BT OE35 User manual

Service Manual
Read and observe all warnings on this unit
before operating it.
DO NOT operate this equipment unless all
factory installed guards and shields are
properly secured in place.
WARNING
WARNING
Part no: 301460-003 Date: January 29, 1998
OE35
Electric Counterbalanced Order Selector
Effective Serial Number OE35027319000
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BT Standard Codes
F-code Section C-code
Version no T-code
000
© BT Products 1
Service Manual 1997-07-15
BT Standard Codes
B-Code = Business area
F-Code = Product family
T-Code = Product type
C-Code = Component function
Worksheet standard
W-Code = Working code
R-Code = Reason code
SO-Code = Assortment
C-Code List
No Function Group C-Code
0 Chassis 0000
1 Drive Motor 1000
2 Drive Gear / Transmission 2000
3 Brake / Wheel System 3000
4 Steering System 4000
5 Electrical System 5000
6 Hydraulic / Pneumatic System 6000
7 Operating Function-lifting Mast / Cylinders 7000
8 Peripheral / Installation Equipment 8000
9 Optionals / Attachments 9000
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000
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BT Standard Codes
2 Service Manual 1997-07-15
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Table of Contents
BT Standard Codes ....................................................................................... 1
Warning Symbols .......................................................................................... 9
Warning Levels .......................................................................................... 9
Prohibitory Symbols .................................................................................... 10
Ordinance Symbols .................................................................................. 10
Introduction, Service Manual ...................................................................... 11
Contents, Section M ..................................................................................... 13
Machine Information ................................................................................. 13
General Product Information ...................................................................... 15
Presentation of the OE35 ......................................................................... 15
Main Components ..................................................................................... 20
Inch (SAE) and Metric Fasteners ................................................................ 23
Introduction ............................................................................................... 23
Nomenclature, Threads ............................................................................ 24
Strength Identification ............................................................................... 25
Conversion of Metric and English Units .................................................... 31
Technical Service Data ................................................................................ 33
Ordering Spare Parts ................................................................................... 37
Service Schedule ......................................................................................... 39
Planned Maintenance Schedule ............................................................... 39
Planned Maintenance Procedures .............................................................. 43
Services to be performed daily or at each 8 hour operating shift ............. 43
Services to be performed monthly or every 250 operating hours ............. 45
Services to be performed annually or every 1200 operating hours .......... 48
Lubrication Chart ......................................................................................... 51
Oil and Grease Specifications .................................................................... 53
Approved Oils and Grease ....................................................................... 53
Contents, Section S ..................................................................................... 55
Service Instructions .................................................................................. 55
Inspection Covers ........................................................................................ 57
Removal Of Plastic Dash Panel ................................................................ 58
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Table of Contents
Drive Motor ................................................................................................... 61
General Information .................................................................................. 61
Operating Conditions ................................................................................ 61
Troubleshooting ........................................................................................ 61
Drive Motor 24 Volt ...................................................................................... 67
Component Repair .................................................................................... 68
Inspection and Troubleshooting ................................................................ 69
When changing brushes ........................................................................... 74
Drive Motor 36 Volt ...................................................................................... 75
Component Repair .................................................................................... 76
Inspection and Troubleshooting ................................................................ 77
When Changing Brushes .......................................................................... 82
Transmission ................................................................................................ 83
System description ................................................................................... 83
Troubleshooting ........................................................................................ 83
Removal .................................................................................................... 84
Transmission Disassembly / Assembly ..................................................... 87
Disassembly ............................................................................................. 88
Installation ................................................................................................. 95
Drive Wheel ................................................................................................... 97
Load Wheels ................................................................................................. 99
Stabilizing Caster Spring Loaded .............................................................. 101
Removal ................................................................................................... 102
Inspection ................................................................................................ 104
Disassembly ............................................................................................ 105
