BT_OM Electric Order Picker OPX30 3031253001-up Master Service Manual 311348-000 – PDF DOWNLOAD
FILE DETAILS:
BT_OM Electric Order Picker OPX30 3031253001-up Master Service Manual 311348-000 – PDF DOWNLOAD
Size: 55.8 MB
Fomat: PDF
Language: English
Brand: BT_OM
Type of machine: Forklift – Prime Mover – Electric Order Picker
Type of document: Service Manual
Model: OM OPX30
Part no: 311348-000
Serial no: OPX3031253001-up
Page of number: 570 pages
Date modifided: 04-2003
TABLE OF CONTENTS:
BT_OM Electric Order Picker OPX30 3031253001-up Master Service Manual 311348-000 – PDF DOWNLOAD
Front Cover 1
Standard Codes 3
Table of Contents 5
Warning Symbols 17
1 Warning Levels 17
Prohibitory Symbols 18
1 Ordinance Symbols 18
Safety 19
1 General Safety 19
Battery Safety 23
Static Discharge Precautions 28
Welding Safety 30
Introduction, Service Manual 33
Contents, Section M 35
1 Machine Information 35
General Product Information 37
1 Truck Presentation 37
1 1 Truck Side Views 37
1 2 Intended Truck Application 37
1 3 Prohibited Truck Application 38
1 4 Truck Data 38
1 5 Dimensions 39
1 6 Data Plate 40
2 Main Components 41
Inch (SAE) and Metric Fasteners 45
1 Introduction 45
2 Nomenclature, Threads 46
3 Strength Identification 47
4 Conversion of Metric and English Units 54
Technical Service Data 57
Ordering Spare Parts 61
Contents, Section P 63
1 Planned Maintenance 63
Introduction, Maintenance 65
1 Jacking Truck Off The Floor 66
1 1 Operator Platform 66
1 2 Truck Frame 66
1 3 Baseleg 67
2 Lubricants 68
2 1 Standard 68
2 2 Cold Storage 68
2 3 Freezer 70
Service Schedule 71
1 Planned Maintenance Schedule 71
2 Planned Maintenance Procedures 75
2 1 Services Performed Daily or Every 8 Operating Hours 75
2 1 1 Battery Level (BL) 75
2 1 2 Drive Wheel Indicator 76
2 1 3 Hourmeter 76
2 1 4 Hydraulic System 76
2 1 5 Frame/Sheet Metal 77
2 1 6 Wheels/Tires 77
2 1 7 Functions/Operations 77
2 1 8 Safety Belt, Tether, and Body Harness 77
2 2 Services Performed Monthly or Every 120 Operating Hours 77
2 2 1 Inspection 77
2 2 2 Transmission 77
2 2 3 Battery 78
2 2 4 Electrical Connections 78
2 2 5 Contactor Tips (NOT Sealed) 78
2 2 6 Motor Brushes 78
2 2 7 Drive Motor 78
2 2 8 Hydraulic Reservoir 79
2 2 9 Frame Lube 79
2 2 10 Pivot Points 79
2 3 Services Performed Semi-Annually or Every 720 Operating Hours 79
2 3 1 Inspection 79
2 3 2 Transmission 79
2 3 3 Hydraulic System 80
2 3 4 Brakes 80
2 3 5 Lift and Platform Chains 80
2 4 Services Performed Annually or Every 1440 Operating Hours 81
2 4 1 Battery 81
2 4 2 Brake 81
2 4 3 Hydraulic Fluid 81
Lubrication Chart 83
Oil and Grease Specifications 84
1 Approved Oils and Grease 84
2 Grease Location Points 85
Contents, Section S 87
1 Service Instructions 87
Chassis 89
1 Theory of Operation 90
2 Maintenance 90
3 Troubleshooting 90
4 Repair and Rebuild 90
4 1 Front Cover 90
4 2 Front Panel 91
4 3 Left-hand Cover 91
4 4 Right-hand Cover 92
Operator Platform 93
1 Theory of Operation 94
2 Maintenance 94
3 Troubleshooting 94
4 Repair and Rebuild 95
4 1 Console Cover 95
4 2 Floor Mat 96
Battery Compartment 97
1 Theory of Operation 98
2 Maintenance 98
3 Troubleshooting 98
4 Repair and Rebuild 99
4 1 Battery Stop Plate 99
4 2 Battery 100
4 3 Battery Rollers 101
Operator Controls 103
1 Theory of Operation 103
2 Maintenance 103
3 Troubleshooting 103
3 1 Throttle Potentiometer Test 103
4 Repair and Rebuild 104
4 1 Multi-Function Control Handle 104
4 2 Steer Wheel 106
4 3 Deadman Pedal 107
4 4 Pallet Clamp 110
4 5 Tether 112
Decals 113
1 Decal with Protective Sheet 113
2 Decal without Protective Sheet 113
Electric Motors 117
1 Theory of Operation 117
2 Maintenance 117
3 Troubleshooting 118
