

4. Next, install the retainer ring securing the arm to the cam shaft.

Retainer Ring -@

Figure 11

0

5. Next, install the clevis pin, washer and cotter pin securing the brake linkage to the brake arm.

Washer

&

Brake Arm

&

Cotter Pin

-

Figure 12 WALKIE & RIDER MODELS

6. Check adjustment. Locate the control handle approximately 10 degrees from vertical position.

WITH CONTROL HANDLE FULL UP OR FULL DOWN, THE BRAKE SHOULD BE

SET (ON).

7. Using your hand, see if the brake drum will rotate easily. Now, move the handle full up (and then full down) and try to rotate the brake drum by hand. It should not move. If it does, the brake arm should be repositioned.

+I4

WITH CONTROL HANDLE AT 10 DEGREE POSITION, DRUM SHOULD BE FREE TO ROTATE. \,

Handle

/ Control Handle

I

Typical Illustration

Figure 13 SM568 Sep 91

23-l -7

Section 1

GROUP 23

Brakes

Trucks

Drive Unit

Figure 14 3. While rotating the brake drum by hand, slowly BRAKE SWITCH move the control handle from the lo” (brake Brake switch adjustment is important. Brakoff) toward the brake on (full up) position. ing against drive motor torque will result in exces4. Check to be sure the switch operates just prior sive lining wear and over heating of the drive motor. to the brake shoes making contact with and The switch must cut electrical current to the drive stopping brake drum rotation. (An audible motor before the brake shoes contact the brake drum. click can be heard as the switch operates.)

To check for proper operation, first make 5 Now, locate the steer control handle 10 desure the switch, mounting bracket and brake linkage * grees from the full down (brake on) position are securely mounted and not damaged. and repeat Steps 3 & 4.

1. Make sure the power key switch is in the off 6. With control handle in the full up or full down position. position, the brake switch should be released 2. Locate the steer control handle 10 degrees from and the brake should be fully set. If the switch full up (vertical) position. requires adjustment, refer to pages 9 & 10.

Section 1

23-1-8

Sep 91

SM568

GROUP 23

Brakes

Typical Illustration

Control Handle

Rider Model Trucks

Figure 15

BRAKE SWITCH ADJUSTMENT 1. Locate the control handle 10 degrees from vertical and hold in this position.

2. Loosen stitch mounting screws.

check to be certain the switch is properly adjusted.

3. Move switch until switch roller makes contact with the brake arm. Then move switch enough further to actuate. (An audible click can be heard as the switch operates.)

5. Move the control handle fi-om the full up to the full down position. Note when the switch operates. The switch should actuate 10 degreees from vertical position and again 10 degreees from the full1 down position.

4. Hold switch in the actuated position and tighten the mounting screws. How release the handle allowing it to return to the full up position and

If the switch does not operate at both these points, readjust switch until proper adjustment is obtained.

SM568 Sep 91

23-l -9

Section 1

Brakes

GROUP 23 Spacer

:af/yModel IWD I HWP

r

Late Model Plate

iWD / HWP

(Brake Linkage) &, <:,>

Typical Illustration

rypical Illustration

1

Mounting Plate

Bolt

.‘. -..

‘_.

- ...

.!

/.

Pivot Arm (Brake Linkage) Early Design

Pivot Arm (Brake Linkage) Early Design

Typical Illustration

Typical Illustration

Section 1

23-l-l

0

Sep 91 SM568

GROUP 23

Coast Control

Section 2 Coast Control Optional Equipment Coast

Control Description ................................................................................... 23-2-l

23-2-2 CoastContml heparation ....................................................................................

Coast Control Operational Check ....................................................................... .23-2-2 Coast Control Operational Adjustment ................................................................ 23-2-2

COAST CONTROL DESCRIPTION The coast control consists of a manually operated control lever, a spring loaded rubber stop and guide mounted at the base of the the steering control handle.

The steer control handle, when released, spring returns to the vertical position appling the brake.

However, when the coast control 1ever;s moved to the

“brake off’ position, a spring loaded rubber stop moves forward to prevent the steer handle from completely returning to the vertical position. As the handle springs forwardit will partially apply and then release the brake putting the truck into a “coast m&e” of operation. The brake can be fullly applied when holding the control handle in the full vertical position.

Coast Control Lever

Steer Control Handle

Typical Illustration

Brake Off

Lever Pivot Torque to: 70-80 lb-in [8-10 N-m] (not used early models)

Coast Control Lever

(not used early models)

Spring, Inner

Apply Loctite 271 (Clark Part Number: 2391434) to Fastener Threads and use to secure the ‘Cap” to the Coast Control Lever.

Typical illustration

3

Figure 1 SM568 Sep 91

23-2-l

Section 2

Coast Control

GROUP 23 Coast Control Preparation Be sure the power key switch is in the off position or the truck battery is disconnected.

r

Control Handle

Coast Control Lever -i--

Move the steer control handle through the full vertical position to partially compress the spring loaded rubber stop...hold handlein this position.

Now, move the coast control lever out of the “brake on” position and into the “brake off’ position.

Figure 2

Coast Control Operational Check

\-

Coast Control Lever 7

Control Handle

4. Release the steer control handle. The truck is now set up for a “coast mode” of operation.

5. Reach down and turn the brake drum by hand.

The drum should rotate quite easily. If it does not, if the shoes drag against the drum, then the “spring tension” on the handle return spring should be lessened,

Figure 3

Coast Control Operational Adjustment 6. Loosen the jam nut and back off the spring adjusting nut until the brakedrumtums easily by hand.

7. Now, move the handle downward and then let go of it. The brake should momentarily apply as the handle hits the rubber stop. Then the brake should release as the handle moves away from the stop (or when the handle is just resting against the stop). You can feel this happen while turnning the brake drum by hand. Check for proper operation several times. Tighten jam nut when adjustment is satisfactory.

r

Spring Adjustor

Typical lllustratio~ n

I

I

I

Figure 4 Section 2

23-2-2

Sep 91 SM568

EMRKN$epria\Handling

GROUP 25 GROUP 25 Caster Assembly Contents

Adjustment Check .............................................................................

Adjustment Procedures .....................................................................

25 l-3 .25-l-3

Torque Spec*cations

.25-l-2

.......................................................................

Typical Illustration

SM568 Sep 91

25-l-l

Section 1

GROUP 25 . ‘+

, s;. :.>

\

/ I

/” _.‘.

