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prime mover smx45 Master Service Manual
282 pages
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Master Service Manual
Read and observe all
warnings on this u
nit
before operating it.
DO NOT
operate this equi
pment unless all
factory installed guar
ds and covers are
properly secur
ed in place.
Warning
Warning
Part no: 313084-000
Date
: December 12, 2006
SMX45
Electric W
alkie Low-Lift Pallet T
ruck
Effective Serial Num
ber SMX__4533227001 - UP
Front Cover
Return
2
Table of Contents
Ordering Spare Parts
3
Standard Codes
5
Table of Contents
7
Warning Symbols
15
Warning Levels
15
Prohibitory Symbols
16
Ordinance Symbols
16
Safety
17
General Safety
17
Battery Safety
22
Static Discharge Precautions
27
Welding Safety
29
Introduction, Service Manual
31
Contents, Section M
33
Machine Information
33
General Product Information
35
Truck Presentation
35
Truck Side Views
35
Intended Truck Application
35
Prohibited Truck Application
36
Truck Data
36
Dimensions
37
Data Plate
38
Main Components
39
Inch (SAE) and Metric Fasteners
41
Introduction
41
Nomenclature, Threads
42
Strength Identification
43
Truck Torque Specifications
49
Conversion of Metric and English Units
50
Technical Service Data
53
Contents, Section P
57
Planned Maintenance
57
Introduction, Maintenance
59
Jacking Truck off the Floor
60
Fork Section
61
Tractor Section
61
Lubricants
61
Standard
61
Cold Storage
61
Service Schedule
63
Planned Maintenance Schedule
63
Planned Maintenance Procedures
66
General
66
Hardware
66
Noise
66
Leaks
66
Cables and Connections
67
Grease Location Points
67
Services Performed Daily or Every 8 Operating Hours
67
Frame
67
Brakes
67
Wheels/Tires
67
Steering Control Handle
67
Functions/Operations
68
Battery
68
Battery Connector
68
Services Performed Every Two Months or Every 250 Operating Hours
69
Frame
69
Motors
69
Drive Unit
69
Brake
69
Electrical Control System
69
Battery
70
Electrical Panel
70
Hydraulic System
70
Lifting Devices
70
Services Performed Annually or Every 1500 Operating Hours
70
Drive Unit
70
Hydraulic System
71
Lubrication Chart
73
Oil and Grease Specifications
74
Lubricants
74
Grease Location Points
74
Contents, Section S
75
Service Instructions
75
Frame
77
Theory of Operation
77
Maintenance
77
Inspection
77
Troubleshooting
78
Repair and Rebuild
78
Inspection Covers
85
Theory of Operation
85
Maintenance
85
Troubleshooting
85
Repair and Rebuild
85
Decals
87
Decal with Protective Sheet
87
Decal Without Protective Sheet
87
Electric Motors
89
Theory of Operation
89
Maintenance
89
Troubleshooting
90
Repair and Rebuild
91
Motor Brushes
91
Drive Motor
91
Pump Motor
92
Brush Inspection
92
Brush Replacement
93
Pump Motor
94
Removal
94
Installation
95
Drive Motor
96
Drive Motor
98
Removal
99
Installation
99
Transmission
101
Theory of Operation
101
Maintenance
101
Fluid Changing
101
Troubleshooting
102
Repair and Rebuild
102
Parking Brake System
111
Theory of Operation
111
Maintenance
113
Mechanical Brake Release
113
Brake Adjustment
113
Troubleshooting
114
Repair and Rebuild
115
Drive Wheel
117
Theory of Operation
117
Maintenance
117
Drive Wheel Nut Inspection
117
Troubleshooting
119
Repair and Rebuild
119
Load Wheels
123
Theory of Operation
123
Maintenance
123
Troubleshooting
123
Repair and Rebuild
124
Caster Wheel (Optional)
127
Theory of Operation
127
Maintenance
127
Inspection
127
Troubleshooting
128
Repair and Rebuild
128
Steering Control Handle
131
Theory of Operation