4 Repair 129
4 1 Brush Replacement 129
4 2 Pump Motor 129
4 3 Drive Motor 134
4 4 Fan Motor Assembly 136
5 Rebuild 137
5 1 Pump Motor and Drive Motor Component Disassembly 137
5 2 Inspection 139
5 2 1 Drive End Head 139
5 2 2 Commutator End Head 139
5 2 3 Bearings 139
5 2 4 Brush and Commutator 139
5 2 5 Armature 142
5 2 6 Frame and Field Assembly 143
5 3 Assembly/Testing 144
5 3 1 Bearing Installation 144
5 3 2 Testing 145
5 4 Fan Motor Rebuild 145
Transmission 147
1 Theory of Operation 148
2 Maintenance 148
2 1 Fluid Changing 148
3 Troubleshooting 148
4 Repair and Rebuild 152
4 1 Transmission Disassembly 152
4 1 1 Pivot Ring 154
4 1 2 Drive Unit Gear Case 158
4 1 3 Radial Ring 158
4 1 4 Axle Shaft and Bevel Gear 159
4 1 5 Spiral Gear and Helical Gear 161
4 1 6 Bearing Cup and Shim 163
4 1 7 Spur Gear 165
4 2 Transmission Reassembly 166
4 2 1 Gear Case 166
4 2 2 Axle Shaft 166
4 2 3 Bevel Gear 168
4 2 4 Spiral Gear 169
4 2 1 Gear Set 170
4 2 2 Calculating Shim Formulas 171
4 2 3 Gear Case Bearing Cup and Shim 174
4 2 4 Helical Gear/Spiral Pinion Gear 176
4 2 5 Axle 179
4 2 6 Measuring Backlash 183
4 2 7 Pivot Ring 185
4 2 8 Drive Unit 187
4 2 9 Gear Case Cover 190
Electric Brake 191
1 Theory of Operation 191
2 Maintenance 191
2 1 Brake Air Gap Adjustment 191
3 Troubleshooting 192
4 Repair and Rebuild 193
4 1 Brake Assembly 194
4 2 Brake Friction Plate (Rotor) 195
Drive Wheel 197
1 Theory of Operation 197
2 Maintenance 197
3 Troubleshooting 197
4 Repair and Rebuild 198
Load Wheels 201
1 Theory of Operation 204
2 Maintenance 204
3 Troubleshooting 204
4 Repair and Rebuild 204
4 1 Single Load Wheel 205
4 2 Tandem Articulated Load Wheel 206
4 3 Guide Wheel (Optional) 208
Steering Unit 209
1 Theory of Operation 212
2 Maintenance 212
3 Troubleshooting 212
4 Repair and Rebuild 213
Steering Arm / Wheel / Lever 215
1 Theory of Operation 216
2 Maintenance 216
3 Troubleshooting 216
3 1 Steer Encoder Test 216
4 Repair and Rebuild 218
4 1 Steering Wheel 218
4 2 Steering Encoder 219
Steering Bearing 221
1 Theory of Operation 222
2 Maintenance 222
3 Troubleshooting 222
4 Repair and Rebuild 222
Electrical Functions 225
1 Theory of Operation 225
1 1 Battery Plugged In 226
1 3 Deadman 232
1 3 2 Closing Deadman Switches (S2 and S23) 232
1 4 Steering 238
1 5 Travel 240
1 6 Lift/Lower 246
1 6 2 Lower (S4) 250
1 Maintenance 273
1 1 Horn Button Pass Codes 273
1 2 Wiring 279
1 2 1 Definitions 280
1 2 2 Shorts to Frame Test 281
2 Troubleshooting 285
2 1 Maintenance (Chirp) Mode 287
2 1 1 Entering Maintenance Mode Using Deadman Pedal 287
2 1 2 General Testing 287
2 2 Platform Manager Fault Codes 289
Electronic Components 331
1 Theory of Operation 333
2 Maintenance 334
3 Troubleshooting 334
4 Repair and Rebuild 334
Battery 337
1 Theory of Operation 337
2 Maintenance 337
2 1 Inspection and Care 337
2 2 Exterior Cleaning 338
2 3 Charging 338
2 4 Storage 339
2 5 History Record 339
3 Troubleshooting 340
4 Repair and Rebuild 341
Battery Connector 343
1 Theory of Operation 343
2 Maintenance 343
2 1 Inspection 343
3 Troubleshooting 344
4 Repair and Rebuild 344
Lights (Optional) 347
1 Theory of Operation 347
2 Maintenance 347
3 Troubleshooting 347
4 Repair and Rebuild 347
4 1 Overhead Guard Light 347
4 2 Adjustable Lights (Optional) 350
4 3 Warning Light 351
Horn and Travel Alarm 353
1 Theory of Operation 353
2 Maintenance 353
3 Troubleshooting 353
4 Repair and Rebuild 354
4 1 Horn 354
4 2 Travel Alarm 355
Instrument Panel and Displays 357
1 Theory of Operation 357
1 1 Start Up 357
1 2 Battery Level Display LED Messages 359
1 3 Steering Indicator Messages 362
1 4 Display Messages 363
1 5 Hourmeter 363