Torque Generator ........................................................................................ 107
Disassembly ............................................................................................ 109
Assembly ................................................................................................. 114
Steering System Pump ............................................................................... 121
General Information ................................................................................. 122
Removal ................................................................................................... 122
Installation ................................................................................................ 123
Disassembly ............................................................................................ 125
Inspection ................................................................................................ 126
Assembly ................................................................................................. 126
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Table of Contents
Steering System .......................................................................................... 129
General Information ................................................................................. 129
Electrical System with TX and TT Card ..................................................... 131
Electrical Schematic Part 1 ...................................................................... 131
Electrical Schematic Part 2 ...................................................................... 132
Basics Of Circuit Operation ..................................................................... 133
Control Features ...................................................................................... 135
General Maintenance Instructions ........................................................... 143
Trouble-shooting Instructions .................................................................. 144
Battery Controller / Hourmeter / Lift Interrupt .......................................... 147
General Information ................................................................................. 147
Electrical .................................................................................................. 147
Battery Controller (BC) ............................................................................ 148
Troubleshooting ....................................................................................... 151
Dash Display ................................................................................................ 155
General Information ................................................................................. 155
Location ................................................................................................... 156
Operational Checks ................................................................................. 156
Status Codes ........................................................................................... 157
EV100 LX Control Status Codes ................................................................ 159
SCR Component Checks ............................................................................ 177
Main Logic Card ....................................................................................... 177
Capacitor 1C ............................................................................................ 178
Contactors Forward, Rearward, 1A, Power Steering, and Pump ............ 178
Potentiometer in Accelerator ................................................................... 178
SCR’s (1REC, 2REC, 5REC) .................................................................. 178
Rectifiers (3REC, 4REC, Diode Blocks) .................................................. 180
Thermal Protector (TP) ............................................................................ 180
Filter Block (23FIL, etc.) ........................................................................... 181
Filter Block (23FIL, etc.) ........................................................................... 181
1X Choke and Reactor T3-T4 .................................................................. 181
Replacement of EV100 Components ...................................................... 181
Instructions - EV100 Plugs ...................................................................... 183
Direction Contactor ..................................................................................... 185
General Information ................................................................................. 186
Remove / replace contact tips ................................................................. 186
1A Speed Contactor .................................................................................... 191
General Information ................................................................................. 192
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Table of Contents
Disassembly ............................................................................................ 192
Assembly ................................................................................................. 194
Electrical System Troubleshooting ........................................................... 197
Control Circuits and Power Circuits ......................................................... 199
Electrical System Troubleshooting Charts ............................................... 201
Pump Contactor .......................................................................................... 213
General Information ................................................................................. 214
Disassembly ............................................................................................ 214
Assembly ................................................................................................. 216
Steering Pump Contactor ........................................................................... 219
General Information ................................................................................. 220
Disassembly ............................................................................................ 220
Assembly ................................................................................................. 222
EV100 Handset Operation .......................................................................... 225
General Information ................................................................................. 225
Purpose ................................................................................................... 226
Operation ................................................................................................. 227
Function Set-Up Procedures ................................................................... 228