*~---~~ -’

_’

,.

~ ,. ” x___ _-

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,

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.

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.I

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c...

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,,:“. , ,;= . .// ’ ,,;i” ,, ” ,.;..‘. , ,’ -. .,.;. , ,.’ ,/ ’ , ..’ ‘.._ _>,’

, ‘.

isI

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Retainer Bolt

./_.:_. c,:.

I

*‘*

.$

g.;.,

Caster

ji :

ji

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ii

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-, ; . . c/ / : .:: i. / ‘, ’ I I ;“ ;:;i ,_ ‘,. ’ :.:: ‘;c ,:..:;I, ::: ; ; ;.2 i;,:,, , ‘2’

TORQUE SPECIFICATION 30 to 33 Ib.ft. (40 - 45 Nom)

Caster Assembly

Jam Nut

Adjusting Screw

Section 1

Sep 91 SM568

GROUP 25

Caster Caster Adjustment

muck must be setting on a level foor with battery in truck and disconnected.

MU. l

l

l

Disconnect

&@

battery.

Check adjustment of both casters. Manually try to move caster left and right (see above). You shoulld not be able to. If you can, the caster(s) must be adjusted sothereismoretirepressureon the floor.

Loosen jam nut (see opposite illustration). Back set screw out and check adjustment.

Backing the set screw outward will increase caster tire loadanddecrease drive tire load thus decreasing steer efsort and providing a jirmer rode.

Continue this process until the casters are correctly adjusted.

l

SM568 Sep 91

Once a satisfactory adjustment is obtained, tighten jam nut(s) to secure adjustment..

25-1-3

Section 1

Cl!!IRIS

Material Handling

GROUP 28

Company

GROUP 28 Hydraulic Unit Contents

SM568

Removal ............................................................................................

28-l-2

Installation ........................................................................................

Torque Specifications ........................................................................

28-l-2

28-l -1

28-l-3

Section 1

Hydraulic System

GROUP 28 fi7

Pressure Line

./’

:,

Label Power Cables and Wiring as to their point of connection.

L Lift Cylinder

::

--I,>..._._ __._..-:i ‘-..., :;; k.....,.;; :: ii

.^. / -

;;

0

ii :: ::

1

,.(

,., ., ‘.

0

/’

2

,’

.“’

Typical Illustration

L

,/

.5;

. _...;_x

CT’: Hydraulic Unit

Typical Illustration

HYDRAULIC UNIT Step 1 Disconnect power cables and control wiring from the hydraulic unit.

- Bolt

Step 2 Disconnect pressure and return lines.

There will be some hydraulic fluid leakage upon disconnecting the hydraulic lines. Place some shop rags beneath the connections.

Step 3 Remove bolts and lo&washers securing the hydraulic unit to the truck frame and remove the unit from the truck.

Installation Installation is the reverse of removal. Refer to page 3 for torque specifications.

NOTE Upon installing the hydraulic unit, torque the fasteners and hoses per specifications listed on page 3.

Once the unit is installed and the reservoir is filled, operate the system several times to purge air from the system. Check reservoir and add fluid as required.

Section 1

28-l -2

Typical ilbstration

SM568

GROUP 28

Hydraulic System Torque Specifications

NOTE3&7

-

NOTE 1 ,* Q NOTE: 1. TORQUE

TO 61-69 Ibfaft [83-93

2. TORQUE

TO 71-88 Ibf*in

18-l 0 N-m]

3. TORQUE

TO 16-20 Ibf*ft

[20-27 N-m]

4. TORQUE

TO 70-80 Ibf*in

[8-9 Nom]

5. TORQUE

TO 18-20 Ibfmft [24-27 N-m]

6. LUBRICATE 7. APPLY

O-RINGS

LOCTITE

N-m]

PRIOR TO ASSY.

271 (P/N 2391434)

TO THREADS.

SM568

28-1-3

Section 1

Material Handling CLqRHCompany

GROUP 28

GROUP 28 Hydraulic Unit Contents Assembly Insstmctions . .. .... .. .. .... .. .. .... .. .. .... .. .. .. .... .. .. .. .. ... ... .. .. .. .. .. .. .. . 28-2-2 Specifications . .. .. ... ... .. ... ... .. .... .. .. .. .. .. .. .. .... .. .. .. .. .. .. .. .. . ....*................... 28-2-3

SM568

28-2-l

Section 2

Hydraulic Unit

GROUP 28

IMPORTANT

Replace old Seals and O-Rings ,ACh hTlxX7 .-8”rB.T

3 2 1

Thru Bolts

k

16

_

8. Install one (1) 5/l 6” Lockwasher to each of the thru bolts.

ASSEMBLY OF HYDRAULIC UNIT 1. Install Relief Valve Seal (1) into port 7 _.

9. Torque thru bolts to 17-19 lbs. ft. (23-26 Nom)

Install Relief Valve Seat (2) into port..

3. Install Ball & Spring (3), and Adjusting Screw (4), into Relief Valve Seat. Install Seal (5) and Cap (6) onto adjusting screw.

4. Install Check Valve (7), into Adapter.

5. Insert Coupling (8) into motor armature (Pack Coupling with grease).

6. Loosen two (2) thru bolts, on rear of motor (see arrows), and remove plastic end cap.

7. Install motor to the adapter, Remove end cap, with motor upright, alternately tap and turn armature until coupling aligns with pump tang.

Section 2

10. Mount Start Switch (9) to motor with l/4-20 x 3/8” Hex Head Screw (lo), Lock Washer (1 1), andFlat Washer (12). Attach lead wire (13), to motor and start switch.

11. Install Plow Control (14) into port.

12. Install Release Valve (15) into port.

13. Install O’Ring (large) (Item 18, refer to illusstration on following page), and attach Retainer (16), with #8-32 x l/4” Screws (17), to Adapter.

28-2-2

SM568

Hydraulic Unit

GROUP 28

14. Grease and insert two (2) O’Rings (19) and Pump Gasket (20), into Adapter.

26. Place magnet (34), into bottom of hydraulic reservoir.

15. Grease O’Ring on Pump Pilot. Install Pump (21), into Adapter.

27.

16. Install Seal (22) onto face of pump drive housing.

17. Install O-ring (23) onto pump drive housing.

18. Insert O’Ring, Retainer and Spring Clip into rear of pump (not shown).

Lightly grease inside edge of reservoir, and attach Reservoir, to Adapter with four (4)1/4-20 x 3/8” Hex Head Thread Forming Screws (35).