1 6 Sounder 364
2 Maintenance 365
3 Troubleshooting 365
3 1 Display 365
3 2 Hourmeter 366
3 2 1 No Display 366
3 2 2 Hourmeter Glass Icon Does Not Flash 366
3 2 3 Hourmeter Glass Icon Always Flashes 366
Start/Stop Switches 367
1 Theory of Operation 368
2 Maintenance 368
3 Troubleshooting 368
4 Repair and Rebuild 369
4 1 Key Switch 369
4 2 Emergency Power Off (EPO) 370
4 2 1 Contact Block 370
4 2 2 EPO Actuator 372
4 3 Deadman Switches 372
Mast Switches 373
1 Theory of Operation 374
2 Maintenance 375
2 1 Adjustment 375
3 Troubleshooting 378
4 Repair and Rebuild 378
Steer Switches 379
1 Theory of Operation 380
2 Maintenance 380
3 Troubleshooting 381
4 Repair and Rebuild 382
Fuses 383
1 Theory of Operation 384
2 Maintenance 384
2 1 Wiring Harness 384
2 2 Power Cables 385
3 Troubleshooting 385
4 Repair and Rebuild 385
Contactor Panel 387
1 Theory of Operation 388
2 Maintenance 388
2 1 Contact Tip Inspection 389
2 2 Resistance Testing 389
3 Troubleshooting 389
4 Repair and Rebuild 390
4 1 Contact Assembly 390
Traction Power Amplifier (TPA) [Transistor Controller] 393
1 Theory of Operation 393
1 1 Basics Of Circuit Operation 393
1 2 Interface 395
1 3 Control Features 395
1 4 Motor Circuit 397
1 5 Control Circuit 398
1 6 Definitions 399
2 Maintenance 400
2 1 Safety 400
2 2 Cleaning 400
2 1 TPA Adjustable Settings 401
3 Troubleshooting 402
3 1 Diagnostics and Troubleshooting 402
3 2 Handset Diagnostics 402
3 3 Fault Codes 405
3 4 Troubleshooting Chart 406
4 Repair and Rebuild 408
Hydraulic System 409
1 Theory of Operation 410
1 1 Lift 410
1 2 Lower 412
2 Maintenance 413
2 1 Changing Hydraulic System Fluid 413
2 2 System Draining 414
2 3 Refilling System 414
2 4 Bleeding Hydraulic System 415
3 Troubleshooting 416
4 Repair and Rebuild 416
4 1 Lift Manifold 419
4 2 Hydraulic Reservoir 422
4 3 Manual Release Valve 423
4 4 Lift Pump 426
Two Stage Mast Staging Cylinder 429
1 Theory of Operation 430
2 Maintenance 430
3 Troubleshooting 430
4 Repair and Rebuild 430
4 1 Bearing and Seals 431
Three Stage Mast Staging Cylinder 439
1 Theory of Operation 440
2 Maintenance 440
3 Troubleshooting 440
4 Repair and Rebuild 440
4 1 Bearing and Seals 441
Three Stage Mast Freelift Cylinder 449
1 Theory of Operation 450
2 Maintenance 450
3 Troubleshooting 450
4 Repair and Rebuild 451
Mast 459
1 Theory of Operation 459
2 Maintenance 460
2 1 Visual Inspection 460
2 2 Chain Inspection 460
2 3 Lubrication 464
2 4 Adjustment 466
3 Troubleshooting 467
4 Repair and Rebuild 467
Platform 495
1 Theory of Operation 497
2 Maintenance 498
2 1 Platform Shimming 498
3 Troubleshooting 500
4 Repair and Rebuild 500
Lifting Gear (Crosshead), Three Stage Mast 507
1 Theory of Operation 509
2 Maintenance 509
3 Troubleshooting 509
4 Repair and Rebuild 509
Fork Assembly 511
1 Theory of Operation 512
2 Maintenance 512
3 Troubleshooting 512
4 Repair and Rebuild 512
4 1 Forks 512
4 2 Pallet Clamp 514
Wire Guidance (Optional) 517
1 Theory of Operation 517
2 Maintenance 520
3 Troubleshooting 527
3 1 Fault Codes 529
Handset Operation 549
1 Operating Modes 552
2 Revert to Previous Settings 555
3 Handset Self Test 555
Electrical Controllers (Handset) 557
1 Display Screen 558
1 1 Menu Navigation Key 558
1 2 Data Inc/Dec Key 558
1 3 Bookmark Keys 558
2 Operation 559
2 1 Menu Structure 559
2 2 Main Menu 560
2 3 Interface Protocols and Backward Compatibility 561
2 4 Parameter Changing 561
2 5 Real-Time Monitoring 562
2 6 Reading Faults and Diagnostic History File 562
2 7 Cloning and Restoring the Previous Programming 563
2 8 Information Displays 563
2 9 Programmer SetUp 564
Index 565
Back Cover 570
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