Description and Location ......................................................................... 230
Function Numbers for Controllers ............................................................ 231
Hydraulic System ........................................................................................ 239
Hydraulic Schematic ................................................................................ 239
General Information ................................................................................. 240
Maintenance ............................................................................................ 242
Adjustments ............................................................................................. 242
Hydraulic Troubleshooting ........................................................................ 243
Troubleshooting Chart ............................................................................. 243
Lift Pump Assembly .................................................................................... 247
Removal ................................................................................................... 248
Disassembly ............................................................................................ 249
Inspection ................................................................................................ 252
Assembly ................................................................................................. 254
Mast, 2 Stage ............................................................................................... 257
Shimming Mast on Truck. ........................................................................ 258
Two Stage Mast ....................................................................................... 262
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Table of Contents
Mast, 3 Stage ............................................................................................... 267
Shimming Mast on Truck. ........................................................................ 268
Three Stage Mast .................................................................................... 273
Lift Cylinder, 2 Stage .................................................................................. 279
Cylinder Repair ........................................................................................ 280
Freelift Cylinder, 3 Stage ............................................................................ 283
Freelift Cylinder Repair ............................................................................ 284
Staging Cylinder, 3 Stage ........................................................................... 287
Micro 70 Wire Guidance Important Information ....................................... 291
Powering Up: ........................................................................................... 291
Powering Down: ....................................................................................... 291
Micro 70 Wire Guidance ............................................................................. 293
Electrical Schematic Part 1 ...................................................................... 293
Electrical Schematic Part 2 ...................................................................... 294
Electrical Schematic Part 3 ...................................................................... 296
Electrical Schematic Part 4 ...................................................................... 298
Cautions and Warnings ........................................................................... 300
Operation Information .............................................................................. 302
Component Function and Relationship .................................................... 306
Truck Set Up On Site ............................................................................... 308
Troubleshooting Information .................................................................... 311
Troubleshooting Charts ........................................................................... 314
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Table of Contents
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Warning Symbols
PS
F-code Section C-code
Version no T-code
000
© BT Products 9
Service Manual 1997-07-15
Warning Symbols
Always follow the warnings given in this Instruction Manual
and on the truck to avoid accidents and incidents from
occurring.
1. Warning Levels
Always follow the warnings given in this Instruction
Manual and on the truck to avoid accidents from
occurring.
Warning levels
Warning texts are given in four levels and provide information
on the risks, describe the consequences, and instruct how to
avoid accidents.
DANGER
Warns that an accident will occur if you do not follow the
instructions.
The consequences are serious personal injury or
possibly death, and/or extremely large material damage.
WARNING
Warns that an accident can occur if the instructions are
not followed.
The consequences are serious personal injury or
possibly death, and/or large material damage.
CAUTION
Warns that an accident can occur if the instructions are
not followed.
The consequences are personal injury and/or material
damage.
NOTE!
Marks the risk of a crash/breakdown if the instructions are
not followed.
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000
Version no T-code
F-code Section C-code
Prohibitory Symbols
10 Service Manual 1997-07-15
Prohibitory Symbols
NO SMOKING
If smoking occurs in situations where a restriction agains
smoking is stated, a serious accident can occur.
OPEN FLAMES PROHIBITED
If open flames are used in situations where open flames are
prohibited, a serious accident can occur.
GENERAL PROHIBITION
If the prohibition is ignored, a serious accident can occur.
1. Ordinance Symbols
SAFETY SHOES
When the directive for safety shoes is given, safety shoes
shall always be worn to avoid personal injury.
PROTECTIVE GLASSES
When the directive for protective glasses is given, protec-
tive glasses shall always be worn to avoid personal injury.
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Introduction, Service Manual
M
F-code Section C-code
Version no T-code
000
© BT Products 11
Service Manual 1997-07-15
Introduction, Service Manual
The information in this Service Manual covers models OE35
order selector.
Federal and State laws require that operators be completely
trained in the safe operation of lift trucks.
An Operator’s Manual is attached to every BT lift truck when
it is manufactured. If the Operator’s Manual is missing from
the truck, a new manual may be obtained by contacting:
BT Prime-Mover, Inc.
3305 N Highway 38
Muscatine, Iowa 52761-8800
[phone]
This service manual is not a training manual. The information
contained in this service manual is intended as a guide to
help authorized technicians safely service this truck.
The Service Manual is divided into four separate sections
which cover different kinds of information needed for
servicing these truck types. The main subject for each of
these sections is described below.