28. Fill reservoir with oil (Refer to Group 1)to within l/2” of the Filler /Breather Hole. (1 l/2 Qt. capacity) 29

Install Fill/Level Plug (36).

30. Jog Motor 3-4 times to prime pump.

19. Install O’Ring (24), Push-On Ring (25), andFlat Washer (26) into Relief Valve exhaust hole.

20.

21.

Insert O’Ring (27), Retaining Ring (28), and Washer (29), into 3/8” Return Port

31* Start unit and adjust relief valve to 2350 PSI setting.

32. Refer to Section 1 for installation instructions.

Grease and install l/4” Return Tube (30).

22. Grease and install 3/8” Return Tube (3 1).

23.

Grease and install l/2” Inlet Tube (32).

24. Wash strainer in cleaning fluid and allow to air dry.

25. Push Inlet Strainer (33), onto Inlet Tube.

SM568

28-2-3

Section 2

Material Handling El!!l_RK Company

GROUP 34 Section 1 Lift Cylinder Contents

Removal . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . .. .. ..I.................. 34-l-2 Block Lift Frame . .. .. .. .... .. .. .. . ... ... . .. .. ... ... .. ... . .. .. ... . ... ... . ... .. .. .. .. .. .. . .. ... .. 34-l-3 Disconnect Hoses . .. .. .. .. .. .. .. .. ..I........ . .. .. ... ... .. .. .... .. .. .. .. .. ... ... .. .. .. .. .. .... . 34-l-4 Disconnecting Lift Cylinder from Lift and Main Frames . . . . . . . . . .. .. . . . . . . .34-l-5 Disassembly & Reassembly . .. .. .. .. .. .... .. .... . ... .. .. .. .. . ... .. .. .. ... . .. .. .. .. .. ... . .. 34-l-6 Installation Specifications . .... .. ... .. ... .. .. .. .. .. .. .. .. .... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 34-l-7

Rod End

Return to Reservoir

Pressure tine from Pump

Base End

Lift Cylinder typical Illustration

SM568

Dee 91

34-l-l

Section 1

Lift Cylinder

GROUP34 LIFT CYLINDER REMOVAL

Bralce ApplleU

Key Switch Off

Move truck to a flat level surface.

Fully lower pallet forks.

Turn key switch to off position. Be sure control handle is in the full vertical (brake on) position.

Models having “coast control”, be sure the control lever is moved to the brake on position.

Disconnect Battery Typical Illustration

Disconnect truck battery.

Discharge capacitors. Refer to Group 19, Section 1.

Typical illustration Load Back Rest

Remove load back rest.

Lift Frame & Fork Side Plate

Remove battery from truck. Refer to Group 12, Section 1 for battery removal instructions.

Uncovered Batteries:

Typical Illustration

Cover With llywood or Heavy Cardboard ==@J

Container

I I

insulated Spreader Bar,

,.....’

I ,

::::::.,

m ........

ifI2 ,$$ ,,&$: .:*;::. ,:gS

.:.A..

.:<<.c .z;; y::::: :a :::::::: .:::::.

‘SF;

Y.

Section 1

34-l -2

........$.

‘:‘.

,,.::p?

Dec91 SM568

GROUP 34

Lift Cylinder Battery Cable Extensions (If required) Use two 2-foot lengths (0.6Omm) l/o (or 1) Size Cable.

r Block Lift Frame l

Connect battery to truck.

l

Fully elevate lift forks.

l

Place 4x4 blocking beneath forks as shown.

l

l

Depress lower button until forks are flat on blocks and hold button a few seconds longer allowing fluid and line pressure to dissipate.

Disconnect battery.

,

r SM568Dec91

Section1

Lift Cylinder

GROUP34 yx

Disconnect

Pressure tine

Line at Fitting

ji : .L.T. ,. ,.i :.: ‘2 :: :: ._..: :: :: :: :: :: ii :: :: j; ;I :. ;: jj :j i’{j ,: !: ^“!. ;$j’ .., :i :: j: :: ‘. : -. :; ‘. *.._ .i : jj ji

I’

Disconnect Hoses Place a drip pan or some meaans of collecting the hydraulic fluid that will be released upon disconnecting the hoses.

Section1

.

Disconnect pressure line at base of the lift cylinder.

.

Disconnect return hose at connection on side of cylinder.

34-l-4

Dee 91 SM568

GROUP 34

Lift Cylinder Typical Illustration

Typical Illustration

7

r

Pallet Fork Lift Frame

Pallet Fork Lfft Frame

U

Lift Cylinder

Top View

W

Disconnect Lift Cylinder Disconnect Winder Rod End from Lift Frame l

Remove snap rings from pivot shaft.

l

Tap shaft free of frame and rod end.

Disconnect Cvlinder Base End from Main Frame l

l

Remove retainer bolt, lo&washer, washer and spacer securing lift cylinder to frame.

Base End :-SJ

Remove lift cylinder out the top of truck.

Washer

-@

bckwasher

-&

Retainer Bolt ---A

SM568 Dee 91

34-1-5

Section 1

Lift Cylinder

GROUP34

Lift Cylinder

Brass Jaws

Typical Illustration

blow dry. Inspect threaded parts for signs of damage.

Examine cylinder barrel for scoring or internal damage . Replace all damaged or unserviceable parts.

Disassembly l

l

l

Place cylinder in a vise (see above).

Using pointed pliers, grasp locking ring located just in side the return port. Rotate gland assembly by hand while gently pulling/guiding the locking wire out the port.

Pull piston rod, gland assembly and internal components out of the barrel assembly.

Inspection l3 -_-_v.xd-_

nldseals. ___l__l.

Reassembly l

l

l

Wash tmt-ts in &aning -.~r__._

solvent and

Assembly parts using a new Repair-Kit and start them into the barrel assembly.

Rotate gland by hand and feed locking wire into position thru cylinder return port.

Torque jan nut to specifications. Install and connect lines. Refer to specifications on page 7. _

L

-

r Nut, Piston

K

(Seals) K (Wear Ring) r

Barrel Assembly

-

--“$A, Gland

/

_-. ._ -----I.

L Nut

Toraue Smcification 200 - 225 lb&.

Typical illustration

Section1

34-l-6

/

K = Repair Kit Dec91 SM568

GROUP 34

Lift Cylinder INSTALLATION SPECIFICATIONS

NOTE3&7

\,.-.