131
Maintenance
131
Inspection
131
Troubleshooting
131
Repair and Rebuild
132
Steering Control Head
137
Theory of Operation
137
Maintenance
137
Troubleshooting
137
Repair and Rebuild
138
Steering Bearing
143
Theory of Operation
143
Maintenance
143
Troubleshooting
143
Repair and Rebuild
144
Electrical Functions
147
Theory of Operation
147
Battery Plugged in with Keypad
148
Battery Plugged in with Key Switch
149
Main ON/OFF Switch/Keypad on
150
Travel, Low Speed
152
Travel, High Speed
154
Reverser
155
Lift
156
Lower
157
Maintenance
158
Wiring
158
Definitions
158
Shorts to Frame Test
159
Troubleshooting
163
Troubleshooting Flowchart
163
Main Harness Replacement
166
Operator Display and Programming
170
Special Modes
170
Service Display
171
Digital Inputs/Outputs from Transistor Controller
172
Transistor Controller System Mode
173
Changing Driver Accessible Parameters (P)
174
Changing Service Parameters
176
Parameter Description
178
Operating Parameter Programming
181
Display Part Numbers (Pn)
181
Error Codes (E)
182
Error Code History
182
Truck Fault Codes
183
Troubleshooting Chart Index
190
Travel (Forward / Rearward) System
190
Wiring System
190
Other Possible Troubleshooting Issues
190
Troubleshooting Charts
191
Electrical Schematic 1(2)
196
Electrical Schematic 2(2)
197
Battery
201
Theory of Operation
201
Maintenance
201
Inspection and Care
201
Exterior Cleaning
202
Charging
202
Storage
203
History Record
204
Troubleshooting
204
Repair and Rebuild
205
Swing out Battery Pack
207
Theory of Operation
207
Maintenance
207
Electrical Testing
207
Required Equipment
207
Instructions
207
Troubleshooting
212
Repair and Rebuild
212
Battery Connector
217
Theory of Operation
217
Maintenance
217
Inspection
217
Troubleshooting
217
Repair and Rebuild
218
Switches
221
Theory of Operation
221
Maintenance
222
Troubleshooting
224
Repair and Rebuild
225
Main ON/OFF Switch
226
Arm Angle Switches
226
Lift Limit Switch
227
Key Switch (Optional)
228
Horn Switch
228
Converting Keypad to Key Switch
229
Fuses/Circuit Breakers
231
Theory of Operation
231
Maintenance
231
Wiring Harness
232
Power Cables
233
Circuit Breaker
234
Master Control Relay
235
Troubleshooting
236
Repair and Rebuild
236
Contactor Panel
237
Theory of Operation
237
Maintenance
237
Troubleshooting
237
Resistance Testing
237
Repair and Rebuild
238
Transistor Controller
241
Theory of Operation
241
Basics of Circuit Operation
241
Interface
242
Control Features
243
Motor Circuit
243
Control Circuit
244
Definitions
245
Maintenance
246
Safety
246
Cleaning
246
Troubleshooting
247
Diagnostics and Troubleshooting
247
Fault Codes
247
Repair and Rebuild
249
Electronic Tiller Arm Card (ETAC)
251
Theory of Operation
251
Maintenance
252
Troubleshooting
252
Repair and Rebuild
253
Hydraulic System
255
Theory of Operation
255
Lift
256
Lower
257
Relief Pressure
258
Maintenance
259
Changing Hydraulic System Fluid
259
Hydraulic Pump Pressure Relief Valve
261
Troubleshooting
261
Troubleshooting Chart Index
262
Troubleshooting Charts
263
Repair and Rebuild
266
Hydraulic Unit
268
Hydraulic Solenoid
269
Reservoir
270
Filter Screen and Inlet Tube
271
Lift Pump
272
Lift Cylinder
273
Theory of Operation
273
Maintenance
273
Inspection
273
Troubleshooting
273
Repair and Rebuild
274
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prime mover smx45 Specifications
General
Brand
prime mover
Model
smx45
Category
Lifting Systems
Language
English
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