SECTION SUBJECT
M MACHINE INFORMATION
P PLANNED MAINTENANCE
S SERVICE INSTRUCTIONS
O OPTIONS
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M
000
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Introduction, Service Manual
12 Service Manual 1997-07-15
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Contents, Section M
M
F-code Section C-code
Version no T-code
001
© BT Products 13
Service Manual 1997-07-15
Contents, Section M
1. Machine Information
M1.0 GENERAL PRODUCT INFORMATION
M2.0 TECHNICAL SERVICE DATA
M3.0 ORDERING SPARE PARTS
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M
001
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F-code Section C-code
Contents, Section M
14 Service Manual 1997-07-15
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General Product Information
PS M1.0
F-code Section C-code
Version no T-code
000 OE35
© BT Products 15
Service Manual 1997-09-24
General Product Information
1. Presentation of the OE35
OE-35 is a battery powered counterbalanced order selector
trucks.
These trucks are intended solely to be operated handling
pallets or similar load carriers indoors.
In their standard design, the trucks are equipped with a
steering wheel with all the controls for operating within easy
access.
The trucks have a maximum lifting capacities of 3000 lbs.
(review data plate on the truck to note the maximum lifting
capacity).
These trucks are equipped with a 24V or optional 36V
electrical system and the speed is regulated by means of a
SCR controller to provide gentle control of acceleration and
speed while operating.
The forks are raised by means of an electric powered
hydraulic pump unit. Both raising and lowering are done
electrically with separate push buttons on the control handle.
The trucks can be specially equipped to work in cold
conditions.
1.1. Intended Application of theTrucks
The trucks are solely designed and manufactured to handle
goods. The trucks should be fitted with the appropriate
accessories relevant to the application.
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PS M1.0
000 OE35
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F-code Section C-code
General Product Information
16 Service Manual 1997-09-24
1.2. Forbidden Application of theTruck
The trucks are designed for handling goods indoors. It is not
permitted to use the trucks for other purposes including the
following:
-Do not use in areas that contain gases which can
cause fires or explosions
-Do not use as a towing truck for trailers
-Do not use to tow other trucks
-Do not use to transport/lift passengers
-Do not use to drive on gravel or grass
1.3. Truck Data
The following table provides information regarding some
technical data which is of value with daily use of the trucks.
The truck’s lifting capacity, and weight can be found on the
truck’s data plate.
Truck data 24Volt 35 Volt
Lifting capacity rated load, lb Up to 3000 lb.
Lift height, inches Up to 300 in.
Operating speed without load, mph
Below 24 in.
24 in. to 150 in.
151 in. and 225 in.
Above 225 in.
5.4 mph
2.5 mph
1.0 mph
0 mph
5.8 mph
2.5 mph
1.0 mph
0 mph
Operating speed with load, mph
Below 24 in.
24 in. to 150 in.
151 in. and 225 in.
Above 255 in.
4.6 mph
2.2 mph
0.8-1.0 mph
0 mph
5.2 mph
2.2 mph
0.8-1.0 mph
0 mph
Service weight without battery, lb
2 stage mast (with 48 in. forks)
3 stage mast (with 48 in. forks) 5200 lb 5500 lb
Service weight including battery, lb
Minimum battery weight is 1100 lbs. Above + battery weight Above + battery weight
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General Product Information
PS M1.0
F-code Section C-code
Version no T-code
000 OE35
© BT Products 17
Service Manual 1997-09-24
1.4. OE35 Dimensions
The following diagram shows external dimensions for the
OE35 truck in its standard design.
2.0”
33.0”
41.0”
OALH
58.2”
76.0” (2-Stage)
77.0” (3-Stage)
2.5”
7.5”
27.0”
36.0”
60.0”
Picking
Height
76.0”
or
80.0”
42.0” 24.0” Minimum
30.0” Maximum
4.0”
70”Turning Radius
Fork
Length
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PS M1.0
000 OE35
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General Product Information
18 Service Manual 1997-09-24
1.5. Data Plate
The following diagram shows the data plate used on the
truck.
Legend
1. Truck model number
2. Truck serial number
3. Truck capacity
4. Mast serial number
5. Attachments
6. Truck type
7. Truck weight (less battery)
8. Back tilt degree (NOT USED ON THIS TRUCK)
9. Minimum battery weight
10. Maximum battery weight
11. Battery maximum AMP hours
12. Battery voltage
13. Battery type
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