NOTE4

I-

:

:

NOTE 5

NOTE 4

:: ,. i: _.J .

,.,.... ii ‘ji

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r;

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___-::::=-.:lii::____

x, ‘--.“:>,<,e

e:z./i-

I’

:

: ,:

1 I

I

_;i”” /: _./.‘i

” 1 (

NOTE 1,’ Q

NOTE: 1. TORQUE

TO 61-69 Ibf+t

2. TORQUE

TO 71-88 Ibfein 18-10 N-m]

[83-93 N-m]

3. TORQUE

TO 16-20 Ibfaft [20-27 Nom]

4. TORQUE

TO 70-80 Ibfain [8-9 Nom]

5. TORQUE

TO 18-20 Ibfdt

6. LUBRICATE 7. APPLY

O-RINGS

LOCTITE

124-27 N-m]

PRIOR TO ASSY.

271 (P/N 2391434)

TO THREADS.

SM568Dec91

34-l-7

Section1

GROUP 35

LIFT LINKAGE

SECTION 1 LIFI- LINKAGE & LOAD WHEELS Section

Page

1 Operational Check ........................................................... ...35-l- 2 Pull Rod Adjustment Check .......................................... 35-l-2 Pull Rod Adjustment .....................................................

35-l-3 Lift Linkage ...................................................................... .35-l-5 Exploded View .............................................................

35-l-6 Removal ...................................................................... .35-l-7 Installation ..................................................................

35-l-25 Bushing Identification ............................................................. 35-l-4 Removal& Cleaning & Inspection.. ............................ .35-l-18 Bushing Installation ................................................... .35-l-19 Load Wheels (Single) .......................................................

35-l-22 Load Wheels (Dual) .........................................................

35-l-23 Pallet Entry/Exit Skids ......................................................

35-l-26

Front of Truck Lift Frame & Fork

3e

Rear of Truck

Typical Illustration

SM568 OCT 91

Section 1

LIFT LINKAGE

GROUP 35 OPERATIONAL CHECK l

If pallet forks do not elevate evenly, pull rod adjustment should be checked as outlined below.

l

l

If there is binding when elevating or lowering the pallet forks, this may indicate either lack of lubrication or damaged bushings in the load wheel brackets, or in the upper and lower lifting links located at the front of the pull rods and in the upright assembly. Lubricate the truck and again check operation. If binding still exists, the bushings should be checked and replaced as necessary.

-

-

-

-Load Back Rest (Pallet Forks)

Elevating Bracket (Upright -to- Lift Linkage)

If linkage appears to be loose or sloppy, this indicates the bushings am worn beyond their wear limits and should be replaced.

Load Wheel Bracket

__ _.”

Pull Rod Adjustment Check l

Park the truck on a flat, clean surface.

l

Place the forks in the fully lowered position.

l

Turn power key switch off.

l

Disconnect truck battery.

l

Check Clearance In

Check clearance between the bottom of the pallet fork atthe lowestpoint and the floor. This is easily checked by using a l/8” (Minimum), l/4” (Maximum) rod or drill. The drill should just fit between the fork and the floor as shown.

If a l.Wdrill will not fit between the floor and fork, or if there is clearance between the top of a l/4” drill andthefork,thepullrodsmustbeadjustedasoutlined on the following pages.

Section 1

35-1-2

Typical Illustration

.,_ ....A

Fork

toFloor C~ea~ncQ l/8’ Minimum

Rod or Drill

Wiih the forks fully lowered, “specified rod or drill” should just fit between bottom of forks and floor at the lowest wint as show here.

OCT 91 SM568

GROUP 35

LIFT LINKAGE Pull Rod Adjustment (Standard Pallets) l

l

l

Pallet Fork 81Pull Rod

Elevate pallet forks to their upper limit and shut the truck down (disconnect battery).

Jam Nut

Loosen jam nut (early models) and lock nut located just behind yoke.

I I-

Using a l/4”rod or punch (see illustration), rotate adjuster as required to obtain correct adjustment Shorren pull, rod length to raise pallet

l

l

l

Nut

Yoke

/

fork or lengthen rod to lower the pallet

fork. l

L&k

225

Adjustor Special Nut

Torque Specifications to 250 lb. ft. (305 to 339 Nom)

Connect battery and lower pallet forks,

Measuring

Shuttruckdownandcheckadjustmentusingthe l/8 or l/4” rod/drills as specified. Repeat above steps until correct adjustment is obtained.

Device

Secure adjustment. Elevate forks and torque lock nut to: 225 to 250 lb. ft. (305 to 339 N*m).

Tighten jam nut if so equipped. l/8” (Minimum)

l/4” (Maximum)

Typical Illustration

Final Adjgstment (Special or Reworked PPlleb)

the “tip” or “heel” of the forks “hang-up” upon

lf

entering or leaving the pallet, the heel of each fork must be adjusted toyour specific pallet requirement. l

l

l

Lower forks and and slowly

enter pallet. When theloadwheels moveoverandrestuponthefirst board, shut the truck down (disconnect battery).

Using a straight edge (or level) as shown, check distance between bottom of straight edge and top of fork as shown. Distance should be equal at all points. Correct as necessary.

Straight Edge

\ \

To adjust fork heel, refer to the instructions on the following page.

SM568 OCT 91

Distance measured should ba

Pallet

35-1-3

1st Pallet Board

CorrectAdiustment Section1

GROUP 35 NOTE Access to heel adjustment at lift cylinder piston rod is shown here.

LIFT LINKAGE 1

1 Pallet Fork

Frame I I I uft

I

I

I

I

_.

Truck Frame

l

l

l

l

l

l

l

l

Adjust fork heel until the forks are perfectly level with the pallet being entered. The adjustment is made at the Lift Cylinder Rod .

Loosen lock nut.

Rotate piston rod uf rodflats clockwise to increase overall height (raise fork heel).

Typical illustration

r

Pallet Fork Lfft Frame

Rotate rod countercloc&sie to decrease overall height (lower fork heel).

Tighten lock nut to secure adjustment.

Connect battery (turn key switch on) and lower forks.

Enterandexitpalletcheckingforcorrectadjustment.

Ifadjustmentis not as desired, repeat procedures as necessary.

Enter and exit pallet several times.

Correct heel adjustment until desired operation is obtained. Tighten locknut upon completing adjustment.

