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PS P2.0

000 OE35

Version no T-code

F-code Section C-code

Service Schedule

44

Service Manual 1997-10-21

5110

1700

2550

0000

0640

3100

3500

4100

5200

5300

5400

5710

6000

7310

7400

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Table of Contents

BT Standard Codes5
- Table of Contents5
Warning Symbols11
- Warning Levels11
Prohibitory Symbols12
- Ordinance Symbols12
Introduction, Service Manual15
Contents, Section M15
- Machine Information15
- Presentation of the OE3517
General Product Information19
- Main Components24
- Introduction25
- Nomenclature, Threads26
Inch (SAE) and Metric Fasteners27
- Strength Identification27
- Conversion of Metric and English Units35
Technical Service Data37
Ordering Spare Parts41
Service Schedule43
- Planned Maintenance Schedule43
Planned Maintenance Procedures47
- Services to be Performed Daily or at each 8 Hour Operating Shift47
- Services to be Performed Monthly or Every 250 Operating Hours49
- Services to be Performed Annually or Every 1200 Operating Hours52
Lubrication Chart55
Oil and Grease Specifications57
- Approved Oils and Grease57
Contents, Section S59
- Service Instructions59
Inspection Covers61
- Removal of Plastic Dash Panel62
Drive Motor65
- General Information65
- Operating Conditions65
- Troubleshooting65
Drive Motor 24 Volt71
- Component Repair72
- Inspection and Troubleshooting73
- When Changing Brushes78
Drive Motor 36 Volt79
- Component Repair80
- Inspection and Troubleshooting81
- When Changing Brushes86
Transmission87
- System Description87
- Troubleshooting87
- Removal88
Transmission Disassembly / Assembly91
- Disassembly92
- Installation99
Drive Wheel101
Load Wheels103
Stabilizing Caster Spring Loaded105
- Removal106
- Inspection108
- Disassembly109
Torque Generator111
- Disassembly113
- Assembly118
Steering System Pump125
- General Information126
- Removal126
- Installation127
- Disassembly129
- Inspection130
- Assembly130
Steering System133
- General Information133
Electrical System with TX and TT Card135
- Electrical Schematic Part 1135
- Electrical Schematic Part 2136
- Basics of Circuit Operation137
- Control Features139
- General Maintenance Instructions147
- Trouble-Shooting Instructions148
Battery Controller / Hourmeter / Lift Interrupt151
- General Information151
- Electrical151
- Battery Controller (BC)152
- Troubleshooting155
Dash Display159
- General Information159
- Location160
- Operational Checks160
- Status Codes161
EV100 LX Control Status Codes163
SCR Component Checks181
- Main Logic Card181
- Capacitor 1C182
- Contactors Forward, Rearward, 1A, Power Steering, and Pump182
- Potentiometer in Accelerator182
- Scr's (1REC, 2REC, 5REC)182
- Rectifiers (3REC, 4REC, Diode Blocks)184
- Thermal Protector (TP)184
- Filter Block (23FIL, Etc.)185
- Choke and Reactor T3-T4185
- Replacement of EV100 Components185
- Instructions - EV100 Plugs187
Direction Contactor189
- General Information190
- Remove / Replace Contact Tips190
Speed Contactor195
- General Information196
- Disassembly196
- Assembly198
Electrical System Troubleshooting201
- Control Circuits and Power Circuits203
Electrical System Troubleshooting Charts205
Pump Contactor217
- General Information218
- Disassembly218
- Assembly220
Steering Pump Contactor223
- General Information224
- Disassembly224
- Assembly226
EV100 Handset Operation229
- General Information229
- Purpose230
- Operation231
- Function Set-Up Procedures232
- Description and Location234
- Function Numbers for Controllers235
Hydraulic System243
- Hydraulic Schematic243
- General Information244
- Maintenance246
- Adjustments246
Hydraulic Troubleshooting247
- Troubleshooting Chart247
Lift Pump Assembly251
- Removal252
- Disassembly253
- Inspection256
- Assembly258
Mast, 2 Stage261
- Shimming Mast on Truck262
- Two Stage Mast266
Mast, 3 Stage271
- Shimming Mast on Truck272
- Three Stage Mast277
Lift Cylinder, 2 Stage283
- Cylinder Repair284
Freelift Cylinder, 3 Stage287
- Freelift Cylinder Repair288
Staging Cylinder, 3 Stage291
Micro 70 Wire Guidance Important Information295
- Powering up295
- Powering down295
Micro 70 Wire Guidance297
- Electrical Schematic Part 1297
- Electrical Schematic Part 2298
- Electrical Schematic Part 3300
- Electrical Schematic Part 4300
- Cautions and Warnings301
- Operation Information303
- Component Function and Relationship307
- Truck Set up on Site309
- Troubleshooting Information312
- Troubleshooting Charts315

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