Typical Illustration

Section 1

OCT 91 SM568

GROUP 35

LIFT LINKAGE BUSHING IDENTIFICATION . Split Steel Backed Serf Lubricating Bushing used in Normal Applications. The inside color

of the bushing is yellow. .

The bushing must be installed so the grease hole in the bushing aligns with the hole in the bracket.

.

Bronze Bushing used in Heavy Duty Applica-

tions. .

Thebushingmustbeinstalledsothegreasehole in the bushing aligns with the hole in the bracket.

.

Elevating Bracket (1) is drilled to accomodate four prea.sefittin=. The hole in the bushing(s) must line up with the grease hole(s) in the bracket(s).

l

l

Bushing

Trail WheelBracket (2)isdrilledtoaccomodate mse fittings. The hole in the bushing(s) must line up with the grease hole(s) in the bracket(s).

Upper Links are equipped with two bushingand grease fittings. Grease holes must line up.

SM568OCT91

35-l-5

Section1

LIFT’LINKAGE

GROUP 35

Shaft (2)

‘\. \, 1

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\ \

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I’ ::

1,. ),,’ _’ j ,,,0 ,.( :

(Pallet Fork 8 Bracket) d

,;,

,..l

. / \

,,.I

: j :

f : :

Illustration

Section 1

35-l-6

OCT 91 SM566

GROUP 35

LIFT LINKAGE LIFT LINKAGE REMOVAL

Key

Brake AppLled

Switch Off

Thefollowing procedures cover complete overhaul of the lift linkage. It may not be necessary to completely remove the lift linkage for individual problems.

Separate Lift Frame from Main Frame l

Disconnect Battery

Move truck to a flat level surface.

1

TyDical illustration l

l

l

l

l

l

/*

Fully lower pallet forks.

Tum key switch to off position. Be sure control handle is in the full vertical (brake on) position. h4o&is having “coast control”, be sure the control lever is moved to the brake on position.

Typical Illustration Load Back Rest

Disconnect truck battery.

Discharge capacitors. Refer to Group 19, Section 1.

Remove load back rest.

Remove battery from truck. Refer to Group 12, Section 1 for battery removal instructions.

Uncovered Bafteriesr )

Typical Illustration

Cover With +wood or Heavy Cardboard ==J-

Container

I I

Insulated Spreader Bar 7

SM568

OCT91

I,

Section1

GROUP 35

LIFT LINKAGE

Elevate and block truck as shown. l

l

Use 4 x 4 blocks at both sides and at the front.

Use l/2 x 4 x 12” long blocking under each fork as shown below.

AWARNING Makecertainthetruckissetting . firmly on blocks. The main frame must be blocked at all pointssothat upon disconnecting the llftframeand load wheel assemblies the main framewill~ stand by itself.

Typical Illustration

BLOCK LIFT FRAME AND

MAIN FRAME

Load Wheels to set flush on floor.

Typical Illustration

Section 1

35-1-8

OCT91 Stvl568

GROUP 35

LIFT LINKAGE

Pallet Fork Lift Frame

Top View

Remove Cylinder Pivot Shaft NOTE Check blocking beneath each fork. The lift forks must be supported to relieve strain on the Pivot Pin at the Cylinder Rod End and the Lift Frame. l

Remove snap ring from pivot shaft.

l

Tap shaft free of frame and rod end.

Lift Forks

Block Forks to relieve strain on

Pivot Shaft at frame and rod rod.

SM568 OCT 91

35-1-9

Section 1

GROUP 35 ___ __ ---

LIFT’ LINKAGE

Typical Illustration

Remove Lever Pivot Shaft l

l

l

Remove retainer bolts securing shaft retainer pins to the lift frame.

Pull retainer pins free of each pivot shaft, Tap pivot shafts free of the lift frame and upper links.

NOTE

separated from the main frame, the upper links can be removed from the main frame.

Once the lift frame is

Section 1

35-l-10

OCT 91 SM568

GROUP 35

LIFT LINKAGE

Shaft (2)

- Shaft (5

SM568 OCT 91

35-l-l

1

Section 1

LIFTLINKAGE

GROUP 35

Battery Compartment

Elevating Bracket

Remove Left and Right Elevating Bracket Pivot Shafts .

Remover retainer bolts securing shaft retainer to the main l?ame.

l

Full retainer pins free of each pivot shaft.

l

Pull pivot shafts free of the main frame and elevating brackets.

Elevating Bracket

Access Hole

Section 1

35-1-12

OCT 91 SM568

GROUP 35

LIFT LINKAGE

Move Lift Frame away from Main Frame

Chain Hoist -

Safety Hook Lift Frame on it’s ride sitting flat on floor with chain hoist and lifting strap attached.

Lift Frame sitting upside down flat on the floor

SM568OCT91

35-1-13

Section1

GROUP 35

LIFT LINKAGE

I-

Typical Illustration

Elevating Bracket

3attery Compartmer

Pivot Shaft Retainer Pin 7

1 Lift Fork

Typical lllustratior~

Disconnect Load Wheel Bracket l

l

I

1

Elevating Bracket Typical Illustration

Disconnect Elevating Bracket e

Remove roll pin(s) securing pivot shaft(s) to lift fork(s).

Tap pivot shaft free of lift fork and bracket.

Allow wheel bracket and rod to rest on the 4x4 support at each lift fork.

l

Removebolt(s)andpullretainerpin(s)fiomthe elevating pivot shaft(s).

Tap each pivot shaft free of lift fork and elevating bracket. Allow bracket and rod to rest on the 4x4 support at each lift fork.

Remove Rods & Brackets l

Section 1

Pull rod

assemblies fmm beneath each lift fork.

35-l -14

OCT 91 SM568

GROUP 35

LIFT LINKAGE Single Load Wheel & Pull Rod

/

PivotShaft

Pull Rod

Disconnect Load Wheel Bracket

SM568OCT91

l

Remove bolt (1) and washer (2) from yoke.

l

Pull retainer pin (3) free of pivot shaft.

l

Tap shaft free of wheel bracket and yoke.

35-1-15

Section1

LIFTLINKAGE

GROUP 35

Allen Wrench-----]

Pivot Shaft

ElevatingBracket

Disconnect Elevating Bracket

Section 1

l

Loosen lock nut (1).

l

Remove set screw (2) from pull rods.

.

Tap pivot shaft free of brackets and pull rods.

35-1-16

OCT91 SM566

GROUP 35

LIFT LINKAGE

TOP VIEW Main Frame

Typical Illustration

i I

Remove Upper Links l

Remove bolts (1) fi-ommain fi-ame.

l

Pull retainer pins (2) from both pivot shafts.

l

l

Upper Links

Tapthepivotshafts(3)freeoftheupperlinksand main frame.

Remove upper links (4) from main frame.

Typical Illustration

SM568OCT 91

35-1-l 7

Section 1

GROUP 35

LIFT LINKAGE

Bushing Removal

I

Priortoremoving a bushing, note if it isflushmounted or pressed to a certain depth. A press is recommended for the removal and installation of bushings.Ifapressisnotavailable,thebracketsorlinks should be clamped (retained) in a safe manner to a work bench. The new bushing should be installed to the specifications listed on pages 11 and 12.

0 If a press is not available, clamp or retain the component to be worked on to a work bench. l

Using a bushing driver, tap the bushings free of their housing bores NOTE

If one bushing is bad, we recommend that all bushings be replaced.

I [/ / // > I / , *

Cleaning & Inspection l

l

l

l

l

Visually inspect linkage for wear and damage.

Replace parts as necessary.

Inspect the bushing bores for damage. Using a crocus cloth, remove any burrs from the bores that might cause distoration or damage to a new bushing upon installation.

Clean surface with solvent and a brush.

Be certain grease passages are clean and free of debris.

Wipeoutersurfaceofpartsdrywithacleanshop rag.Allowtimeforsmall(grease)passagestoair dry-

Section 1

35-l -18

OCT 91 SM568

GROUP 35

LIFT LINKAGE

Grease Hole in Bushing MUST LINE UP WITH Grease Hole in Housing.

Grease Fitting

Upper Link Shown Here Typical lllustratic

Elevating Bracket Shown Here

Bushing Installation l

l

l

Position new bushing so the grease hole lines up with the grease hole in the link or bracket.

n

Ifthebushingisofthe”splittype”,becertainthe split side of the bushing faces inward (away from load force) as shown above. Bushing “gaps” (shown above) would actually be in a closed state after installation. a pressis not available, clamp or retain the bracket to a work bench. Using a bushing driver, tap new bushing into position. Refer to Bushing “PI&’ Specifications on pages 11 and 12.

If

NOTE Split Side of Bushings must face INWARD away fmm load force.

Typical

SM568 OCT 91

35-1-19

Section 1

GROUP 35

LIFT LINKAGE

Typical Illustration

Section 1

35-l-20

OCT91 SM568

GROUP 35

LIFT LINKAGE

BUSHING INSIDE SURFACE.

“PRESS’ SPECIFICATIONS

Pull Rod Elevating Bracket

Bushing to be FLUSH with OUTSIDE SURFACE. Align Grease Hole in Bushing witt-

Typical Illustration

SM568 OCT 91

35-l-21

Section 1

GROUP 35

r

LIFT LINKAGE

Inspection Check bearings for looseness or binding. Replacebearings found to have the above conditons.

Lubricate new bearings prior to assembly.

Pivot Shaft T

Roll Pin

Replace tires that have excessive wear, bad cuts or breaks (chunking), or any that have bond failure.

Replace any damaged or missing grease fittings.

Check bracket spindles for damage. Remove any nicks with a crocus cloth.

Make certain bushings are in good condition. If one is found to be bad, replace them all.

-

Shield, Outer

Assembly

-Shield,

-

l

Install components as shown.

l

Be sure shielded side of bearings face outward.

l

Torque retainer nuts to specifications shown.

Inner

Shielded Side of Bearing to Face Outwan

- Torque Nut to: 100 - 140 lb. ft. (135190 Nom: Section 1

35-1-22

OCT 9 1 SM568

GROUP 35

LIFT LINKAGE

SINGLE LOAD WHEELS

Inspection , l

l

l

l

.

Roll Pin

Check bearings for looseness or binding. Replace bearings found to have the aboveconditons.

Lubricate new bearings prior to assembly.

.. .,_.: a,..’

Replace tires that have excessive wear, bad cuts or breaks (chunking), or any that have bond failure.

Replace any damaged or missing grease fittings.

Replace seals that have cuts or curling of the seal lip.

Washer __

Make certain bushings are in good condition. If one is found to be bad, replace them all.

Assembly l

l

l

Install components as shown.

PressLipSealintowheel0.16”(5.0mm)-0.20” (5.0 mm) as shown. Make certain the sealing lip is facing toward the outside of the fork. Refer to the sectional view in the opposite column.

Install axle so the axle head and the rollpin is located to the outside of the truck.

Grease Fitting -

- Seal, Axle Wheel

Typical Illustration

_

SECTIONAL VIEW OF LOAD WHEEL SM568

OCT 91

35-1-23

Section

1

GROUP 35

LIFT LINKAGE

Shaft (2)

L Shaft (5

,‘:

..,. “_* 1 Tru,.k Frame 1 ’

Zshaft

Section 1

(4)

‘j y , .’

\

1

/

\

35-1-24

1 Bracket m

;::.

; : : Shaft

j

jr;.‘... . -_

OCT 91 SM568

GROUP 35

LIFT LINKAGE LIFT LINKAGE INSTALLATION Reassemble pull rods, elevating brackets and load wheel brackets so they may be installed as subassemblies to the lift and main frames. .

r-1-1

Install assembled lift linkage to the lift frame, reference page12 thru 14.

.

Install upper links to the main frame, reference page 17.

.

Temporarily secure lift cylinder out of the way to main frame allowing assembly of linkage between frames.

.

Shaft,

r

Bolt1 D-r-:..,..

Shaft

/-

Bolt

I

Dir

Top

y

w

I I

View

I

Locate lift frame in position to the main frame and block both frames so they can not move during assembly, see example below.

u

Typical Illustration

c

I I

Typical Illustration

I-

Snap Ring-

I l

l

l

Connect rod end of lift cylinder to lift frame using new snap rings, reference page 9.

Connect upper links to lift frame, reference page 10.

Connec elevating brackets to main frame, reference page 12.

l

Lower truck to floor, refer page 10.

l

Install truck battery, reference page 7.

l

Perform an operation check for correct linkage adjustment, reference page 2. Adjust linkage as required, reference pages 2 thru 4.

I Side View

Retainer Pin

I I l I I I 1

Banery Compartment T

pull

I

d Clevis Pin 7

Retainer Pin

b

Make certain the lift linkageadjustorlock nuts are torqued to specifications,rderence page 3.

Elevating Bracket-

/

(Pull R&to-Upright)

Grease Fitting

Typical Illustration

SM568

OCT 91

35-1-25

Section1

LIFT LINKAGE

GROUP 35

Retainer Screw

Pallet Entry Skids Installation InstructionS .

l

l

Section 1

Position Plastic Skids with the "R" pointing in the direction of the battery compartment.

Coat the threads of the retainer screws with Loctite 222 (or 242) or use Permabond MM1 13 (or MM1 15).

Tighten bolts until “snug” then tighten screws an additional l/4 turn ... no more.

35-1-26

OCT 91 SM568

Material Handling ElgRRCompany

GROUP 39 Section 1 Body Parts Contents

Drive Motor ......................................................................................

Pump Motor ......................................................................................

Electrical motor mainmance General Procedures ...............................

16-1-1 16-1-2 16-1-3

PWD&P

HWD & HWP

SM568 Ott 91

Section 1

Body Parts

GROUP 39 Walkie Model Trucks

a WARNING

(Standard Equipment)

NO RIDING i Decal PART NQ 2777835

Operator’s Manual and Manual Compartment

I

Door Instrument

/

7/

Fastener

Panel

Battery Instruction DecaL

.

Door

.I

:.

/

-.:-*.

::: ,..’

-

;. ,,,

:..:I

:. y:::j j

Truck

i Frame

.‘:

x ._

:j

’

i,:;; ; ii r ;:; :: .;o*, : * jl

CLARK LOGO D Patent Legend -

Lh WARNING

Section 1

39-l -2

act 91 SM568

GROUP 39

Body Parts a

Rider Model Trucks

WARNING

NO RIDING i PART Decal

(Standard Equipment)

NO. ZliB3S

WARNING Coast Control Decal Fastener--jr Operator’s

Manual

/

7 Safety Instruction Dee

Manual Compartment

Instrument

Panel

Cover

Decal

Maintenance

7

/Fastener

CLARK LOGO Decal

a WARNING

battery before handlfng components. Polarity must be correct to prevent damage.

Dlsconneci electrical

Battery Instruction Decal

SM568 Ott 91

39-1-3

Section 1

Body Parts

GROUP 39

40

Coast Control Decal (Optional Equipment)

40 AWARNING

(0

Walke Model Trucks

Truck Name (Data) Plate Section 1

39-l -4

Ott 91 SM568

Handling Cl!!lRK Material Company

GROUP 40

Section 1 Truck Specifications

Clark products and specifications are subject to improvements and changes without notice.

SM568 OCT 91

40-l -1

Section 1

GROUP 40

Specifications

BATTERY SB-2 / 175 Amp

Battery Connector:

24 Volt

System Voltage:

Battery Recommendations: Type: Lead Acid

Capacity: 6 Hour Rate

Battery with Cover

AmDer Hour

Battery Compartment Size Range: Small: 7.0 x 35.5”

255 - 330

Large: 13.6 x 31.4”

510 - 930

Battery Weights:Mininum: Small: 7.0 x 35.5”

528 - 575

Large: 13.6 x 31.4”

971- 1461

Battery Specific Gravity:

1)

Hydrometer Test:

State of Charae

1.260 - 1.300

100% Charged

1.230 - 1.250

75% Charged

1.200 - 1.220

50% Charged

1.170 - 1.190

25% Charged

1.140 - 1.160

Very Weak

1.110 - 1.130

Discharged

Test at least six cells across battery with a temperature corrected

2) Battery bad Test:

Stxcific Gravitv Test

hydrometer (refer to GROUP 19)

(24 Volt Battery)

19.2 Volts

Charge (or replace) the battery if voltage drops below 80% of the rated voltage of the battery.

Use both the above tests to check out battery.

Section 1

40-l-2

OCT 91 SM568

GROUP 40

Specifications BRAKE, MOTOR

Brake Drum to Brake Shoe Clearance: 6.77 lb. in. (0.2 mm) Brake Holding Torque with a full rated capacity load on a 15% grade: Check the name (data) plate for the specific load capacity of your truck.

The brake must fully set (apply) when the control handle is in the vertical (park) and in the full down positions. Refer to Group 23, Section 1 for service procedures.

The brake must be canable of holding the truck; with a full rated canacitv load. on a 15% made.

Coast Control (Optional Equipment) With the coast control lever in the “brake off” position (battery disconnected and control handl released to its operational position) the brake drum must be free to rotate by hand.

Moving the control to the full up or down position must fully set (apply) the brake. Refer to Group 23, Section 2 for service procedures.

CONTROL (EV-TS SOLID STATE CONTROL Voltage:

Fixed

24 Volts d.c.

Low Voltage Cut-Off: Creep Speed:

Fixed Adustable

16 Volts d.c.

5% to 15% On-Time

Current Limit:

(Do Not Adjust)

Factory Preset

Plugging:

Adjustable

100 to 350 Amps

Accelerator Position Plug:

Operator Controllable. 100 Amps to Plugging Current Setting.

Ramp Start:

Standard

200 - 350 Amps

Controlled Acceleration:

Adjustable

0.5 to 2.5 Seconds

1A Timed Picked Up:

Fixed

Follows C/A by 0.2 sec. & Accel. Volts less than 0.5.

Thermal Cutback:

Standard

Startat 9OC

Static Return to Off:

Standard

1.5 Second Delay

Accelerator Input:

___________

3.5 (to) “0” Volts

Ambient Temperature Range: ---------

-30” (to) +5O”C

Coil Drivers:

F,R, 1A & Line

On-Board 2 Amps Maximum

Accel. Start-Up Lock-Out:

Standard

Accelerate less than 2.5 Volts

SM568 OCT 91

40-l-3

Section 1

GROUP 40

Specifications

ELECTRICAL Contactor Coil Resistance;

Forward & Reverse

14.4 +/- 10% ohms

1A Contactor

14.4 +/- 10% ohms

Line Contactor

14.4 +/- l-% ohms

____________-__------_-__---Ground Tests G?uck);

Used Trucks 30,000 ohms min. New Trucks 50,000 ohms (i-)

(RxlO,OOOScale - as measured from negative battery connector to truck frame.)

Ground

1,OOO,OOO ohms (Rx10,000Scale-asmeasuredfromeachfieldcoilandarmatureterminalstudtotruckframe.)

_______________-__--_--_----_-__ $wi tches;

Brake Switch

Must shut off drive motor prior to brake shoes making contact with brake drum. Refer to Group 23, Section 1.

Control Switches

Refer to Group 19, Section 2.

Lift Limit Switch

Must shut off pump motor just prior to lift forks reaching full up 9.5” posi tion as measured from top of forks to floor.. Refer to Group 13, Section 1.

Emergency Reversal

Button should push in at minimum of

-----_--___----------_-_--_-____

Travel Sneeds;

Walk& w PWD and P

Empty

4.0 mph

P25 andPWD25

5,m

3.0 mph

P30 and PWD30

6,000++

2.8 mph

PWD36

8,ooo#

2.5 mph

HWDandHWP

Empty

7.7 mph

HWD25 and HWP25

X)OO#

5.4 mph

HWD30 and HWP30

6,ooo#

4.9 mph

J5wD36

8,00@+

4.5 mph

Walkie / Riden

&stem Fuses;

Main Fuse: 300 Amr, (1FU)

Control Fuse: 15 AmD (2FU)

I L Section 1

40-l-4

OCT 91 SM568

GROUP 40

Specifications HYDRAULIC SYSTEM Hvdraulic Unit;

Lift Cvlinder DrifI Test;

Pump Flow

2.5 GPM

Pump Displacement:

0.97 cm

Relief Valve Setting:

2350 PSI

Reservoir Capacity:

l-1/2 Quart

0.25 in (6.35 mm) in a five minute period with a capacity load on th forks.

J_,iftinPSoeeds,.

Lifting Time in Seconds Max. Load.

Emptv

Lowering Time in Seconds

Loaded

Empty

Loaded

Model

P25

5,m

3.75

4.75

6.5

6.4

P30

6,m

3.75

4.85

6.5

6.4

HWP25

5,m

3.75

4.75

6.5

6.4

HWP30

6,ooo#

3.75

4.85

6.5

6.4

PWD25

5,ooo#

2.75

35

4.5

4.5

PWD30

6,m

2.75

3.9

45

45

HWD25

5,ooo#

2.75

3.5

6.5

4.5

HWD30

6,000+#

2.75

3.9

6.5

4.5

HWD36

3.75

5.2

6.5

PWD36

3.75

5.2

6.5

’

6.4 6.4

TIRES Tire Size;

prive Tire

Load Tire

10.00 x 4.75 6.5

3.38 x 2.63

(Dual Tires)

3.38 x 5.75

(Single Tire)

Caster fStabilizin~1;

Hwp 4.0 x 2.5

SM568 OCT 91

4.0 x 2.5

40-l-5

Section 1

GROUP 40

Specificat ions

TRUCK SERVICE WEIGHTS with minimum battery weight and without load

SMALL BAITERY 7.0 x 35.5” Compartment

Section 1

LARGE BATTERY

13.6 x 31.4” Compartment

P-25 / 30

15501bs

703kg

1975lbs

896kg

HWP-2s / 30

16651bs

755kg

20901bs

948kg

PWD-25 / 30

14OOlbs

635kg

1825bs

828kg

HWD-25 / 30

15051bs

683kg

19301bs

875kg

HWD36

16651bs

755kg

209Olbs

948kg

PWD36

15501bs

703kg

19751bs

896kg

40-l-6

OCT 91 SM568

GROUP 40

St3ecifications Torque Specifications Torque Brake Mounting Bolts to 170 to 191 Ib.ft.

(19 - 22 Nom) 9

Torque Drum Nut To: 18 to 22 Ib.ft.

(24 - 30 N*m)

I...

- ^ .+.. ....

..I_ ,,

--“*x.

,.:.:.

.. . ._.,. ,_ ,,_.--

Nut Plate Weldment

. ..‘-’

/ j‘..”,.’ ..__.__

Torque 6 MM Mounting Bolts to 15 Ib.ft. (20 N*m)

Torque Bolts to: 213 io 240 Ib.ft.

(258 - 325 Nom)

-I SM568 OCT 91

40-l-7

Section 1

GROUP 40

Specifications Torque Specifications Drive Tire & Wheel Assembly Typical Illustration

Torque Bolts to: lOOlb.ft. (113 Nom)

Torque t Lug Nuts to: 81 to 92 Ib.ft_

Control Handle

(110 - 125 N*M)

-‘--: . . .‘_.

..s r <.::’’

Control Handle

. .._-

, ./

I ,.”

1 /I ,z.’ ,_‘.;

,-’

,,.-

Torque Nut 30 to 33 Ib.ft.

Stability

Zaster ‘;---.-...

_..

-..z_ _ ..... __..

8mm Bolt&Washer

Torque Bolt to: 60 lb.ft. (6.8 Nom)

Section 1

40-l-8

OCT 91 SM568

EDIIRK

Material Handling Company

GROUP 40

Section 2 Wiring Schematics Contents IN-22222 (Early Model Trucks) Schematic ...I....................... _. . . . . . . . . . . . 40-2-2 (Early Model Trucks) Diagram ............. ..I............... .. ......... 40-2-3 Early Model EV-T5 Control is equipped with Wire Terminal Strip

IN-24029 (Late Model Trucks) Schematic ........................................ -40-2-4 (Late Model Trucks) Diagram.. .......................................... 40-2-5 Late Model EV-TS Control is equipped with Wire Terminal Plugs

SM568

40-Z-l

Section 2

r

I

_o-2-_

N-2-N

o-o-2

=I-+-k+tl-+tl--H-

N--N-_

I

III

I!I!

/II

h

I

I

I

I

P/PWC WIRE Y78 SHOULO BE CONNECTED TO WIRE #i/7A AT HANOLE HARNESS ON WALKIE TRUCK lP/PWOI.

_

HW”,UWP

WIRE 178 S~0u1.0 BE DISCONNECTED AND WIRE #,,,A AT THE HAN3LE HARNESS AND CONbZCTEO TO WIRE Y7F IN THE GRAB BAR HARNESS ON THE r(ALK’RIDE TRUCK THWD/HWP) ONLY.

EG

2.

THE CIRCUIT IS CONFIGURED AS FOLLOWS iSOLID LINE - STANDARD P TR”c-K DASH LINE - ADO ON FOR HWP TRUCK PHANTOM LINE - OPTIONS .._I.~

3

REPLACEMENT OF TERMINAL BOARD (SCREW1 CARD WITH PLUG TYPE CARD REOUIRES CONNECTING WIRE Y15 TO CONNECTOR COIL WIRE Y7.

r

Y

L

I-

!

Y iru-